ALUMINUM CONDUCTOR FIBER REINFORCED

NIHONBASHI FRONT BLDG. 6-2 NIHONBASHI 3-CHOME CHUO-KU TOKYO 103-8306 JAPANTel.: + 81 3 6366 7731, Fax: +81 3 3278 6870

TOKYO ROPE MFG. CO., LTD.

http://www.tokyorope.co.jp/english/product/acfr/index.htmlE-mail: inquiry_cfcc@tokyorope.co.jp

TOKYO ROPE MFG. CO., LTD.

Innovative HTLS Transmission Conductor With Core®About Tokyo Rope

Tokyo Rope was established in 1887 and has been the leader in Japan's wire rope industry. Our global operations are expanding. Our main products are Steel Wire Rope, Fiber Rope, Steel Cord for tire, and CFCC.

Japan Head Office●Gamagori CFCC Plant●Tsuchiura Plant●Kitakami Plant●Kitakami Works●Sakai Plant●Tokyo Seiko Rope●Ako Rope

China●Shanghai office●Hong Kong office

Kazakhstan●Astana City Office●Almaty Plant

Thailand●Bangkok Office

Vietnam●Binh Duong Plant

Brazil●Rio de Janeiro Office

USA●Detroit Office●Michigan CFCC Plant

Russia●Moscow Office

17-03-SA

Low Loss

High Capacity

Low Sag

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Today's Overhead Conductor's market

Current Status

ACSR is a conventional type of conductor which has three drawbacks as follows:

●Heavy steel core●Large Thermal Expansion●Corrosion

ChallengeTransmission Owners are facing the following requirements:

●Huge Electric Demand●Environmental Concern(CO2)●Sag Violations●Right of Way Issue●Construction Cost & Period●Lower Life Cycle Cost

ALUMINUM CONDUCTOR FIBER REINFORCED

Annealed Aluminum Wire(or TAL / Hard Drawn Wire)

ACFR Structure

ACFR stands for Aluminum Conductor Fiber Reinforced

Core

Core

Light Weight and Small Thermal Expansion

Solution

Next generation conductor cable=

●Low Transmission Loss●High Transmission Capacity●Low Sag●Longevity●Easy Handling

Trapezoidal Shape

Trapezoidal Aluminum Wire Large Cross Sectional Area

Notes *1: TW(X.XX) stands for Trapezoidal Shaped Wires for which the equivalent outside diameter is X.XX mm. *2: Current Carrying Capacity is solved using the Cigre Method.

Calculation Conditons: Ambient temperature: 35°C, Wind: 0.9 m/s, Wind direction: 45°, Solar radiation: 0.1 W/cm2, Absorptivity and Emmisivity of conductor surface: 0.5, Frequency: 50 Hz, Sea level: 0m

at 75°C

at 175°C

Conductor

Core

Conductor

Core

No./mm

kN

mm

mm

mm2

mm2

mm2

kg/km

Ω/km

A

A

GPa

GPa

×10-6/ °C

×10-6/ °C

Aluminum No./mm

7/2.6

95.15

21.79

7.80

309

37.2

346

917.3

0.0910

678

1250

74.7

130

18.9

1.0

7/3.2

135.47

21.79

9.60

285

56.3

342

884.6

0.0985

652

1202

79.0

135

16.8

1.0

7/3.2

147.44

28.14

9.60

522

56.3

578

1540.2

0.0539

932

1748

74.5

135

19.1

1.0

7/4.2

228.03

28.14

12.50

474

95.4

570

1461.0

0.0593

890

1668

77.2

123

17.1

1.0

8/TW(4.44)12/TW(4.43)

10/TW(3.88)14/TW(3.90)

10/TW(3.97)14/TW(3.98)18/TW(3.98)

10/TW(5.01)14/TW(5.02)

10/TW(4.75)14/TW(4.77)

Equivalent conventional ACSR

Type of design

Size

Stranding*1

Rated Tensile Strength

Diameter

Cross Sectional Area

Weight

DC Resistance at 20°C

Current Carrying Capacity *2

Modulus of Elasticity

Coefficient of Thermal Expansion

Conductor

Core

Conductor

Core

Total

Core

Hawk Drake Curlew

Low Loss

310/40

Low Sag

290/55

Low Loss

520/55

7/3.6

186.39

31.62

10.80

659

71.3

730

1938.4

0.0426

1074

2032

73.7

126

19.3

1.0

8/TW(4.82)12/TW(4.83)16/TW(4.83)

Low Loss

660/70

7/5.1

331.05

31.62

15.20

573

141

714

1811.0

0.0490

1006

1900

79.6

127

16.1

1.0

12/TW(3.90)16/TW(3.90)20/TW(3.90)

Low Sag

570/140

Bison

7/2.9

126.63

27.00

8.80

486

47.3

533

1425.1

0.0578

892

1668

73.6

131

19.5

1.0

8/TW(4.13)12/TW(4.14)16/TW(4.16)

Low Loss

490/45

7/4.2

225.66

27.00

12.50

427

95.4

523

1331.1

0.0658

838

1565

78.0

123

16.7

1.0

Low Sag

430/95

12/TW(4.46)16/TW(4.47)

Zebra

7/3.2

148.48

28.62

9.60

542

56.3

599

1597.1

0.0518

954

1791

74.3

135

19.2

1.0

8/TW(4.38)12/TW(4.38)16/TW(4.38)

Low Loss

540/55

7/5.1

324.22

28.62

15.20

439

141

580

1437.1

0.0641

861

1614

82.4

127

14.7

1.0

Low Sag

440/140

Low Sag

470/95

The following is standard ACFR Design Example. Final design should be agreed with the conductor's manufacturer.

Standard ACFR Design Example

Performance Example compared to ACSR

Design Concept Transmission Loss Transmission Capaicty Sag

Low Loss

High Capacity

Low Sag-Low Loss

Low Sag-High Capacity

27% Less

More

9% Less

More

Same

120% More

Same

103% More

Same

Same

12% Less

10% Less

Case Study Accessories (Dead End Clamp and Mid Span Joint)

Supply SchemeHighCapacity

LowSag

*This figure depends on design and operating conditions.

Basic Design is the same as those for the conventional ACSR conductor, except for using an aluminum buffer which grabs the CFCC core securely.

Tokyo Rope provides CFCC to local conductor producer which will make ACFR.

ALUMINUM CONDUCTOR FIBER REINFORCED

Reference

LocalConductorProducer

Advisor: ACFR Design

Accessoriesdevelopment

Advisor: Accessories Installation TrainingConductor Stringing Training

TransmissionOwner

Contractor

AccessoriesProducer

*These pictures are for example purposes. Actual design to be decided by the customer's requirements.

Dead End Clamp Mid Span Joint

Reduction of total construction cost includig land, foundation and tower.

LowLoss

ACSR

100A 90A 100A

27% Less

ACSR

ACSR

ACSR

Longer spanDeduction of tower structual cost

Lower tower’s height

100A

100A

200A

93A

Twice capacity usingexsiting tower

TOKYO ROPE

CFCC core's development was started in the 1980s. Initially, CFCC was used for civil engineering applications. In 2002, Tokyo Rope supplied CFCC core to conductor partners which produce ACFR, and since then, more than 10 years have passed with satisfactory operations.

1980s

1986

2001

2002

2002

2007

2011

2012

2015

2016

Started development of CFCC

Supplied for PC Bridge project in Japan

Supplied for PC Bridge project in Michigan/USA.

Supplied for ACFR project in Japan

ACFR presentation in CIGRE* session 2002

Supplied for ACFR project in Korea

Established Gamagori CFCC Plant in Japan (First full-scale integrated CFCC factory.)

Supplied for ACFR project in China

Supplied for ACFR project in Indonesia

Established Michigan CFCC Plant in USA(First overseas CFCC production facility.)

*CIGRE is international council on Large Electric System

Gamagori CFCC Plant

CARBON FIBER COMPOSITE CABLE

®

CFCC Development History CFCC Advantage

Standard Specification of CFCC

Standard Characteristics

Designation(Configuration diameter)

DiameterNominal crosssectional area

Breakingload

Nominal massdensity*

Tensile elasticmodulus*

(kN/mm2)(g/m)(kN)(mm2)(mm)

U

1×7

1×7

1×7

1×7

1×7

1×7

1×7

1×7

5.0φ

6.8φ

7.8φ

8.3φ

9.6φ

10.8φ

12.5φ

15.2φ

20.9φ

5.0

6.8

7.8

8.3

9.6

10.8

12.5

15.2

20.9

19.6

28.2

37.2

42.1

56.3

71.3

95.4

141

267

41.9

60.3

79.5

90.0

121

153

204

302

571

30

45

61

69

93

111

146

221

412

135

122

130

131

135

126

123

127

129

Properties Item 1×7 7.8φ HT Type

General mechanical properties

Static properties

Others

Tensile strength

Tensile elastic modulus

Elongation at break

Specific gravity

Relaxation

Creep strain

Coefficient of linear expansion

Specific resistance

Creep failure load ratio

Fatigue capacity(Stress range)

Bending stiffness

Heat resistance

Acid resistance

Alkaline resistance

*1: Calculated by nominal cross sectional area*2: 0.7pu, 1000hrs(20±2℃), according to JSCE-E534.*3: 0.6pu, 1000hrs(20±2℃)*4: 20℃～200℃, according to JSCE-E536.*5: Tests of CFCC 1×12.5φ according to JSCE-E533 “Test Method for Creep Failure of Continuous Fiber Reinforcing

Materials” gave a load ratio of 0.85 at 1 million hours.*6: Average load is 75% of breaking load. The number of cycles is 2×106, according to JSCE-E535.pu: breaking load

2.14

130

1.70

1.60

1.3

0.07×10-3

Less than 1

3,000

0.85

780

56.9

Superior to steel

Almost the same as steel

*Reference value

(kN/mm2)

(kN/mm2)

(%)

(%)

(×10-6/℃)

(µΩcm)

(N/mm2)

(kN・cm2)

(℃)

*1

*1

*2

*3

*4

*5

*6

CFCC core is uniquely stranded CFRP and has eight advantages:

Non-magnetic

Lightweight

High Flexibility

High Corrosion resistance

High Tensile Fatigue

Small Thermal Expansion

High Modulus

Low Creep

No Iron Loss

1/5 of Steel

Can be wound to the small Drum

Against acid, alkali, water and UV　

Able to withstand wind vibration

1/10 of Steel (CFCC: 1.0×10-6; Steel : 11.5×10-6)

Superior to other FRP

Similar to Steel

Michigan CFCC Plant in USA

Tendons of the prestressed concrete pier(Partly used)“Excellent construction resistances”

175℃(Operating) 200℃(Emergency)