Applications of Copper-Clad Steel in Grounding Applications

A primary concern of electrical engineers is reducing the chance of hazards to personnel and valuable equipment caused by dangerous voltages and high potential gradients during fault conditions. Whether at electric utility plants, telecommunications stations, military installations or in general industry, elimination of possible damage from lightning strikes or short-circuits is paramount. A reliable grounding system to dissipate the surge current to the ground is required.

Dead soft annealed (DSA) Copperweld® wire and strand have been used for over 90 years as efficient, strong, non- rusting grounding/earthing conductors. Combining the strength of its steel core with the conductivity and corrosion resistance of its copper cladding, Copperweld®

ground wire provides a long- lasting, low impedance path to earth. When annealed, Copperweld® exhibits the flexibility necessary for easy handling and is adaptable to standard installation techniques. DSA Copperweld® strand has become widely accepted as

a more advantageous alternative to solid copper for ground grids in substation and industrial installations.

Whatever the grounding application may be, there is a Copperweld® conductor available in the size, conductivity, and strength that is required. The selection of a particular size DSA Copperweld® wire or strand depends on many factors, such as short-circuit ampacity, area in contact with the earth, and temperature rise.

The most important step in designing a substation, transmission or distribution grid is to implement a proper grounding system. Directing surges to ground prevents contact with dangerous voltage, and protects valuable equipment, maintenance personnel or any other individual who might come in contact.

DSA Copperweld® wire and strand have the high current-carrying capacity characteristics in short-time durations, high strength properties and corrosion resistance to effectively and economically meet IEEE recommendations (as shown in Table 2 opposite). These advantages are particularly evident when compared to a low-strength material such as solid copper. Solid copper conductors must be upsized in many installations to meet the mechanical demands within

a system design.

Optimum ground grid design depends on the dual, complementing action of the conductor and the connected ground rods. A grounding system utilizing DSA Copperweld® strand provides efficient and economical grounding--permanently.

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The most common grounding applications for Copperweld® wire and strand include grounding conductors for substations, pole ground wire for transmission and distribution systems, and counterpoise wire for high-voltage transmission lines. The inherent characteristics of Copperweld® wire make it excellently suited for all of these uses.

Substation Grounding

In substation grounding, solid copper conductor's ability to handle the maximum fault current is compromised by its low breaking strength. As a result, it is not unusual to select a larger, more costly copper conductor that far exceeds the ampacity rating needed in order to meet the design criteria for minimum breaking strength. DSA Copperweld® conductors, with their steel core, can be selected to meet the designed ampacity standards and have a breaking strength exceeding IEEE criteria. Rugged Copperweld® copper-clad

steel products offer a variety of configurations and sizes that can meet the requirements of any substation designs for grounding, including our innovative new product, Copperweld® 4THOUGHTTM, a genuine 4/0 19-wire strand that features the added benefit of easy flexibility, and utilizes the same connectors as solid copper.

Pole Ground Wires

DSA