Whats new with Copperweld!

Exciting developments in Copperweld copper-clad steel (CCS) conductors

Copperweld 4THOUGHT
A New Alternative to 4/0 Solid Copper
Prior configurations of Copperweld DSA strand have long been available for substation grounding purposes and provided a mechanically stronger conductor than 4/0 copper. However, these configurations also evidenced more stiffness due to the stronger steel core.

Challenges
The larger diameter required different cadweld type molds, an added expense for the installers The larger diameter added more stiffness than 4/0 copper

4THOUGHT provides resolution to these challenges and more!

4THOUGHT is a 4/0 CCS (copper-clad steel) strand with the same diameter as 4/0 copper No additional expense for new Cadweld molds 4THOUGHT uses smaller size rod material making it just as flexible as copper Eliminates the stiffness issue 4THOUGHTs steel core provides greater breaking strength as compared to 4/0 copper > 1000 lbs stronger 4THOUGHT is generally less expensive than 4/0 copper 4THOUGHT is an outstanding theft deterrent since the steel core reduces the scrap value to that of steel Fushi Copperwelds proprietary manufacturing process ensures a permanent metallurgical bond between the copper jacket and steel core that is devoid of oxygen Eliminates any concern regarding corrosion

4THOUGHT Specification Details

4THOUGHT is composed of 40% IACS dead soft annealed copper-clad steel. The values below are only validated for genuine Copperweld THOUGHT 4/0-compatible strand manufactured by Fushi Copperweld Inc.

4THOUGHT compared to 4/0 Copper

Considerations
Industry Standard IEEE Position

Copper Clad Steel

Other configurations widely adopted in a variety of conductor applications Viable alternative especially for high-theft areas

Copper
4/0 Copper Cu is most commonly used for grounding

Merits of each product compared:

Breaking Strength Fusing Current @ 30 Cycles (0.50 sec) Flexibility Connectorization Theft Resistance Dimensions Cost Pricing volatility 4THOUGHT = 5,979 pounds 4THOUGHT = 28.60 kA Easy to form Exothermic & mechanical Yes: No scrap value Same Slightly less expensive than copper Less affected (36% copper by volume) 4/0 = 4,933 pounds 4/0 = 42.67 kA Easy to form Exothermic & mechanical No: High scrap value Same More expensive than CCS Severely affected (100% copper)

Further questions? We have a very close relationship with Fushi Copperwelds engineering team, and well be happy to get you the answers!

Whats new with Copperweld Pole Ground

New CAMO Colored Pole Ground
New jacketed version is designed to NOT have the appearance of copper pole ground:
Jacket material is UV-stabilized PVC Color is GREY Currently available for solid pole ground only Target release date is July 2010 Photo is prototype; final product may vary in appearance

New Green Spools

Green spool easily identifies the pole ground as Copperweld (solid copper material is shipped on a black spool).

Whats new with Copperweld Pole Ground (contd)

New Stranded Pole Ground
New stranded version offers greater flexibility and ease-of-handling while matching the strength of solid copper Sizes available are #2 and #4 stranded 40% DSA Same cost as single pole ground Package Options: 25 lb equivalent spool (same footage as solid CCS) Weighs less per foot as compared to the copper equivalent Available now for use

Selecting the right Copperweld products to optimize grounding systems

The Traditional Selection Process Has Been Replaced

Selecting The Right Copperweld Strand For Your Application

Design Engineers should be concerned with two factors when selecting a conductor for a ground grid The conductor must meet the maximum fault current for a certain duration The conductor must meet a minimum breaking load as required by the substation design (typically 5,000 pounds) Traditionally, we have used a chart comparing the ampacity ratings of copper and Copperweld CCS that allowed the user to visually select the Copperweld equivalent. For example: The equivalent to 4/0 copper per the graph is 19#9 40% DSA A typical maximum fault current for a distribution substation is ~18kA at 30 cycles A 2/0 Copper or 7#6 CSS conductor will meet this requirement instead of the larger size 4/0 copper commonly used for ground grids
7#6 CCS Conductor safety margin 30%

Most engineers upsize to 4/0 copper in order to meet the mechanical strength requirement 7#6 CCS meets the fault current and mechanical strength requirements The advantage of CCS in this case is the cost savings at least 25% per foot!

What we have learned: A new method is needed for the selection process!

Simple New Computerized Selection Program for Sizing Copperweld

18kA with 30% Safety Factor Value

Entering the fault current, with a safety factor (if required) and fault duration is all that is needed to determine the appropriate size Copperweld conductor

Validating the data that drives the new program for sizing Copperweld
To confirm the values used in this program, Fushi Copperweld conducted fusing current testing at a third-party laboratory. The primary purpose of the testing was to determine the accurate fusing of Copperweld conductors with respect to how IEEE Standard 80 rated copper-clad steel conductors. For this testing, fusing was defined as any physical change to the conductor that would prevent the conductor from handling an additional short circuit current of the same magnitude and duration. The testing validated the fusing current of copper matched exactly the fusing current calculated using IEEE Std 80 formula. However, the testing also revealed that Copperweld conductors can carry 105 108% of the calculated current using the IEEE Standard 80 formula.

Demo Time

ADVANTAGE: COPPERWELD
Copperweld 4THOUGHT 19-wire CCS strand is entirely suitable as a stronger, more cost-effective, and replacement for 4/0 copper in most substation grounding applications Copperweld CAMO colored pole ground is specifically designed to further deter theft by masking its resemblance to copper Lightweight stranded Copperweld pole ground offers greater flexibility while matching the strength of solid copper, at the same cost of single-wire ground New green spools make Copperweld products identifiable at a glance on the truck or at the warehouse Old fusing charts replaced with a simple-to-use computer sizing calculator

Copperweld (Copper-Clad Steel)

Earthing (Grounding) Wire for use in Electrical Utility Applications

Product Features
Bimetallic wires combine the features of dissimilar metals to achieve a cost and/or a performance advantage Copper-Clad Steel Conductivity of copper (high frequency applications) Strength of steel Fatigue Resistant Corrosion resistance Fusing current similar to copper Durability Low scrap value

- Excellent theft resistance

Solid Metal Cladding Process

Take-up

Cooling

Copper Copper Thickness 6% of total diameter for 30% 10% of total diameter for 40%

Steel

Copperweld is a composite in which a concentric copper cladding is metallurgically bonded to a steel core through a continuous, solid cladding process using pressure rolling for primary bonding that seals out moisture.

Metallurgical Bond
100

80

Compostion, wt%

60

Cu Fe

40

20

0 0 100 200 300 400 500 600 700 800

Distance, nm
STEM-HAADF-XEDS with drift correction
As tested by University of Alabama Tuscaloosa, Alabama

Copper-Clad Steel

Production Process

Hard Drawn

Annealed

Bimetallic Wire Quality

Must have:

Exceptional bond integrity to prevent copper separation and moisture penetration Highest Quality Raw Materials
Poor (Dirty) Steel results in premature breakages; lower strength; and poor bond Poor (Dirty) copper results poor signal and current transmission; lower conductivity; and moisture and corrosion propagation points.

Bimetallic Wire Quality

COPPERWELD Low Carbon 40% Poor Quality Producer Low Carbon 40%

Bimetallic Wire Quality

COPPERWELD Low Carbon 40%

Poor Quality Producer - Low Carbon 40%

Grounding Products (CCS)

Available in Single End (pole ground), 3, 7 and 19 strand Types Dead Soft Annealed (DSA) wire for greater flexibility High Strength & Extra High Strength for overhead grounds/messenger wire/down guys Oxygen-Free Copper Cladding 30% & 40% Conductivities

THEFT RESISTANT
Some utilities reporting one incident per day

Composite Conductors (CCS)

Combination of Hard Drawn Copper and 30% Copperweld Lighter weight compared to copper, provides minimum sag over longer spans Higher ampacity over standard Copperweld strand
Type G
Some Examples

Type A

Ideally suited for corrosive environments 30 different sizes & combinations

Type EK

THEFT RESISTANT

FAQs
Question: What does the percentage conductivity mean?

Answer:
For the Copperweld product, when you see the reference 40% Conductivity, this is the percentage of conductivity the Copperweld material has as compared to its diameter equivalent of copper. If this was for a continuous current carrying condition, then the Copperweld product would not be suitable.

Grounding Applications
Transmission Structure Grounding Counterpoise Grounding Distribution Ground Connections Pole Ground Wires Substation Ground Grid

Provides the same System Reliability as Copper

Grounding Applications
Generation Plant
Lightning Protection

Switch Yard & Transmission Substation

Transmission Line

Building Ground

Substation Grounding Grid Wire

Buried Counterpoise Wire

R

Grounding Applications
Sub Transmission Line Distribution Substation Distribution Line
Transformer Ground

Pole Ground Wire

Fence Ground

Pole Ground Wire

Copperweld CCS for Pole, Structure, and Substation Grounding

Theft resistant High mechanical strength

has approximately 100% more breaking strength than copper conductors.

Excellent fatigue properties Ample current carrying capacity & provides reliable low impedance path to ground Lower cost over life of installation 8-12% lighter than copper Resist fusing at high temperatures 5 to 6 times the conductivity of ordinary steel wire Corrosion resistance

Copperweld is Compatible with Standard Connectors

Bolted Clamps Cadweld Process

Cable codes: Pg B-3 in their catalog

FAQs
Question: Steel is sacrificial to copper. What happens when I cut the wire? Wont this expose the steel? Will this allow the conductor to corrode?

Answer:
For corrosion to occur between dissimilar metals, you must have an anode (steel), a cathode (copper), and an electrolyte (moisture). Given the bond achieved between the thick copper cladding and the steel core, no moisture can migrate into the interface between the cathodic material and the anodic material. This precludes corrosion from propagating further into the wire. Based on analysis of old buried wire samples, corrosion will only advance into the cut end a maximum distance of twice the diameter of the wire. At this depth a rust barrier is formed and effectively seals out the moisture. Without the electrolyte the corrosive action ceases. Also, when Copperweld is cut, the copper cladding cold flows to partially cover the cut end. This reduces the area of exposure of the steel.

Copperweld Corrosion Test

Use of Copperweld in buried conditions has prompted questions regarding the effect of corrosion on performance Five year corrosion study was initiated using destructive and non-destructive test along with microscopic analysis to evaluate Samples were buried in various soil conditions with monitoring systems to check soil PH, moisture, conductivity and temperature Second year results support our claim that The Copperweld wire does not become hollow tubes Exposing the steel core does not compromise performance

Corrosion Study

(continued)
Corrosion Scab seals off exposed steel and prevents further deterioration

Depth of corrosion was 0.056 inches, 70% of the diameter

Corrosion Concerns
Question: In Galvanic corrosion, steel is sacrificial to copper. What happens when I cut the wire and expose the steel? Will this allow the steel to corrode and leave a hollow copper tube?

Answer:
For galvanic corrosion to occur between dissimilar metals, you must have an anode (steel), a cathode (copper), and an electrolyte (moisture). A Superior bond means no moisture migration between the cathodic material and the anodic material. Based on current and historical studies, corrosion will only advance into the cut end a maximum distance of twice the diameter of the wire. At this depth a rust barrier is formed and effectively seals out the moisture. Without the electrolyte the corrosive action ceases. Also, when Copperweld is cut, the copper cladding cold flows to partially cover the cut end. This reduces the area of exposure of the steel.

Grounding
All energized electric power systems require grounding (earthing) for safety and protection of personnel and equipment This applies to power transmission & distribution, railroads, and commercial & industrial power systems Typical applications include pole grounds, substation grounds, counterpoise, mats, etc.
CCS Grounding wire

FAQs
Question: How does the flexibility compare to Copper? Answer:
With the steel core, the Copperweld product is somewhat stiffer, but the stranding configuration is flexible enough to shape easily for all applications You may experience some complaints from the lineman, but given the choice between replacing stolen material numerous times verses the stiffness, the theft deterrent issue always wins!

FAQs
Question: How durable is the copper jacket, our operations group is concerned with impact damage from shovels or hammers? Answer:
The copper jacket is permanently bonded to steel and cannot be separated To compare, we performed to test to determine the amount of force to cut #6 copper pole ground. That same force applied to the Copperweld product only dented the outside surface. The steel was not exposed.

Fatigue Comparison to Solid Copper

Steel core provides fatigue resistance Copper cladding provides conductivity More durable than solid copper

Durable !

ASTM Specifications
Specifications ASTM B 227 - Hard-Drawn Copper-Clad Steel Wire ASTM B 228 - Concentric-Lay- Stranded Copper-Clad Steel Conductors ASTM B 229 - Concentric-Lay-Stranded Copper & Copper-Clad Steel Composite Conductors ASTM B 452 - Copper-Clad Wire for Electronic Application ASTM B 910 - Annealed Copper-Clad Steel Wire.

Test Methods ASTM B 193 - Resisitivity of Electrical Conductor Materials ASTM E 8 - Tension Testing of Metallic Materials