CURRENT CARRYING CAPABILTY OF POLYESTER CARBON...
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CURRENT CARRYING CAPABILTY OF POLYESTER CARBON COATED
FOR ELECTRICAL CONDUCTOR
MOHD HAIDIR BIN MANAF
UNIVERSITI TEKNOLOGI MALAYSIA
CURRENT CARRYING CAPABILTY OF POLYESTER CARBON COATED
FOR ELECTRICAL CONDUCTOR
MOHD HAIDIR BIN MANAF
A project report submitted in partial fulfillment of the
requirement for the award of the degree of
Master of Engineering (Electrical-Power)
Faculty of Electrical Engineering
Universiti Teknologi Malaysia
DECEMBER 2014
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To my beloved mum and my late father,
my wife, my children, my siblings,
mother and father in law, brothers and sisters in law,
my colleagues and my friends
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ACKNOWLEDGEMENT
I like to express my sincere gratitude to my project supervisor Associate
Professor Dr. Hj. Mohd Muhridza Yaacob for his brilliant ideas, guidance,
encouragement and friendship in completing this project. Also, I like to dedicate my
gratitude to Dr. Joe Lui Muk Lam, Mr. Khairuddin Abd. Majid and his friend Mr.
Rizal for their support in technical and material in this project.
I also like to thanks my beloved wife Masnira Mat Daud and also our
daughters Murni Aqilah and Mirza Faqihah for their patient, support and being my
strength to complete my master course project. Special thanks to Muhammad Nizam
Kamarudin, Ahmad Fauzi Nawawi, and Azreen Hazree Baharom for their support,
contribution and encouragement. Not forgotten too, to all lecturers in my Master of
Electrical Engineering Course.
Lastly, I like to express my appreciation to my mother, my siblings, my father
and mother in law, brothers and sisters in law, my colleagues at SK Sungai Jerneh
my friends, and also to those whose has involve directly or indirectly to complete this
project.
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ABSTRACT
Copper and aluminum has been used as electrical conductor for power system
transmission and distribution a long time ago. Due to higher demand of copper and
aluminum in various sectors, copper and aluminum price has rose over a time and it
has become a catalyst of cable theft activities. The utilities company throughout the
world has lost billions of money due to cable theft activities. In this project, a carbon
fiber based material known as polyester carbon coated is tested as replacement to
copper and aluminum as electrical conductor. The conductor has been approved by
SAE and used commercially as conductor in ignition cable for automotive sector.
The main objective of this project is to study the characteristic and the current
carrying capabilities of the polyester carbon coated as electrical conductor. A
various type of test will be conducted on this conductor. Its include conductor
resistance and resistivity, voltage drop by measurement and calculation and
conductor current carrying capacity. The test that conducts meets British Standard
requirement on power cable testing. The result of this project is a set of testing data
which that will be analyzed in order to determine whether this conductor is suitable
or not suitable to be used as conductor in power system and also a comparison of
performance with existing materials.
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ABSTRAK
Tembaga dan aluminium telah digunakan sebagai pengalir elektrik untuk
sistem penghantaran kuasa dan pengagihan sejak dari dahulu lagi. Oleh kerana
permintaan yang tinggi terhadap tembaga dan aluminium dalam pelbagai sektor,
harga tembaga dan aluminium telah meningkat dari masa ke semasa dan ia menjadi
pemangkin aktiviti kecurian kabel. Syarikat utiliti di seluruh dunia telah kerugian
berbilion ringgit disebabkan oleh kecurian kabel. Dalam projek ini, bahan berasaskan
serat karbon dikenali sebagai ‘polyester carbon coated’ diuji sebagai bahan gantian
kepada tembaga dan aluminium sebagai pengalir elektrik. Pengalir tersebut telah
digunakan secara komersial dalam kabel pencucuhan untuk sektor automotif dan
telah mendapat keluluskan dari SAE. Objektif utama projek ini adalah untuk
mengkaji ciri dan keupayaan membawa arus ‘polyester carbon coated’ sebagai
pengalir elektrik. Pelbagai jenis ujian akan dijalankan pada pengalir ini. Ia
termasuklah pengujian rintangan dan kerintangan pengalir, kejatuhan voltan melalui
pengiraan dan pengukuran dan keupayaan pengalir membawa arus,. Ujian yang
dijalankan adalah memenuhi piawaian ‘British Standard’ pengujian terhadap kabel
kuasa . Hasil projek ini adalah satu set ujian data yang yang akan di analisis untuk
menentukan sama ada pengalir ini sesuai atau tidak sesuai untuk digunakan dalam
sistem kuasa dan juga perbandingan prestasi dengan bahan-bahan yang sedia ada.
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CHAPTER TITLED PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xii
LIST OF ABBREVIATIONS xv
LIST OF SYMBOLS xvi
LIST OF APPENDICES xvii
1. INTRODUCTION
1.1 Definitions of Conductor 1
1.2 Problem Statement 3
1.3 Objective 4
1.4 Scope of Work 5
1.5 Expected Result 5
1.6 Thesis Outline 6
TABLE OF CONTENTS
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2. LITERATURE REVIEW
2.1 Electric Cable 7
2.2 Copper and Aluminum Conductor 10
2.3 Carbon Fiber 13
2.4 Properties of Carbon Fiber 16
2.5 Electric Properties of Carbon Fiber 18
2.6 Advantages and Disadvantages of Carbon Fiber 19
3. METHODOLOGY
3.1 Introduction 21
3.2 Electric Resistivity Measurement 24
3.3 Voltage Drop Measurement 27
3.4 Current Measurement 29
3.5 Temperature Measurement 33
3.6 Conductor DC Resistance Measurement 34
3.7 Current Carrying Capacity Measurement 35
3.7.1 Measurement Circuit for 0.52 AC current 37
3.7.2 Measurement Circuit for 1.0 AC current 38
3.7.3 Measurement Circuit for 1.52 AC current 39
3.7.4 Measurement Circuit for 2.0 AC current 40
3.7.5 Measurement Circuit for 2.52 AC current 41
4. RESULT, ANALYSIS AND DISCUSSION
4.1 Introduction 42
4.2 Conductor DC Resistance Measurement Result 43
4.3 Measurement Result
4.3.1 Measurement by 0.52 Amp AC Current 45
4.3.2 Measurement by 1.0 Amp AC Current 48
4.3.3 Measurement by 1.52 Amp AC Current 50
4.3.4 Measurement by 2.0 Amp AC Current 53
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4.3.5 Measurement by 2.52 Amp AC current 56
4.4 Resistance and Resistivity Analysis 60
4.5 Voltage Drop Analysis 64
4.6 Power Dissipation Analysis 67
4.7 Conductor Temperature Analysis 69
4.8 Current Carrying Capacity Analysis 71
5. CONCLUSION
5.1 Conclusion 75
5.2 Further Works 76
REFERENCE
Appendices A - E
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79 - 103
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TABLE NO.
LIST OF TABLE
TITLED PAGE
1.1 Resistivity of material 2
2.1 Advantage and disadvantage of copper and aluminum 13
4.1 Load voltage, load current and power for 0.52 Amp 45
4.2 Conductor temperature for 0.52 Amp 46
4.3 Load voltage, load current and power for 1.0 Amp 48
4.4 Conductor temperature for 1.0 Amp 49
4.5 Load voltage, load current and power for 1.52 Amp 51
4.6 Conductor temperature for 1.52 Amp 52
4.7 Load voltage, load current and power for 2.0 Amp 54
4.8 Conductor temperature for 2.0 Amp 55
4.9 Load voltage, load current and power for 2.52 Amp 57
4.10 Conductor temperature for 2.52 Amp 58
4.11 Resistance and resistivity comparison 60
4.12 Voltage drop and power dissipation by calculation 63
4.13 Voltage drop on conductor 64
4.14 Load power, power dissipation, and efficiency 67
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FIGURE NO. TITLED PAGE
1.1 Problem statement 3
2.1 Electric cable cross-sectional area 8
2.2 Cable insulation layer 9
2.3 Copper prices trend in 10 years 10
2.4 Aluminum prices trend in 10 years 11
2.5 The process for making carbon fiber from PAN and
pitch precursors 15
2.6 Carbon fiber fabrication process 16
2.7 Properties of some PAN based carbon fiber 17
2.8 Thermal properties of the most advance pitch based
Carbon fiber 17
2.9 Electrical resistivity versus temperature for carbon
Fiber 18
3.1 Research methodology flowchart 21
3.2 Ignition cable with carbon fiber conductor 22
3.3 High performance ignition cable cross-sectional area
Diagram 23
LIST OF FIGURES
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3.4 Configuration of electrical resistivity measurement of
carbon fiber 25
3.5 Measured and declares value of carbon fiber resistivity 26
3.6 Current measurement by using ammeter 31
3.7 Voltage measurement by using voltmeter in parallel
with shunt resistor 31
3.8 Current measurement by using clamp-on ammeter 32
3.9 Schematic representation of thermocouple 33
3.10 Measurement setup 34
3.11 Measurement circuit 36
3.12 Measurement circuit for 0.52 Amp 37
3.13 Measurement circuit for 1.0 Amp 38
3.14 Measurement circuit for 1.52 Amp 39
3.15 Measurement circuit for 2.0 Amp 40
3.16 Measurement circuit for 2.52 Amp 41
4.1 Temperature versus period for 0.52 Amp 47
4.2 Temperature versus period for 1.0 Amp 50
4.3 Temperature versus period for 1.52 Amp 53
4.4 Temperature versus period for 2.0 Amp 56
4.5 Temperature versus period for 2.52 Amp 59
4.6 Load voltage and voltage drop for measurement 65
4.7 Permissible voltage drop BS7671 66
4.8 Load power and power dissipation 68
4.9 Conductor temperature 70
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LIST OF ABBREVIATIONS
BS British Standard
IET Institution of Engineering and Technology
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronic Engineer
TNB Tenaga Nasional Berhad
TM Telekom Malaysia
IACS International Annealed Copper Standard
SI Systeme Internationale
PVC Polyvinyl Chloride
XLPE Cross Linked Polyethelyene
PAN Polyacrylonitrile
RFI Radio Frequency Interference
EMI Electromagnetic Interference
SAE Society Automotive Engineers
RTD Resistance Temperature Detector
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LIST OF SYMBOLS
M Micro
Q Ohm
OC Degree Celsius
K Kelvin
A Ampere
kA kiloAmpere
mA miliAmpere
Amp Ampere
V Volt
kV kilovolt
mV miliVolt
W Watt
P Rho
m meter
cm centimeter
mm millimeter
% percent
LIST OF APPENDICES
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APPENDIX
A
B
C
D
E
TITLE PAGE
TABLE 4D1A BS 7671 CURRENT CARRYING
CAPACITY 82
TABLE 4D1B BS 7671 VOLTAGE DROP 84
ULTRA POWER IGNITION LEAD PATENT
DOCUMENT 83
BS EN 60288 CONDUCTOR OF INSULATED
CABLES 98
BS 7671 REQUIREMENT FOR ELECTRICAL
INSTALLATION 105
CHAPTER 1
INTRODUCTION
1.1 Definitions of Conductor
Conductor is a material or medium which permits an electron flow through it.
The electron in low resistivity material will flow when electromotive force (emf) was
applied on it. The flow of this electron is known as electric current and measured in
unit Amperes (A). Copper and aluminum is an example of conductor materials.
Copper and aluminum is widely used as conductor in wire and cable. It has been
used for power generation, transmission, distribution, telecommunication, electronic
circuitry and wiring for residential, commercials and industries.
The capability of material to conduct electric current is very relying to it
resistivity. Material with low resistivity is the best conductor and the material with
high resistivity is a bad conductor. The example of material with low resistivity is
silver, but it is too expensive to be used as conductor. Some material resistivity is
depicted in table 1.1 below.
Table 1.1 : Resistivity of material (metal)1
From the table the less expensive material but has good resistivity after silver
is copper and aluminum. The selection of conductor not only depending to it
resistivity, but the tensile strength, stiffness, thermal conductivity, life span include
corrosion and oxidization also has to considered.
There are also non-metallic conductor such as graphite, solution of salt,
carbon, plasma and etc. It has been found that carbon fiber is a good electric
conductor. In this project, a carbon fiber known as polyester coated carbon is tested
to find the potential of the material to be used as replacement for copper and
aluminum for wire and cable conductor in power system transmission and
distribution. This conductor currently has used as conductor in ignition cable for
automotive sector.
Material Resistivity
Cooper 0.0178µΩm
Aluminum 0.0285 µΩm
Tin 0.114 µΩm
Silver 0.0163 µΩm
Brass 0.06-0.09 µΩm
Iron 0.100 µΩm
Lead 0.218 µΩm
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1.2 Problem Statement
Copper and aluminum is widely used as conductor in wire and cable since in
the early stage of electric power system is developed. Copper and aluminum also
popular in industrial sector, commercials and house appliance, building construction,
automotive parts, machinery parts and etc. Due to high demand in multiple sectors,
the price of copper and aluminum is steadily rose year on year. This caused electric
cable theft activities which peoples can resale the cable as scrap metal to earn money.
Even though there are some efforts from the utility company and authority to prevent
these activities, it is cannot be fully prevented.
There are a lot of impact due to cable theft activities to utility company,
industries and consumer site. As reported by News Straits Times, Tenaga Nasional
Berhad (TNB) loses RM180 million in cable theft almost a decade. Utusan Malaysia
reported that Telekom Malaysia (TM), loses RM29 million in eight months due to
cable theft. The impact of this cable theft is the utility company need to spend much
money to replace the missing cable. In addition, cable theft caused a fault in power
system and telecommunication system. This will increase their interrupting time to
troubleshoot and restore their services. Figure 1.1 shows the newspaper cutting
regarding to this problem.
Figure 1.1 Problem statement2
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In consumer site, cable theft caused failure to their electrical equipment and
appliance due to voltage incremental. The industrial, commercial and services sector
suffers a lost in millions due to power interrupting. The power interrupting will
impact on their productivity as their plant cannot operate as usual. In commercial
and services sector, telecommunication services interrupting caused difficulties on
operation since they were unable to communicate via internet or intranet. The
situation is worsening when electric and electronic equipment cannot operate due to
power supply is not available. Many of tasks cannot be done until the power system
and or telecommunication services were restored.
One way to overcome the problems is by replacing copper and aluminum
with other material which did not have a resale value. Through this project,
polyester coated carbon was proposed to solve cable theft problem. Polyester carbon
coated is material which were derived from man-made fiber through carbonization
process, which are stronger than metal, lighten than copper and aluminum. It also
has a high tensile strength, and good electrical properties.
1.3 Objective
The objective of this project is as below:
1. To study characteristic of polyester carbon coated as high voltage cable
conductor.
2. To conduct current carrying capacity test on the material.
3. To compare the performance with existing material.
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All testing and experiment will be done at High Voltage and High Current
Institute, Universiti Teknologi Malaysia. To meet the objectives, all test or
experiment that will conduct on this conductor will follow to standard testing
procedure on power cable.
1.4 Scope of work
Scope of work on this project is to complete the following tasks:
1. Testing the current carrying capability of polyester carbon coated.
2. Measurement on resistivity, losses and voltage drop of the conductor.
3. Determination the capability of the conductor to conduct continuous AC
current.
1.4 Expected Result
The result expected from this project is an understanding of the characteristic
of polyester carbon coated as electric conductor through the analysis of the testing
data. The data will be analyzed to find the performance of the material, current
carrying capability and comparison with existing material. The result will be
determined the advantages and disadvantages of the material as electrical conductor.
These result also will determined whether the conductor is suitable or not suitable to
be used as electric conductor for power transmission and distribution.
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1.5 Thesis Outline
This thesis is divided into five chapters. There are:
i. Introduction. This chapter describes the problem statement, objective, scope
of work and expected result.
ii. Literature review. This chapter is concentrate in detail on cable, copper and
aluminum as conductor, carbon fiber properties and characteristic,
advantageous and disadvantageous of carbon fiber.
iii. Methodology. This chapter explains in details the project methodology,
conductor resistance testing technique, voltage and current measurement
procedure in electric circuit and conductor temperature measurement
technique.
iv. Result, Analysis and Discussion. This chapter presenting in details the
testing and measurement result of conductor resistance and resistivity,
voltage drop measurement, load current measurement, power dissipation
measurement, and conductor temperature measurement, the detail analysis
and discussion on data from calculation and testing result, characteristic of
the conductor under AC current, and determination of current carrying
capability of polyester carbon coated.
v. Conclusion. Summary of project findings and further works.
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REFERENCES
1. Giancoli, Douglas C., Physics, 4th Edition, Prentice Hall, 1995.
2. Veena Babulal, TNB loses RM180m in cable theft, News Straits Times,
Jun 2013.
3. M. Khalifa, High-Voltage Engineering, Theory and Practice, Marcel Dekker,
Inc., 1990.
4. Andrew Mickey, Copper: The Bull Market Continues, Wealth Wire Special
Report, 2011.
5. Micheal Petro, Material and Services – Direct, Metals, Accenture, 2013.
6. Deborah D. L. Chung, Carbon Fiber Composites, Butterworth-Heinemann,
1994.
7 Luk Mui (Joe) Lam, Ignition Apparatus, US007819109B2, 2010.
8 A. G. Clegg, N. V. Dovaston, Conductor and Super Conductor, In: M. A.
Laughton, D. F. Warne, Electrical Engineer Reference Book, Sixteenth
Edition, Newnes, 2003, 5/1-5/13
9. Veronika ŠAFÁŘOVÁ, Jan GRÉGR, ELECTRICAL CONDUCTIVITY
MEASUREMENT OF FIBERS AND YARNS, 7th International Conference
TEXSCI, Liberec, Czech Republic, Technical University of Liberec,
2010, 1-8 .
10 Serge Rebouillat, Michael E.G. Lyons, Measuring the Electrical Conductivity
of Single Fibres, International Journal of Electrochemical Science, 2011, 6
(2011),5731 – 5740.
11 Darrell Locke, Guide to Wiring Regulations, 17th
Edition IEE Wiring
Regulations (BS 7671:2008), John Wiley and Sons Ltd, 2008.
12 Tony R. Kuphaldt, Lesson In Electric Circuit, Volume I – DC, Design
Science License, 2006.
13 Larry D. Jones, A. Foster Chin, Electronic and Instrument Measurement,
Second Edition, Prentice Hall, 1995.
14 British Standard, Conductor of insulated cables, London, BS EN 60228,
2005.
15 British Standard, Requirement for Electrical Installations, London, BS 7671,
2013.
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