The ELECTRICAL ENGINEER
ABOUT THE COVER:
Third Quarter 2012
Table of Contents from the office of the National President
6
Know his Eight-Point Agenda for 2012 ....
Under IIEE spotlight See the different activities conducted by our Chapters in snaphots...
7 10
cover story Feed in Tariff in the Philippines
technical feature
13
• Product Assessment of Power Copper Clad Aluminum
21
from the member’s point of view
• A growing awareness of the criticality of the environment has also led to an equivalent inner state panic to most clean energy advocates encouraging alternative means rather than the insatiable exploitation of fossil fuels.
2012 IIEE BOARD OF GOVERNORS AND OFFICERS National President Jules S. Alcantara VP-Internal Affairs Gregorio R. Cayetano VP-External Affairs Alex C. Cabugao VP-Technical Affairs Ma. Sheila C. Cabaraban National Secretary Larry C. Cruz National Treasurer Florigo C. Varona National Auditor Angel V. De Vera, Jr. Governor-Northern Luzon Ronaldo G. Lamaroza Governor-Central Luzon Virgilio S. Luzares Governor-Metro Manila Eusebio A. Gonzales Governor-Southern Luzon Jozane F. Jalbuena Governor-Bicol Edwin G. Parañal Governor-Western Visayas Cirilo C. Calibjo Governor-Eastern/Central Visayas Federico C. Mercado Governor-Northern Mindanao Remegio B. Gonzales Governor-Southern Mindanao Benjamin A. Arboso Governor-Western Mindanao Richard O. Lizardo Immediate Former President Armando R. Diaz Executive Director Ramon P. Ayaton
IIEE NATIONAL SECRETARIAT DEPARTMENT HEADS Administrative Niellisa Joy B. Bandong Technical-OIC Ma. Elena U. Liongson Marketing Allen M. Pido Membership Marjorie Aguinaldo-Muñoz
PUBLICATIONS COMMITTEE Chairman: Rolito C. Gualvez Vice Chairman: Ronald Vincent M. Santiago Members: Ernesto M. Cabral Marvin H. Caseda Glynn Andy O. Gayman Dr. Allan C. Nerves Roland P. Vasquez Overseer: Ma. Sheila C. Cabaraban
The ELECTRICAL ENGINEER The Electrical Engineer is published quarterly by the Institute of Integrated Electrical Engineers of the Philippines, Inc. (IIEE), with editorial and business offices at #41 Monte de Piedad St., Cubao, Quezon City, Philippines. Tel Nos. (632) 722-7383, 7273552, 412-5772, 414-5626, Fax Nos. (632) 721-6442 & 410-1899. Website: www.iiee.org.ph, E-mail: iiee@iiee.org.ph. The present circulation of the magazine is 32,000 copies per issue to members and industry stakeholders. The ELECTRICAL ENGINEER Editorial Board Chairperson Ma. Sheila C. Cabaraban Editor-in-Chief Rolito C. Gualvez Associate Editor: Ronald Vincent M. Santiago Technical Consultant: Dr. Allan C. Nerves Administrative Officer: Ramon P. Ayaton Advertising and Marketing Account Executive Joan Q. Delos Santos 727-3552 loc. 101 410-1899
Clean and Affordable Electricity An advocacy for everyone Nearly 90% of electricity comes from different sources that gradually affect our environment: fossil fuels such as coal, oil and natural gas (source: All Energy Solutions, 2009). Fossil-fuelled power plants contribute to the increase in pollutants causing acid rain, smog, and other forms of air and water pollution. These pollutants also cause respiratory illness such as asthma, among people, specifically in children. Furthermore, developing countries such as the Philippines have been increasing their dependence on energy sources that emits Green House Gases (GHG) that contribute to climate change. According to the Asian Development Bank, about 65% of global GHG emissions come from the energy consumption. Asia is one of the faster growing sources of GHG emission. The Republic Act 9513 known as the Renewable Energy Act of 2008 aims to promote the development, utilization and commercialization of renewable energy sources. Renewable energy sources include solar, wind, ocean, biomass, geothermal and hydropower. This act hopes to lead in reducing the dependence of the country on fossil fuels that deteriorate the environment. Furthermore, it aims to adopt the use of clean energy, thereby mitigating adverse effects of climate change. As one of the most primary advocacies of the government, industries and environmentalists nowadays, let us also do our share. Let us all support the promotion of “Clean and Affordable Electricity”.
---The Electrical Engineer Editorial Board
Views or opinions expressed by the authors of letters,
articles and research studies published in The Electrical Engineer DO NOT necessarily reflect the views of the Institute of Integrated Electrical Engineers of the Philippines, Inc. (IIEE). The IIEE trusts the integrity of these authors. The IIEE exercises due diligent review but it is possible that the contents of the articles contributed may not be verified due to time constraints. Articles or visual materials may not be reproduced without written consent from IIEE. The IIEE reserves the right to accept or refuse submitted materials for publication. Articles, reactions and feedback from readers may be sent through e-mail at publications_committee@yahoo.com.
from the office of the National President
Engr. Jules S. Alcantara 2012 IIEE National President The Eight-Point Agenda introduced early this year is guided by the core values of the Institute – the IIEE or Integrity, Innovation, Empowerment and Excellence. Integrity is a virtue necessary for the progress of an organization. It’s the most basic core value. The second core value of Innovation is about continual improvement and progress - in skills, knowledge, ideas, processes and even relationships. Empowerment allows the various IIEE chapters to undertake programs for the benefit of the members and the community and be recognized for it. Lastly, Excellence in our profession needs to be raised to an even higher level in light of the competitive environment of engineering services in a global economy. The following are the details of what were done for the year: 1. Implementation of the Amended Constitution and By Laws In compliance to the Amended Constitution and By-Laws of the IIEE ratified last May 21, 2011 in Bacolod City, the IIEE Board of Governors has done the following: • The appointment of Ad-Interim Governors for the newly created regions --- Metro Manila and Western Mindanao in the persons of Engr. Eusebio “Elboy” Gonzales for Metro Manila (NCR) and Engr. Richard O. Lizardo for Western Mindanao; • Defined the Western Mindanao Region as composed of the following chapters: (1) Misamis Occidental; (2) Zambasulta; (3) Zamboanga Del Norte; (4) Zamboanga Del Sur and (5) Zamboanga Sibugay. 2. Construction of Phase 1 of the New Building Project of IIEE. • The new five-storey building constructed on a 117 sq.meter lot besides the existing IIEE building is scheduled for completion this December 14, 2012 • This building will provide the needed additional space to host the secretariat, technical document centre, more library space, sleeping quarters for IIEE officers and members from the provinces, an expanded laboratory, the Energy Efficiency Training Center and additional training/ conference rooms; • The construction of this new five-storey building costs PhP10.67M which contractor was determined through an open and competitive bidding. 3. Improving the Services to Members. • Implemented the Balanced Scorecard System (BSC) used by many corporations with good governance. BSC measures performance and aims for continual improvement. We believe in the saying that “What we can measure, we can improve”. Performance indicators allowed the Institute to check and track its service performance, to adjust for the better its systems, policies and procedures to meet the requirements of its members, officers and the community; • IIEE, through Chapter Excellence Awards, recognized the Chapters who unselfishly served the members and the community with excellence. This is aside from the Most Outstanding Chapter Awards in Small, Big and Foreign Chapter Categories; • Based on the BSC, the IIEE secretariat recognized key areas that need improvements and set a culture of continual self improvement in the various aspects of corporate work in their service for IIEE officers and members; • The Institute also reduced the Life Membership Fee from PhP 10,000 to PhP 5,000 with the requirement that the member should have been a Regular Member of Good Standing for at least twelve (12) years. 4. Improvement of IIEE Processes. • Developed and implemented the Membership On-line Registration and E-card System (or MORE System) - an on-line registration system for the present and future regional conferences, National Mid-Year and Annual National Conventions together with an E-Card System that updates the antiquated member database system; • The IIEE Manual of Approvals and an updated Manual of Operations were prepared to guide the present and future officers and members in many of the IIEE processes they are involved in. These manuals will ensure continued good governance in the management of IIEE National Office and Chapters. 5. Expansion of Information Dissemination through the effective use of the Internet, the IIEE Web Site and community works. • The new look and the continued updating of the IIEE website aims for the sharing of knowledge and information through technical articles, technical questions and answers, positive experiences and activities of members and chapters, community works including the downloadable EE Magazines, technical articles a nd list of members with expiring membership; • Direct contact information of the IIEE National Secretariat is posted in the IIEE Website to address in a timely manner the concerns and requests of the members through direct contact with the staff-in-charge; • An Official Facebook Page administered by the Vice President for Technical Affairs to provide an additional communication channel to the members. 6. Promotion of Safety, Energy Efficiency, Power Quality advocacies through joint efforts and cooperation with other organizations and groups. • Partnerships were developed with different government, private and industry sectors such as the Department of Energy (DOE), National Electrification Administration (NEA), International Copper Association (ICA) and various electric utilities;
Third Quarter
PRESIDENT’S REPORT
• • • • •
•
• •
The DOE and IIEE jointly published three (3) books on Energy Efficiency through the PELMATP Project; The ICA and IIEE jointly published three (3) manuals on Electrical Safety, Residential Inspections and PEC Primer through the IIEE ESEA Committee; The new phase of our program on power quality is launched this year through the international conference on Power Quality; The International Finance Corporation is set to sign a MOA with IIEE in establishing the Energy Efficiency Training Centre to fast tract the advocacy of energy efficiency in the Philippines; Last May 5, about seventeen chapters and the IIEE National Office participated in simultaneous fun run activity by the IIEE’s Electrical Safety Enforcement and Awareness (ESEA) Campaign in celebration of the Electrical Safety Month; The IIEE intensified its efforts to enjoin the LGUs to consider the role of registered electrical practitioners in their municipalities in order to ensure electrical safety in the residential and commercial establishments in their municipalities. For the same reasons, the IIEE and NEA agreed to help each other in the training of barangay electricians to become Registered Master Electricians in compliance with the provisions of the New Electrical Engineering Law. IIEE encouraged the LGUs to follow the direction of the City of Tagum who worked closely with the local IIEE chapter to ensure a safe community. Many things are still to be done in this aspect such as the full realization of the Electricians Academy for electrician apprentices by the IIEE chapters; IIEE updated the Philippine Electrical Code 1 with a PEC 1 2012 edition; Partnered with MERALCO on accreditation of electrical contractors in the interest of electrical safety.
7. Enhancing the skills of IIEE Members and Students and future Master Electricians. • Develop new strategies in formulating a series of both technical and management trainings for the members, officers, exhibitors and sponsors. In addition to the usual technical trainings for its Continuing Professional Education program, there were two economic/ business briefings undertaken for IIEE members, the IIEE secretariat, exhibitors and sponsors; • Extended trainings to out-of-school youths, barangay electricians and students. The IIEE encouraged the chapters to train barangay electricians to upgrade their careers to Registered Master Electricians (RME) and to actively engage students and out-of-school youths in the realization of future careers in electrical engineering. Sponsors like NGCP are supporting student activities during the ANC. The Board of Governors approved the concept of an Electricians Academy to train barangay electricians as Apprentices through the various IIEE Chapters. Several IIEE chapters have supported trainings for our marginalized fellow citizens to become RMEs; • Cooperated fully with the Professional Regulation Commission (PRC) on the Philippine Road Map for skills development to meet the challenge of the Mutual Recognition Agreement (MRA) among ASEAN countries in the practice of engineering. • This MRA enhances cooperation amongst ASEAN Member Countries in order to improve efficiency and competitiveness and diversify the supply and distribution of services by recognizing the education and experience of the engineers of an ASEAN member country in another member country for licensing purposes. Thus, we have to be prepared and competitive in relation to other engineers belonging to other ASEAN countries; • Participated with the Philippine Technological Council in the implementation of the Washington Accord- an international agreement that recognizes substantial equivalence in the accreditation of qualifications in professional engineering tertiary education; • The 120 exhibitors and sponsors completely filled up all the booths and have shown passionate support to IIEE thru innovative products and knowledge-enhancing presentations during the 37th Annual National Convention. Delegates would be able to see, technically understand and consider the use of newer technologies and the excellent electrical products available in the market. 8. For a safe nation, IIEE is advocating preparedness in response to the effects of climate change and to disasters like earthquakes, typhoons and floods. • Initiated actions in support of its advocacy for a better disaster response. IIEE responded to Cagayan de Oro City and Iligan City in their call for help from IIEE, electrical engineers, master electricians and electrical inspectors as an aftermath of typhoon “Sendong”; • The National Mid Year Convention in Cagayan De Oro City last May, 2012 and this 37th Annual National Convention highlighted the effects of climate change, natural disasters and the ideal responses by electrical practitioners to these disasters. CEPALCO and MERALCO are supporting IIEE in this advocacy.
Under the IIEE Spotlight
IIEE Aklan Chapter conducting a technical seminar on Short Circuit Calculations and Motor Protection and Control last July 7 at Garcia College of Technology attended by 46 members and 43 students from the chapter. IIEE Capiz Chapter during its Chapter Officers Meeting last June 21 . The meeting discussed the updates on the Brigada Eskwela Project of the chapter this coming August.
IIEE iloilo Chapter during its Mid-Year Technical Seminar and General Assembly last July 6 at Rizal Queen Hotel.
IIEE Leyte Samar Chapter during a Livelihood Skills Development Training last July 28-29 in La Paz, Leyte.
The Central Laguna Chapter conducting an RME Premier Review at Fuji Haya last August 25.
3rd QUARTER 2012
THE ELECTRICAL ENGINEER
7
Under the IIEE Spotlight
IIEE Cagayan De Oro Chapter supporting the Brigada Eskwela Project of the Department of Education by providing free electrical wiring inspection prior to the opening of school year 2012-2013.
IIEE Bulacan Chapter’s 2012 VP-Internal Affairs Engr. Edgardo C. Calantuan and 2012 VP-External Affairs Engr. Romeo B. Indiongco at the “Orientation Forum About 8th Gawad Kaligtasan at Kalusugan (GKK) and 13th National Occupational Safety and Health (NOSH)Congress” last July 17, 2012 (Tuesday) at the DOLE RO III Building inside the Regional Government Center, Barangay Maimpis, City of San Fernando, Pampanga.
IIEE-Negros Occidental Members during the Mid-year Summit held last June 29, 2012
IIEE Leyte Samar Chapter conducting a meeting with the Eastern Visayas State University (EVSU) President for the Rehabilitation of the Electrical System in EVSU last July 10.
Under the 8
THE ELECTRICAL ENGINEER 3rd
QUARTER 2012
Under the IIEE Spotlight
IIEE CDO Chapter during the 2nd Kuryente Sports festival last July 14, 2012 .
IIEE Antique Chapter conducting a technical seminar on Fundamentals of Distribution System Engineering last July 21. IIEE Antique Chapter Former President, Engr. Tacogdoy, explaining to the IIEE-University of Antique Student Chapters (IIEE-UASC) members the different conductors used in the distribution system
The IIEE- Zamboanga Sibugay Chapter conducted an oath taking ceremonies of 2012 officers last May 30, at Casa Mia Hotel Ipil Zamboanga Sibugay.
...iiee spotlight 3rd QUARTER 2012
THE ELECTRICAL ENGINEER
9
Cover Story
Feed in Tariff in the Philippines On July 27, the Energy Regulatory Commission (ERC) approved the final rates for the Feed in Tariff (FIT), which is expected to attract more investors for renewable energy in the Philippines. Although the rates were lower compared to what was set by the National Renewable Energy Board (NREB), investors in the power sector are now incentivized with the following tariffs according to the ERC: Php 5.90 per kilowatt-hour (kWh) for hydroelectric power sources, Php 6.63/kWh for biomass energy sources, Phpp 8.53/kWh for wind, and Php 9.68/kWh on solar power. Final rates were not yet issued for ocean thermal energy resources as it is still undergoing review and further studies. The Renewable Energy Act The approval of the FITs brings the country's energy sources closer to the goals of the Republic Act No. 9513 also known as the Renewable Energy Act of 2008, which aims to "accelerate the development of emerging renewable energy resources, a feed-in tariff system for electricity produced from wind, solar, ocean, run-of-river hydropower, and biomass" (Chapter III, Sec. 7). Encouraging the use of "green energy", the Renewable Energy Act is expected to accelerate exploration and development of renewable energy resources in the country, thru institutionalization of the development of national and local capabilities in using renewable energy systems. In addition, the Act is also expected to minimize the country's dependence on fossil fuels, thus a reducing the "country's exposures to price fluctuations in the international market (Chapter I, Sec. 2.a),� and "effectively prevent or reduce harmful emissions and thereby balance the goals of economic growth and development with the protection of health and environment (Chapter I, Sec. 2.b)�. The Act also mandates the establishment of all necessary infrastractures and mechanisms for its implementation.
10
THE ELECTRICAL ENGINEER 3rd
The Feed-in Tariff System Under the feed-in tariff system, renewable energy generators would be provided with a "guaranteed market and a guaranteed price for their power, in addition to tax credits for developers and value added tax and duty-free importation of renewable technologies." (cleanenergysolutions.org). This energy system incentive is already being implemented in several countries worldwide, including the United States, United Kingdom, Canada, France, and in Asian countries such as Japan, China, India, and Thailand. According to climatepedia.org, well-designed feed-in tariffs ensures a market for renewable power, making it easier and cheaper for renewable energy projects, attracting investment; reducing the risk of market volatility thru a predetermined rate, reducing transaction costs; and is the most cost-effective way to foster renewable power sources. On its July 2010 press release, the ERC said that the FIT rules offers a guaranteed payments over a definite period of time to Renewable Energy (RE) developers. The National Grid Corporation of the Philippines (NGCP) shall be tasked to allocate the energy to the customers, who shall then be required to pay a uniform peso per kWh charge, which shall be called as the Feed-in Tariff Allowance (FIT-All). The National Transmission Corporation (Transco) has been endorsed by the NREB to act as administrator of the FIT-All which shall be collected from the electricity customers. Proceeds of the FIT-All collected shall go to a fund from which the payment for the FIT-eligible Renewable Energy Developers shall be taken.
QUARTER 2012
Cover Story
Although the rates were lower compared to what was set by the National Renewable Energy Board (NREB), investors in the power sector are now incentivized with the following tariffs according to the ERC: Php 5.90 per kilowatt-hour (kWh) for hydroelectric power sources, Php 6.63/kWh for biomass energy sources, Phpp 8.53/kWh for wind, and Php 9.68/kWh on solar power. Final rates were not yet issued for ocean thermal energy resources as it is still undergoing review and further studies. The Renewable Energy Act The approval of the FITs brings the country's energy sources closer to the goals of the Republic Act No. 9513 also known as the Renewable Energy Act of 2008, which aims to "accelerate the development of emerging renewable energy resources, a feed-in tariff system for electricity produced from wind, solar, ocean, run-of-river hydropower, and biomass" (Chapter III, Sec. 7). Encouraging the use of "green energy", the Renewable Energy Act is expected to accelerate exploration and development of renewable energy resources in the country, thru institutionalization of the development of national and local capabilities in using renewable energy systems. In addition, the Act is also expected to minimize the country's dependence on fossil fuels, thus a reducing the "country's exposures to price fluctuations in the international market (Chapter I, Sec. 2.a),� and "effectively prevent or reduce harmful emissions and thereby balance the goals of economic growth and development with the protection of health and environment (Chapter I, Sec. 2.b)�. The Act also mandates the establishment of all necessary infrastractures and mechanisms for its implementation. The Feed-in Tariff System Under the feed-in tariff system, renewable energy generators would be provided with a "guaranteed market and a guaranteed price for their power, in addition to tax credits for developers and value added tax and duty-free importation of renewable technologies."
(cleanenergysolutions.org). This energy system incentive is already being implemented in several countries worldwide, including the United States, United Kingdom, Canada, France, and in Asian countries such as Japan, China, India, and Thailand. According to climatepedia.org, well-designed feed-in tariffs ensures a market for renewable power, making it easier and cheaper for renewable energy projects, attracting investment; reducing the risk of market volatility thru a predetermined rate, reducing transaction costs; and is the most cost-effective way to foster renewable power sources. On its July 2010 press release, the ERC said that the FIT rules offers a guaranteed payments over a definite period of time to Renewable Energy (RE) developers. The National Grid Corporation of the Philippines (NGCP) shall be tasked to allocate the energy to the customers, who shall then be required to pay a uniform peso per kWh charge, which shall be called as the Feed-in Tariff Allowance (FIT-All). The National Transmission Corporation (Transco) has been endorsed by the NREB to act as administrator of the FIT-All which shall be collected from the electricity customers. Proceeds of the FIT-All collected shall go to a fund from which the payment for the FIT-eligible Renewable Energy Developers shall be taken. For the first three years of implementation, the NREB has set FIT targets: 250MW for hydro, 250MW for Biomass, 220MW for Wind, 100MW for Solar, and 10MW for Ocean, accumulating to a total of 830MW for the first three years. The recently approved tariffs, according to the ERC, shall be valid for 20 years, and shall be subject to (1) adjustments due to economic factors such as inflation of currency exchange rates and (2) review to assess if the targets are achieved, and for any significant changes to costs. DOE on Renewable Energy
3rd QUARTER 2012
THE ELECTRICAL ENGINEER
11
Technical Feature
PRODUCT ASSESSMENT OF COPPER CLAD ALUMINUM By Engr. Feldimir D. Siao, REE, EE, MTM
PART 1 – OVERVIEW OF CCA OVERVIEW
2010 (shown in Figure 2). Aluminum prices have also Copper-clad aluminum (CCA) wire is a composite wire risen but to an extent that is less than copper (shown with an aluminum core covered by a thin copper coating in Figure 3). The copper to aluminum price ratio have as shown in Figure 1. There are several variations of the increase from about 1.5 in 2004 to almost 3.5 at the wire with respect to the volume percentage of copper start of this year (shown in Figure 4). Taking into cladding. However, majority of these wires would have consideration the specific gravity and conductivity 10% or 15% copper by volume with reference to ASTM of both metals, means that an equivalent copper B-566 (2004). conductor cost about 7 times that of aluminum.
Figure 1: Copper-Clad Aluminum wire cross section
Paul Dion and Martin Carr invented manufacture of this CCA for Texas Instruments Inc. US patent application was filed on April 26, 1967 and granted on July 15, 1969 as US Patent No. 3,455,016. This development made it possible to have a light weight conductor without the inherent problems of aluminum with oxidation and connection compatibility. Though it appears that CCA was developed as a low cost alternative to copper due to the majority of the composite wire made of cheaper aluminum, it is not so since copper to aluminum ratio is about 1.5 during that time. The cost savings recognized with cheaper aluminum is easily negated by the fabrication cost and at times more costly than their copper equivalents when copper prices fall. Starting in 2003, copper prices have dramatically risen to more than 5 times its record peak in 2008. Copper prices retrenched due to the US recession but have quickly recovered to its pre-recession price in 1
Figure 2: London Metal Exchange Copper Prices1
Figure 3: London Metal Exchange Aluminum Prices1
Source: ICF Raw Materials Update, ICF News Issue 68
3rd QUARTER 2012
THE ELECTRICAL ENGINEER
13
Technical Feature
Figure 4: Copper/Aluminum Price Ratio1
CCA is traditionally used for high frequency applications such as coaxial cables. However, with high prices of copper, these wires are now being marketed as a low cost alternative to copper, expanding its applications as low voltage building wires. Product standard that provides the specification for CCA is ASTM B 566, UL-83, and UL-1581. ASTM B 566 specifies the varieties of CCA wires and its technical requirements while UL-83 governs the use of CCA as conductor for thermoplastic insulated wires. The Underwriter’s Laboratories’ UL 83 disallowed the use of CCA as thermoplastic insulated wires and cables in Canada and Mexico, but allowed this application in the US with special requirements. UL 83 stipulates that CCA should be used only with equipment marking to indicate that it is to be used with aluminum conductors. Also, CCA conductors shall comply with the requirements of Section 11 of UL 1581 for copper-clad aluminum conductors. The Philippine Electrical Code has included this type of conductors for general wiring with ampacities equivalent to that of aluminum. Minimum conductor size for CCA shall be 3.5mm2 or 2.0mm in diameter. PROPERTIES OF CCA The physical and electrical characteristic of copper-clad aluminum in comparison with copper and aluminum are as follows:
1 2
It is not surprising that CCA has characteristics that closely resemble that of aluminum conductor due to its large aluminum volume content. MANUFACTURING METHODS OF CCA There are several methods of producing copper clad aluminum conductors and these methods are: a. Electrochemical plating Electroplating (also known as “electro-deposition) is the process of producing a metallic coat on the surface of a base material through the flow of an electric current. The aluminum wire to be coated is cleaned and prepared by employing solvents. Then it is submerged into a liquid solution known as the electrolyte or plating bath. This is a specially designed chemical solution containing dissolved submicroscopic particles of copper with positively charged ions. Available copper plating solutions are cyanide copper plating, non-cyanide alkaline copper plating and acid copper plating. The aluminum is negatively charged and acts a cathode; then a positively charged anode completes the circuit when current is supplied by a battery or
Source: ICF Raw Materials Update, ICF News Issue 68 Source: Mirae Special Metal Co. Ltd.
14
THE ELECTRICAL ENGINEER 3rd
QUARTER 2012
Technical Feature rectifier. This electric arrangement directs positively charged ions to move towards the negatively charged aluminum cathode causing a film deposit on the cathode. When the desired thickness of coating is achieved, it is removed from the plating bath. A completely integrated machine in producing CCA through electroplating is available in the market (shown in Figure 5).
d. Tube weld cladding and drawing In tube weld cladding and drawing production process, copper clad aluminum wire is produced from a copper strip being formed into a cylindrical shape placed on the outer surface of the aluminum core wherein the seam is welded together. This forms a clad wire of aluminum core with copper coat which is then subjected to drawing to produce a copper-clad aluminum wire. The welding of the copper strip seam is done in a closed environment filled with an inert gas through an integrated machine (see Figure 6). The diameter reducing process is carried through a die at a temperature of about 200째C to insure a complete metallurgical bond between the two metals. It may further undergo drawing and heat treatment several times to meet the customers' technical requirement on the diameter, electrical property and mechanical property.
Figure 5: Electroplating machine
b. Rolling pressure welding In pressure welding process, the cladded strips are produced by continuous rolling wherein the surfaces are prepared before the rolling process. Welding is done in a single pass. Subsequent heat treatment, such as sintering, diffusion and recrystallization, may be employed to improve the weld quality. c. Hydrostatic extrusion In hydrostatic extrusion, all regions of the billet other than the part in contact with the die are surrounded by fluid. The billet can deform only by extruding. The pressure required to achieve a given reduction is not only less than that required in conventional extrusion processes with the friction effect at the billet/container interface eliminated, but is also independent of the length-to-diameter ratio of the billet. Furthermore, the use of a high-pressure fluid as a pressure-transmitting medium rather than a direct mechanical contact, transmission of a hydrostatic pressure to the billet yields a significant improvement in the ductility of the resulting extruded material.
Figure 6: Tube weld cladding machine
e. Continuous filling core casting Continuous filling core casting process uses an upper and lower resistance furnace and an induction furnace designed to melt the inner and outer metals. When the heaters reach the preset temperature, the outer molten metal would flow into a crystallizer through a dummy bar drawn by an electric machine forming the outer metallic conduit layer. This is where the inner molten metal flows into: between the crystallizer and honeycomb duct. The inner and outer metals would be composited and pulled at a special pulling rate. Subsequent plastic processing is done through hydrostatic extrusion process so as to take advantage of the excellent lubrication between the metal and the die for a more uniform metal flow. Reducing to smaller wire diameter is done through drawing process.
Source: Totoku Electric Co. Ltd, Enameled Copper-Clad Aluminum Wire brochure. 3
3rd QUARTER 2012
THE ELECTRICAL ENGINEER
15
Technical Feature APPLICATION OF CCA In recent years, the application of CCA wires has grown from just a main conductor in coaxial cables to other fields such as braided outer conductors of shielding cables, winding wire, household appliances, building wires, battery cables, power cables, and bus bars. In terms of production volumes, the application of CCA can be grouped into five major classifications: a. Communication cable Copper-clad aluminum is widely used as main conductor for coaxial cables to take advantage of the skin effect principle. This causes alternating currents to flow more on the outer regions of the wire at high frequencies so that the resistance of the wire is almost the same as that of pure copper. Some Chinese producers have offered LAN cables containing CCA at prices significantly lower than conventional LAN cables. However, these low cost substitutes do not meet all the technical performance requirements for LAN cables used in business premises, but might find application at low-end LAN cable markets such as home networks. b. Cables and wires for electric equipment Copper-clad aluminum wires are promoted as low cost substitutes to copper wires in underdeveloped areas. There is still little experience on this area of application considering that in many countries the mandatory building wires used is solely copper. Also, there is a consensus regarding the hidden dangers of connections involving aluminum conductors, majority of which is the component of CCA.
With the high cost of copper, CCA has been applied as cable shield wherein it is weaved to form the shielding layer for some cables of electrical equipments and audio cables for sound systems. c. Power cables There are no standards on the use of CCA conductors as power cables since IEC, ICEA, AEIC and NEMA includes only copper and aluminum conductors as power cables. Manufacturers produce these CCA power cables based on own standards or customer requirements. The main users of these CCA power cables would be the power industry particularly the client work projects involving customer-owned electric facilities and not the distribution utilities. Main reason for this is when the client is more sensitive to the cable cost unlike those of the distribution utilities Although there has been growth in the utilization of CCA power cables, it still remains at minuscule share compared to copper power cables. d. Enameled wire The special properties of enameled CCA wires such as light weight, high conductivity, and good heat dissipation, has found application in acoustic coils (Figure 7), TV deflection coils, degaussing coils, hard drive actuator arm coil (Figure 8), optical disk laser lens pickup coil (Figure 9) and motor winding.
Using CCA as conductors for welding machine cables reduces the cost by as much as 40% even with a 20% increase in cable size compared to copper welding cable.
Figure 7: Application of CCA as acoustic coils3
CCA battery cables are still in its initial stage of testing. It needs to be two gauges bigger than its equivalent copper conductor to have similar resistance and current capacity. Using CCA can reduce the weight of the battery cable by 40%. Figure 8: Application of CCA as hard drive actuator arm coil3 Source: Totoku Electric Co. Ltd, Enameled Copper-Clad Aluminum Wire brochure. 3
16
THE ELECTRICAL ENGINEER 3rd
QUARTER 2012
Technical Feature
Figure 9: Application of CCA as optical disk laser lens pick-up coil.3
There are many cases wherein CCA wires are used for small motors of grinders, pumps, electric fans, vacuum cleaners, microwave turntables, etc. Also, CCA wires are used in winding small transformers, lamp ballasts, relays, and others. e. Busbars CCA busbars, which overcome the problem of oxidation in aluminum busbars, have the connecting performance of copper busbars and at the same time, cost relatively cheaper. Its light weight eases transportation and installation.
4. Mirae Special Metal Co., Ltd., Company Profile and Copper-Clad Aluminum Product Catalog 5. M. Schlesinger, Electroplating, Electrochemistry Encyclopedia, September 2002, http://electrochem. cwru.edu/encycl/ 6. J. R. Davis, Copper and Copper Alloys, ASM International Handbook, 2001 7. T. Yamaguchi, T. Takayama and M. Hiderita, Method of Producing Copper-Clad Wire, US Patent No. 3,854,193, December 17, 1974 8. H. Liang, Z. Xue, C. Wu, Q. Liu and Y. Wu, Research on Continuous Core-Filling Casing Forming Process of Copper-Clad Aluminum Bimetal Composite Material, Acta Metallurgica Sinica, Vol. 23 No. 3, June 2010 9. C. Kun, Some Issues on the Application of CCA in Domestic Cable & Wire Industry, Shanghai Electrical Cable Research Institute (SECRI) 10. Zhang Jiagang Victor Textile Machinery Ltd., Co., Copper-Clad Aluminum Wire Cladding Machine Catalog, http://www.alibaba.com/productgs/200431291/CCA_Wire_Machine.html 11. Totoku Electric Co. Ltd., Enameled Copper-Clad Aluminum Wire Brochure
PART 2 – STANDARDS VIEW OF CCA APPLICATION In Part 1 of this article, we have discussed an overview of copper-clad aluminum conductors: its characteristics, manufacturing methods and common applications. Now on the standards view of CCA application, we take a look at the governing product standards and CCA implications to local product standards and electrical codes. PRODUCT STANDARDS There are four varieties of CCA according copper layer volume and form based on ASTM B566, Standard Specification for Copper Clad Aluminum Wire:
Figure 10: CCA busbars
REFERENCES 1. International Cable Federation, Raw Materials Update, ICF News Issue 68, January 2011 2. P. Dion and M. Carr, Manufacture of Clad Wire and the Like, US Patent No. 3,455,016, July 15, 1969 3. Minerals Information Team, Metal Industry Indicators, US Geological Survey, September 2009
a.10A – Soft form CCA with 10% copper volume ratio b.10H – Hard form CCA with 10% copper volume ratio c.15A – Soft form CCA with 15% copper volume ratio d.15H – Hard form CCA with 15% copper volume ratio
Source: Totoku Electric Co. Ltd, Enameled Copper-Clad Aluminum Wire brochure. 3
3rd QUARTER 2012
THE ELECTRICAL ENGINEER
17
Technical Feature
The main technical requirements for these varieties of CCA wires are: 1. a. The distribution of the copper thickness shall be uniform along the circumferential direction. 2. b. The thinnest point of the copper layer shall be not less than 3.5% of the radius for 10A and 10H or not less than 5% of the radius for 15A and 15H. 3. c. CCA wires shall have a copper layer volume of not less than 8% and not more than 12% for 10A and 10H or not less than 13% and not more than 17% for 15A and 15H.
7. CCA conductors shall be marked “AL (CU-CLAD)”, ALUM (COPPER CLAD)”, “CU-CLAD AL”, or “COPPERCLAD ALUM” wherever the size of the conductor appears on the wire, cable, or package marking. 8. Also, the following statement shall appear on the package: •“Copper–clad aluminum shall be used only with equipment marked to indicate that it is for use with aluminum conductors. Terminate copper-clad aluminum with pressure wire connectors marked for use with copper and aluminum, conductors.” (see Figure 10)
For building wires, UL-83 “Standard for Thermoplastic Insulated Wires and Cables” does not allows the use of CCA for thermoplastic insulated wires and cables in Canada and Mexico but allowed its use in the United States with special requirements as follows: 1. The copper cladding shall be metallurgically bonded to the aluminum core and shall occupy 10 percent or more of the cross-section of a solid conductor or each wire strand of a stranded conductor. 2. Thickness of the copper shall not be less than 2.56% of the diameter of the solid conductor or wire (strand).
Figure 10: Electrical convenience outlet with “CO/ALR” marking
3. Conductors shall be of the same size and assembly indicated for solid and concentric stranded aluminum. 4. The DC resistance of CCA conductor shall not be greater than those specified for aluminum conductors. 5. The tensile strength of a finished CCA conductor tested as a unit or of the wires (strands) from a finished stranded CCA conductor and of a solid CCA conductor shall not exceed 138MN/m2 when specimens are test at a maximum separation speed of 300 mm/min. 6. Elongation of the same specimens shall not be less than 15% in 10 inches or 250mm.
18
THE ELECTRICAL ENGINEER 3rd
QUARTER 2012
Technical Feature
Figure 12: Sample of locally available push-in type switches
COMPLIANCE TO LOCAL STANDARDS The local governing product standard for building wires is PNS 35-1:2004. Electric wires and cables—Thermoplastic insulated copper wires and cables rated 600 volts—Part 1 General Specification covers copper conductor only for building wires. It previously covered aluminum conductors but was later removed to protect the common consumer against problems related to the use of aluminum conductors such as oxidation, creep, and availability of suitable connecting devices that have considerable safety issues. Thus, aluminum wires used for residential houses are considered as potential fire hazards. CCA conductors were not mentioned as an approved material for this application. The local Philippine Electric Code allows the use of CCA wires and cables with ampacity rating and conditions of installation same as those of aluminum cables. For aluminum wires, the required aluminum alloy is the AA-8000 series electrical grade. However, for CCA there is no prescribed aluminum alloy to be used as the core conductor. This condition raises doubt on the possible quality and performance of the aluminum conductor used as the core material. REFERENCES
Figure 13: Sample of locally available screwtype lamp socket
• For 3.31 – 5.26 mm2 (AWG No. 12 to 10 solid), CCA “May be used with wire-binding screws and pressureplate and push-in spring type connecting mechanisms that are acceptable for use with copper conductors.” • “Where physical contact between any combination of copper-clad aluminum, copper and aluminum conductors occurs in a wire connector, the connector shall be of a type marked for such intermixed use and the connection shall be limited to dry locations only.” In China, the primary standard for CCA is S/JT 11232000—a standard applied to copper-clad aluminum wires used as inner conductors of coaxial cables and conductor for electrical equipment.
1. ASTM Organization, ASTM B 566, Standard Specification for Copper-Clad Aluminum Wire, Book of Standards, Volume 02.03, 2004 2. Underwriters Laboratories, UL 83 Standard of Thermoplastic Insulated Wires and Cables, September 1998 3. Bureau of Product Standards – DTI, Philippine National Standard, PNS 35-1 2004, Electric Wire and Cables Rated 600 volts – Part 1: General Specification 4. Bureau of Product Standards – DTI, Philippine National Standard, PNS 260 2004, Electric Wire and Cables – Annealed Copper Wires - Specification 5. Institute of Integrated Electrical Engineers of the Philippines, 2009 Philippine Electrical Code Part 1, Volume 1
3rd QUARTER 2012
THE ELECTRICAL ENGINEER
19
The Clean Cost from the Member’s of Renewable Energy point of view By: Engr. Glynn Andy O. Gayman
Why should we pay attention to the price of a
commodity such as ‘Renewable Energy’ in the first place? That should be a common practical notion for any customer who certainly expends an amount for electrical energy on a regular consumption. Because the planet that we have inhabited is planted with limited physical resources, it is therefore also logical to pronounce that a consistent extraction and utilization of these fossil fuel resources is proof enough that they are bound for extinction. Quite astronomically, human exploration has led to the proliferation of inventions and theoretical formulas translated into concrete structures interwoven with engineering knowledge. This capability has grown to the discovery of a unique commodity later on coined as electricity which was then understandably the object of demand to power up the advanced technology of electrical generating facilities. So what is the deal with this Renewable Energy being an essential article of trade? From what its brand implies, a renewable energy is a product from a process derived from a naturally budding source that is replenished at a faster rate than it is consumed. Common types of this energy lists hydro, wind, solar, biomass and geothermal. Basically, the process utilizes the free advantage of natural phenomenon in order to fuel up a system of mechanical machineries to generate a non-physical commodity more familiarly referred to as electricity. So it was a product of critical thinking and ingenuity that set off the electrical power industry. A heavy investment to conventional power generating plants ensued from the exponential climb of customer demand to electrical energy. With a mathematical play of all sources involved cognizant of inflation and the scarcity of raw materials, the cost of electricity to the buying consumers is not as simple as paying the worth of an end product coherent with its practical use.
Simply put into an economist perspective, renewables reduce the country’s fuel imports from oil-rich countries that have control and an upbeat advantage over the price swings driving the market. It bears no financial obligations to external suppliers where a considerable amount of time and budget could have been needlessly lost on wastage. A good way to put it is that having these available resources somehow insulates the economy from scarcity and excessive costs of fossil fuels. A growing awareness of the criticality of the environment has also led to an equivalent inner state panic to most clean energy advocates encouraging alternative means rather than the insatiable exploitation of fossil fuels. Experts as well as practical science enthusiasts are convinced that these human inflicted exploratory excavations are major contributions of detrimental consequences to the environment. To manifest a few, the explicit shifting of climate phenomenon and the excessive precipitation experienced just lately in the country are adverse effects of negligence and pecuniary interests of the human nature. Market-wise, the sale of electricity is probably the only commodity that is somewhat visibly intangible and complicatedly quantified. Although difficulty is lacking a better term to describe it, the existence of statutory policies and regulatory bodies deal with the dilemma of having to ensure the deliverance of power to every household at the lowest price practicable. From the latest release of the approved rates for renewable energy by the country’s Energy Regulatory Commission (ERC), it may seem that developing a renewable energy power plant would cost more than the rates imposed by conventional energy power plants. This is where we speculate and assess the situation carefully. Eventually, the stretched operational and maintenance expenses relative to these plants are significantly low
Member’s Point of View compared to conventional types. Adding to that is the natural tendency of fossil fuels to deplete in time which means the conventional plants would be mounting expenses to sustain operation. Even more positive effect is the reduction in the emission of greenhouse gases contributing to pollution. So, having a secured investment not to mention the other upsides of developing clean energy sources into a productive exploit could turn displeased energy consumers into all-over-it happy clients. It now becomes a question of running a business or driving it.
22
THE ELECTRICAL ENGINEER 3rd
Engr. Andy Glynn O. Gayman
is a graduate of Saint Louise University with the course of Bachelor of Science in Electrical Engineering in 2008. He is a Register Electrical Engineer and currently connected with the Grid Management Committee - Energy Regulations Commission as a Senior Design Engineer.
QUARTER 2012
3rd QUARTER 2012
THE ELECTRICAL ENGINEER
23