2012 IIEE 3rd Quarter Magazine

The ELECTRICAL ENGINEERThird Quarter 2012

Table of Contents

Under IIEE spotlightSee the different activities conducted by our Chapters in snaphots...

cover story

technical feature

from the member’spoint of view

• Product Assessment of Power Copper Clad Aluminum

7

10

13

21

ABOUT THE COVER:

from the office of the National PresidentKnow his Eight-Point Agenda for 2012 ....

6

Feed in Tariff in the Philippines

• A growing awareness of the criticality of theenvironmenthasalsoledtoanequivalentinnerstate panic to most clean energy advocatesencouraging alternative means rather than theinsatiableexploitationoffossilfuels.

2012 IIEE BOARD OF GOVERNORS AND OFFICERS

NationalPresident JulesS.AlcantaraVP-InternalAffairs GregorioR.CayetanoVP-ExternalAffairs AlexC.CabugaoVP-TechnicalAffairsMa.SheilaC.CabarabanNationalSecretary LarryC.CruzNationalTreasurer FlorigoC.VaronaNationalAuditor AngelV.DeVera,Jr.Governor-NorthernLuzon RonaldoG.LamarozaGovernor-CentralLuzonVirgilioS.LuzaresGovernor-MetroManila EusebioA.GonzalesGovernor-SouthernLuzonJozaneF.JalbuenaGovernor-Bicol EdwinG.ParañalGovernor-WesternVisayasCiriloC.CalibjoGovernor-Eastern/CentralVisayasFedericoC.MercadoGovernor-NorthernMindanaoRemegioB.GonzalesGovernor-SouthernMindanaoBenjaminA.ArbosoGovernor-WesternMindanaoRichardO.LizardoImmediateFormerPresidentArmandoR.DiazExecutiveDirectorRamonP.Ayaton

IIEE NATIONAL SECRETARIAT DEPARTMENT HEADS

Administrative NiellisaJoyB.BandongTechnical-OICMa.ElenaU.LiongsonMarketingAllenM.PidoMembershipMarjorieAguinaldo-Muñoz

PUBLICATIONS COMMITTEE

Chairman: RolitoC.GualvezViceChairman:RonaldVincentM.SantiagoMembers: ErnestoM.Cabral MarvinH.CasedaGlynnAndyO.GaymanDr.AllanC.Nerves RolandP.VasquezOverseer:Ma.SheilaC.Cabaraban

The ELECTRICAL ENGINEER

The Electrical Engineer is published quarterly by the Instituteof IntegratedElectricalEngineersof thePhilippines, Inc. (IIEE),witheditorialandbusinessofficesat#41MontedePiedadSt.,Cubao,QuezonCity,Philippines.TelNos. (632)722-7383,727-3552,412-5772,414-5626,FaxNos.(632)721-6442&410-1899.Website:www.iiee.org.ph,E-mail:[email protected].

The present circulation of the magazine is 32,000 copies perissuetomembersandindustrystakeholders.

The ELECTRICAL ENGINEER Editorial Board

ChairpersonMa.SheilaC.CabarabanEditor-in-ChiefRolitoC.GualvezAssociateEditor:RonaldVincentM.SantiagoTechnicalConsultant:Dr.AllanC.NervesAdministrativeOfficer:RamonP.Ayaton

Advertising and Marketing

AccountExecutiveJoanQ.DelosSantos727-3552loc.101410-1899

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 [email protected].

---The Electrical Engineer Editorial Board

Clean and Affordable ElectricityAnadvocacyforeveryoneNearly90%ofelectricitycomesfromdifferentsourcesthatgraduallyaffectourenvironment:fossilfuelssuchascoal,oilandnaturalgas(source:AllEnergySolutions,2009).

Fossil-fuelledpowerplantscontributetotheincreaseinpollutantscausingacidrain,smog,andotherformsofairandwaterpollution.Thesepollutantsalsocauserespiratoryillnesssuchasasthma,amongpeople,specificallyinchildren.

Furthermore, developing countries such as the Philippines have beenincreasing their dependence on energy sources that emitsGreenHouseGases (GHG) that contribute to climate change. According to the AsianDevelopment Bank, about 65%of globalGHG emissions come from theenergy consumption. Asia is one of the faster growing sources of GHGemission.

TheRepublicAct9513knownastheRenewableEnergyActof2008aimstopromotethedevelopment,utilizationandcommercializationofrenewableenergy sources. Renewable energy sources include solar, wind, ocean,biomass,geothermalandhydropower.

Thisacthopestoleadinreducingthedependenceofthecountryonfossilfuelsthatdeterioratetheenvironment.Furthermore,itaimstoadopttheuseofcleanenergy,therebymitigatingadverseeffectsofclimatechange.

Asoneofthemostprimaryadvocaciesofthegovernment,industriesandenvironmentalistsnowadays,letusalsodoourshare.Letusallsupportthepromotionof“CleanandAffordableElectricity”.

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;

• 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.

from the office of the National PresidentEngr. Jules S. Alcantara2012 IIEE National President

Third QuarterPRESIDENT’S REPORT

3rd QUARTER 2012 THE ELECTRICAL ENGINEER 7

Under the IIEE Spotlight

IIEE Aklan Chapter conducting a technical seminar on ShortCircuitCalculationsandMotorProtectionandControllastJuly7atGarciaCollegeofTechnologyattendedby46membersand43studentsfromthechapter.

IIEE Capiz Chapter during its Chapter OfficersMeeting lastJune21.ThemeetingdiscussedtheupdatesontheBrigadaEskwelaProjectofthechapterthiscomingAugust.

IIEE iloiloChapterduring itsMid-YearTechnicalSeminarandGeneralAssemblylastJuly6atRizalQueenHotel.

IIEE Leyte Samar Chapter during a Livelihood SkillsDevelopmentTraininglastJuly28-29inLaPaz,Leyte.

TheCentralLagunaChapterconductinganRMEPremierReviewatFujiHayalastAugust25.

THE ELECTRICAL ENGINEER 3rd QUARTER 20128


IIEECagayanDeOroChaptersupportingtheBrigadaEskwelaProject of the Department of Education by providing freeelectricalwiringinspectionpriortotheopeningofschoolyear2012-2013.

IIEE-NegrosOccidentalMembersduringtheMid-yearSummitheldlastJune29,2012

IIEEBulacanChapter’s2012VP-InternalAffairsEngr.EdgardoC. Calantuan and 2012 VP-External Affairs Engr. Romeo B.Indiongco at the “Orientation Forum About 8th GawadKaligtasanatKalusugan(GKK)and13thNationalOccupationalSafetyandHealth(NOSH)Congress”lastJuly17,2012(Tuesday)at theDOLERO III Building inside theRegionalGovernmentCenter,BarangayMaimpis,CityofSanFernando,Pampanga.

IIEE Leyte Samar Chapter conducting a meeting with theEastern Visayas State University (EVSU) President for theRehabilitationoftheElectricalSysteminEVSUlastJuly10.

Under the



IIEE CDOChapter during the 2ndKuryente Sports festival last July14,2012.

IIEE Antique Chapter conducting a technical seminar onFundamentals of Distribution System Engineering last July21. IIEE Antique Chapter Former President, Engr. Tacogdoy,explaining to the IIEE-University ofAntique StudentChapters(IIEE-UASC) members the different conductors used in thedistributionsystem

TheIIEE-ZamboangaSibugayChapterconductedanoathtakingceremoniesof2012officerslastMay30,atCasaMiaHotelIpilZamboangaSibugay.

...iiee spotlight


Cover Story

Although the rates were lower compared to what wasset by the National Renewable Energy Board (NREB),investors in thepower sectorarenow incentivizedwiththe following tariffs according to the ERC: Php5.90perkilowatt-hour(kWh)forhydroelectricpowersources,Php6.63/kWhforbiomassenergysources,Phpp8.53/kWhforwind,andPhp9.68/kWhonsolarpower.Finalrateswerenotyetissuedforoceanthermalenergyresourcesasitisstillundergoingreviewandfurtherstudies.

The Renewable Energy Act

The approval of the FITs brings the country's energysources closer to the goals of the Republic Act No.9513alsoknownas theRenewableEnergyActof2008,whichaimsto"acceleratethedevelopmentofemergingrenewable energy resources, a feed-in tariff system forelectricityproducedfromwind,solar,ocean,run-of-riverhydropower,andbiomass"(ChapterIII,Sec.7).

Encouraging the use of "green energy", the RenewableEnergy Act is expected to accelerate exploration anddevelopment of renewable energy resources in thecountry, thru institutionalization of the development ofnationalandlocalcapabilitiesinusingrenewableenergysystems.

In addition, the Act is also expected to minimize thecountry's dependence on fossil fuels, thus a reducingthe "country's exposures to price fluctuations in theinternationalmarket(ChapterI,Sec.2.a),”and"effectivelypreventorreduceharmfulemissionsandtherebybalancethegoalsofeconomicgrowthanddevelopmentwiththeprotectionofhealthandenvironment(ChapterI,Sec.2.b)”.TheActalsomandatestheestablishmentofallnecessaryinfrastracturesandmechanismsforitsimplementation.

The Feed-in Tariff System

Under the feed-in tariff system, renewable energygeneratorswouldbeprovidedwitha"guaranteedmarketand a guaranteed price for their power, in additionto tax credits for developers and value added tax andduty-free importation of renewable technologies."(cleanenergysolutions.org).

Thisenergysystemincentiveisalreadybeingimplementedin several countries worldwide, including the UnitedStates, United Kingdom, Canada, France, and in AsiancountriessuchasJapan,China,India,andThailand.

According to climatepedia.org, well-designed feed-intariffs ensures a market for renewable power, makingit easier and cheaper for renewable energy projects,attractinginvestment;reducingtheriskofmarketvolatilitythru a predetermined rate, reducing transaction costs;and is themost cost-effective way to foster renewablepowersources.

OnitsJuly2010pressrelease,theERCsaidthattheFITrulesoffersaguaranteedpaymentsoveradefiniteperiodoftimetoRenewableEnergy(RE)developers.TheNationalGridCorporationofthePhilippines(NGCP)shallbetaskedtoallocatetheenergytothecustomers,whoshall thenberequiredtopayauniformpesoperkWhcharge,whichshall be called as the Feed-in Tariff Allowance (FIT-All).The National Transmission Corporation (Transco) hasbeen endorsed by the NREB to act as administrator ofthe FIT-All which shall be collected from the electricitycustomers.

ProceedsoftheFIT-AllcollectedshallgotoafundfromwhichthepaymentfortheFIT-eligibleRenewableEnergyDevelopersshallbetaken.

Feed in Tariff in the PhilippinesOn 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.


Cover Story

Although the rates were lower compared to what wasset by the National Renewable Energy Board (NREB),investors in thepowersectorarenow incentivizedwiththe following tariffsaccording to theERC:Php5.90perkilowatt-hour(kWh)forhydroelectricpowersources,Php6.63/kWh for biomass energy sources, Phpp 8.53/kWhforwind,andPhp9.68/kWhonsolarpower.Final rateswerenotyetissuedforoceanthermalenergyresourcesasitisstillundergoingreviewandfurtherstudies.

The Renewable Energy Act

The approval of the FITs brings the country's energysources closer to the goals of the Republic Act No.9513alsoknownastheRenewableEnergyActof2008,whichaimsto"acceleratethedevelopmentofemergingrenewable energy resources, a feed-in tariff system forelectricityproducedfromwind,solar,ocean,run-of-riverhydropower,andbiomass"(ChapterIII,Sec.7).

Encouraging the use of "green energy", the RenewableEnergy Act is expected to accelerate exploration anddevelopment of renewable energy resources in thecountry, thru institutionalization of the development ofnationalandlocalcapabilitiesinusingrenewableenergysystems.

In addition, the Act is also expected to minimize thecountry's dependence on fossil fuels, thus a reducingthe "country's exposures to price fluctuations in theinternationalmarket(ChapterI,Sec.2.a),”and"effectivelypreventorreduceharmfulemissionsandtherebybalancethe goals of economic growth and development withthe protection of health and environment (Chapter I,Sec. 2.b)”. The Act also mandates the establishmentof all necessary infrastractures and mechanisms for itsimplementation.The Feed-in Tariff System

Under the feed-in tariff system, renewable energygeneratorswouldbeprovidedwitha"guaranteedmarketand a guaranteed price for their power, in additionto tax credits for developers and value added tax andduty-free importation of renewable technologies."

(cleanenergysolutions.org).

Thisenergysystemincentiveisalreadybeingimplementedin several countries worldwide, including the UnitedStates, United Kingdom, Canada, France, and in AsiancountriessuchasJapan,China,India,andThailand.

According to climatepedia.org, well-designed feed-intariffs ensures a market for renewable power, makingit easier and cheaper for renewable energy projects,attractinginvestment;reducingtheriskofmarketvolatilitythru a predetermined rate, reducing transaction costs;and is themost cost-effective way to foster renewablepowersources.

OnitsJuly2010pressrelease,theERCsaidthattheFITrulesoffersaguaranteedpaymentsoveradefiniteperiodoftimetoRenewableEnergy(RE)developers.TheNationalGridCorporationofthePhilippines(NGCP)shallbetaskedtoallocatetheenergytothecustomers,whoshall thenberequiredtopayauniformpesoperkWhcharge,whichshall be called as the Feed-in Tariff Allowance (FIT-All).The National Transmission Corporation (Transco) hasbeen endorsed by the NREB to act as administrator ofthe FIT-All which shall be collected from the electricitycustomers.

ProceedsoftheFIT-AllcollectedshallgotoafundfromwhichthepaymentfortheFIT-eligibleRenewableEnergyDevelopersshallbetaken.Forthefirstthreeyearsofimplementation,theNREBhassetFIT targets:250MWforhydro,250MWforBiomass,220MW for Wind, 100MW for Solar, and 10MW forOcean, accumulating to a total of 830MW for the firstthreeyears.

The recently approved tariffs, according to the ERC,shall be valid for 20 years, and shall be subject to (1)adjustmentsduetoeconomicfactorssuchasinflationofcurrency exchange rates and (2) review to assess if thetargets are achieved, and for any significant changes tocosts.

DOE on Renewable Energy


Technical Feature

PRODUCT ASSESSMENT OF COPPER CLAD ALUMINUM By Engr. Feldimir D. Siao, REE, EE, MTM

PART 1 – OVERVIEW OF CCAOVERVIEWCopper-clad aluminum (CCA) wire is a composite wirewithanaluminumcorecoveredbyathincoppercoatingasshowninFigure1.Thereareseveralvariationsofthewire with respect to the volume percentage of coppercladding. However,majority of thesewireswould have10%or15%copperby volumewith reference toASTMB-566(2004).

Figure1:Copper-CladAluminumwirecrosssection

Paul Dion and Martin Carr invented manufactureof this CCA for Texas Instruments Inc. US patentapplicationwasfiledonApril26,1967andgrantedon July 15, 1969 as US Patent No. 3,455,016. Thisdevelopment made it possible to have a lightweight conductor without the inherent problemsof aluminum with oxidation and connectioncompatibility. Though it appears that CCA wasdevelopedasalowcostalternativetocopperduetothemajorityofthecompositewiremadeofcheaperaluminum, it is not so since copper to aluminumratioisabout1.5duringthattime.Thecostsavingsrecognizedwithcheaperaluminumiseasilynegatedbythefabricationcostandattimesmorecostlythantheircopperequivalentswhencopperpricesfall.Starting in 2003, copper prices have dramaticallyrisentomorethan5timesitsrecordpeakin2008.CopperpricesretrenchedduetotheUSrecessionbuthavequickly recovered to itspre-recessionprice in

2010(showninFigure2).Aluminumpriceshavealsorisenbuttoanextentthatislessthancopper(showninFigure3).Thecoppertoaluminumpriceratiohaveincreasefromabout1.5in2004toalmost3.5atthestart of this year (shown in Figure 4). Taking intoconsideration the specific gravity and conductivityof both metals, means that an equivalent copperconductorcostabout7timesthatofaluminum.

Figure 2: London Metal Exchange Copper Prices1

Figure 3: London Metal Exchange Aluminum Prices1

1Source:ICFRawMaterialsUpdate,ICFNewsIssue68


Technical Feature

Figure4:Copper/AluminumPriceRatio1

CCAistraditionallyusedforhighfrequencyapplicationssuch as coaxial cables. However, with high prices ofcopper,thesewiresarenowbeingmarketedasalowcostalternative to copper, expanding its applications as lowvoltagebuildingwires.

ProductstandardthatprovidesthespecificationforCCAisASTMB566,UL-83,andUL-1581.ASTMB566specifiesthevarietiesofCCAwiresanditstechnicalrequirementswhile UL-83 governs the use of CCA as conductor forthermoplasticinsulatedwires.

The Underwriter’s Laboratories’ UL 83 disallowed theuseof CCA as thermoplastic insulatedwires and cablesinCanadaandMexico,butallowedthisapplicationintheUSwithspecialrequirements.UL83stipulatesthatCCAshouldbeusedonlywithequipmentmarkingtoindicatethatitistobeusedwithaluminumconductors.Also,CCAconductorsshallcomplywiththerequirementsofSection11 of UL 1581 for copper-clad aluminum conductors.The Philippine Electrical Code has included this type ofconductorsforgeneralwiringwithampacitiesequivalentto that of aluminum.Minimum conductor size for CCAshallbe3.5mm2or2.0mmindiameter.

PROPERTIES OF CCAThe physical and electrical characteristic of copper-cladaluminumincomparisonwithcopperandaluminumareasfollows:

It isnotsurprisingthatCCAhascharacteristicsthatcloselyresemblethatofaluminumconductorduetoitslargealuminumvolumecontent.

MANUFACTURING METHODS OF CCA

Thereareseveralmethodsofproducingcoppercladaluminumconductorsandthesemethodsare:

a. Electrochemical plating

Electroplating (also known as “electro-deposition)is the process of producing ametallic coat on thesurface of a basematerial through the flow of anelectriccurrent.Thealuminumwiretobecoatediscleanedandpreparedbyemployingsolvents.Thenit issubmerged intoa liquidsolutionknownastheelectrolyteorplatingbath.This is a specially designed chemical solutioncontaining dissolved submicroscopic particles ofcopper with positively charged ions. Availablecopperplatingsolutionsarecyanidecopperplating,non-cyanidealkalinecopperplatingandacidcopperplating.

The aluminum is negatively charged and acts acathode;thenapositivelychargedanodecompletesthecircuitwhencurrentissuppliedbyabatteryor

1Source:ICFRawMaterialsUpdate,ICFNewsIssue682Source:MiraeSpecialMetalCo.Ltd.


Technical Feature

rectifier.Thiselectricarrangementdirectspositivelycharged ions to move towards the negativelychargedaluminumcathodecausingafilmdepositonthecathode.Whenthedesiredthicknessofcoatingis achieved, it is removed from theplatingbath.Acompletely integrated machine in producing CCAthrough electroplating is available in the market(showninFigure5).

Figure5:Electroplatingmachine

b. Rolling pressure welding

In pressure welding process, the cladded strips areproducedbycontinuousrollingwhereinthesurfacesarepreparedbeforetherollingprocess.Weldingisdoneinasinglepass.Subsequentheattreatment,suchassintering,diffusion and recrystallization, may be employed toimprovetheweldquality.

c. Hydrostatic extrusion

Inhydrostaticextrusion,allregionsofthebilletotherthanthepartincontactwiththediearesurroundedbyfluid.The billet can deform only by extruding. The pressurerequiredtoachieveagivenreductionisnotonlylessthanthatrequiredinconventionalextrusionprocesseswiththefrictioneffectatthebillet/containerinterfaceeliminated,but is also independent of the length-to-diameter ratioof the billet. Furthermore, the use of a high-pressurefluid as a pressure-transmitting medium rather than adirectmechanical contact, transmissionofahydrostaticpressuretothebilletyieldsasignificantimprovementintheductilityoftheresultingextrudedmaterial.

d. Tube weld cladding and drawing

In tubeweld cladding and drawing production process,copper clad aluminumwire is produced from a copperstripbeingformedintoacylindricalshapeplacedontheoutersurfaceofthealuminumcorewhereintheseamisweldedtogether.Thisformsacladwireofaluminumcorewithcoppercoatwhich is thensubjectedtodrawing toproduce a copper-clad aluminum wire. The welding ofthe copper strip seam is done in a closed environmentfilled with an inert gas through an integrated machine(seeFigure6).Thediameter reducingprocess iscarriedthroughadieatatemperatureofabout200°Ctoinsureacompletemetallurgicalbondbetweenthetwometals.Itmayfurtherundergodrawingandheattreatmentseveraltimes tomeet thecustomers' technical requirementonthediameter,electricalpropertyandmechanicalproperty.

Figure6:Tubeweldcladdingmachine

3Source:TotokuElectricCo.Ltd,EnameledCopper-CladAluminumWirebrochure.

e. Continuous filling core casting

Continuous filling core casting process uses an upperand lower resistance furnace and an induction furnacedesignedtomeltthe innerandoutermetals.Whentheheatersreachthepresettemperature,theoutermoltenmetalwouldflowintoacrystallizerthroughadummybardrawnbyanelectricmachineformingtheoutermetallicconduitlayer.Thisiswheretheinnermoltenmetalflowsinto:betweenthecrystallizerandhoneycombduct.Theinnerandoutermetalswouldbecompositedandpulledataspecialpullingrate.

Subsequentplasticprocessingisdonethroughhydrostaticextrusionprocesssoastotakeadvantageoftheexcellentlubrication between the metal and the die for a moreuniformmetalflow.Reducingtosmallerwirediameterisdonethroughdrawingprocess.


Technical Feature

APPLICATION OF CCAIn recentyears, theapplicationofCCAwireshasgrownfrom just a main conductor in coaxial cables to otherfields such as braided outer conductors of shieldingcables, winding wire, household appliances, buildingwires, battery cables, power cables, and bus bars. Intermsofproductionvolumes,theapplicationofCCAcanbegroupedintofivemajorclassifications:

a. Communication cable

Copper-cladaluminumiswidelyusedasmainconductorfor coaxial cables to take advantage of the skin effectprinciple. This causes alternating currents to flowmoreon theouter regionsof thewireathigh frequencies sothattheresistanceofthewireisalmostthesameasthatofpurecopper.Some Chinese producers have offered LAN cablescontaining CCA at prices significantly lower thanconventional LAN cables. However, these low costsubstitutes do not meet all the technical performancerequirements forLANcablesused inbusinesspremises,butmightfindapplicationatlow-endLANcablemarketssuchashomenetworks.

b. Cables and wires for electric equipment

Copper-clad aluminumwires are promoted as low costsubstitutes to copper wires in underdeveloped areas.There isstill littleexperienceonthisareaofapplicationconsidering that in many countries the mandatorybuilding wires used is solely copper. Also, there is aconsensus regarding thehiddendangersofconnectionsinvolvingaluminumconductors,majorityofwhichisthecomponentofCCA.

Using CCA as conductors for welding machine cablesreduces the cost by asmuch as 40% even with a 20%increaseincablesizecomparedtocopperweldingcable.

CCAbatterycablesarestillinitsinitialstageoftesting.Itneedstobetwogaugesbiggerthanitsequivalentcopperconductortohavesimilarresistanceandcurrentcapacity.UsingCCAcanreducetheweightofthebatterycableby40%.

With the high cost of copper, CCA has been applied ascable shieldwherein it isweaved to form the shieldinglayerforsomecablesofelectricalequipmentsandaudiocablesforsoundsystems.

c. Power cables

TherearenostandardsontheuseofCCAconductorsaspower cables since IEC, ICEA, AEIC and NEMA includesonlycopperandaluminumconductorsaspowercables.ManufacturersproducetheseCCApowercablesbasedonownstandardsorcustomerrequirements.

The main users of these CCA power cables would bethepower industryparticularly the clientworkprojectsinvolving customer-ownedelectric facilities andnot thedistribution utilities. Main reason for this is when theclient ismoresensitivetothecablecostunlikethoseofthedistributionutilitiesAlthoughtherehasbeengrowthintheutilizationofCCApowercables, itstill remainsatminusculesharecomparedtocopperpowercables.

d. Enameled wire

The special properties of enameled CCA wires such aslightweight,highconductivity,andgoodheatdissipation,has found application in acoustic coils (Figure 7), TVdeflectioncoils,degaussingcoils,harddriveactuatorarmcoil(Figure8),opticaldisklaserlenspickupcoil(Figure9)andmotorwinding.

Figure7:ApplicationofCCAasacousticcoils3

Figure8:ApplicationofCCAasharddriveactuatorarmcoil33Source:TotokuElectricCo.Ltd,EnameledCopper-CladAluminumWirebrochure.


Technical Feature

Figure9:ApplicationofCCAasopticaldisklaserlenspick-up

coil.3

3Source:TotokuElectricCo.Ltd,EnameledCopper-CladAluminumWirebrochure.

There are many cases wherein CCA wires are used forsmall motors of grinders, pumps, electric fans, vacuumcleaners,microwaveturntables,etc.Also,CCAwiresareusedinwindingsmalltransformers,lampballasts,relays,andothers.

e. Busbars

CCAbusbars,whichovercome theproblemofoxidationinaluminumbusbars,have theconnectingperformanceof copperbusbars andat the sametime, cost relativelycheaper. Its light weight eases transportation andinstallation.

Figure10:CCAbusbars

PART 2 – STANDARDS VIEW OF CCA APPLICATIONInPart1of thisarticle,wehavediscussedanoverviewofcopper-cladaluminumconductors: its characteristics,manufacturingmethodsandcommonapplications.NowonthestandardsviewofCCAapplication,wetakealookatthegoverningproductstandardsandCCAimplicationstolocalproductstandardsandelectricalcodes.

PRODUCT STANDARDSThere are four varieties of CCA according copper layervolume and form based on ASTM B566, StandardSpecificationforCopperCladAluminumWire:

a.10A–SoftformCCAwith10%coppervolumeratiob.10H–HardformCCAwith10%coppervolumeratioc.15A–SoftformCCAwith15%coppervolumeratiod.15H–HardformCCAwith15%coppervolumeratio

REFERENCES1. International Cable Federation, Raw Materials

Update,ICFNewsIssue68,January20112. P.Dion andM.Carr,ManufactureofCladWire and

theLike,USPatentNo.3,455,016,July15,19693. MineralsInformationTeam,MetalIndustryIndicators,

USGeologicalSurvey,September2009

4. Mirae SpecialMetal Co., Ltd., Company Profile andCopper-CladAluminumProductCatalog

5. M. Schlesinger, Electroplating, ElectrochemistryEncyclopedia,September2002,http://electrochem.cwru.edu/encycl/

6. J. R. Davis, Copper and Copper Alloys, ASMInternationalHandbook,2001

7. T.Yamaguchi,T.TakayamaandM.Hiderita,Methodof Producing Copper-Clad Wire, US Patent No.3,854,193,December17,1974

8. H. Liang, Z. Xue,C.Wu,Q. Liu andY.Wu,ResearchonContinuousCore-FillingCasingFormingProcessofCopper-CladAluminumBimetalCompositeMaterial,ActaMetallurgicaSinica,Vol.23No.3,June2010

9. C. Kun, Some Issues on the Application of CCA inDomesticCable&Wire Industry,ShanghaiElectricalCableResearchInstitute(SECRI)

10. Zhang Jiagang Victor Textile Machinery Ltd., Co.,Copper-Clad Aluminum Wire Cladding MachineCatalog, http://www.alibaba.com/product-gs/200431291/CCA_Wire_Machine.html

11. Totoku Electric Co. Ltd., Enameled Copper-CladAluminumWireBrochure


Technical Feature

The main technical requirements for these varieties ofCCAwiresare:

1. a. The distribution of the copper thickness shall beuniformalongthecircumferentialdirection.

2. b.Thethinnestpointofthecopperlayershallbenotlessthan3.5%oftheradiusfor10Aand10Hornotlessthan5%oftheradiusfor15Aand15H.

3. c.CCAwiresshallhaveacopperlayervolumeofnotlessthan8%andnotmorethan12%for10Aand10Hornotlessthan13%andnotmorethan17%for15Aand15H.

For building wires, UL-83 “Standard for ThermoplasticInsulated Wires and Cables” does not allows the useof CCA for thermoplastic insulated wires and cables inCanada and Mexico but allowed its use in the UnitedStateswithspecialrequirementsasfollows:

1. Thecoppercladdingshallbemetallurgicallybondedtothealuminumcoreandshalloccupy10percentormoreofthecross-sectionofasolidconductororeachwirestrandofastrandedconductor.

2. Thicknessofthecoppershallnotbelessthan2.56%ofthediameterofthesolidconductororwire(strand).

3. Conductors shall be of the same size and assemblyindicatedforsolidandconcentricstrandedaluminum.

4. The DC resistance of CCA conductor shall not begreaterthanthosespecifiedforaluminumconductors.

5. The tensile strength of a finished CCA conductortestedasaunitorofthewires(strands)fromafinishedstrandedCCAconductorandofasolidCCAconductorshallnotexceed138MN/m2whenspecimensaretestatamaximumseparationspeedof300mm/min.

6. Elongationof the same specimens shall not be lessthan15%in10inchesor250mm.

Figure 10: Electrical convenience outlet with “CO/ALR” marking

7. CCA conductors shall be marked “AL (CU-CLAD)”,ALUM (COPPERCLAD)”, “CU-CLADAL”, or “COPPER-CLAD ALUM” wherever the size of the conductorappearsonthewire,cable,orpackagemarking.

8. Also, the following statement shall appear on thepackage:

•“Copper–clad aluminum shall be used only withequipment marked to indicate that it is for use withaluminumconductors.Terminatecopper-cladaluminumwithpressurewireconnectorsmarkedforusewithcopperandaluminum,conductors.”(seeFigure10)


Technical Feature

Figure 12: Sample of locally available push-in type switches

Figure 13: Sample of locally available screwtype lamp socket

• For3.31–5.26mm2(AWGNo.12to10solid),CCA“Maybeusedwithwire-bindingscrewsandpressure-plateandpush-inspringtypeconnectingmechanismsthatareacceptableforusewithcopperconductors.”

• “Where physical contact between any combinationof copper-clad aluminum, copper and aluminumconductorsoccursinawireconnector,theconnectorshallbeofatypemarkedforsuchintermixeduseandtheconnectionshallbelimitedtodrylocationsonly.”

In China, the primary standard for CCA is S/JT 1123-2000—astandardappliedtocopper-cladaluminumwiresusedasinnerconductorsofcoaxialcablesandconductorforelectricalequipment.

COMPLIANCE TO LOCAL STANDARDSThelocalgoverningproductstandardforbuildingwiresisPNS35-1:2004.Electricwiresandcables—Thermoplasticinsulatedcopperwiresandcablesrated600volts—Part1GeneralSpecificationcoverscopperconductoronlyforbuildingwires.Itpreviouslycoveredaluminumconductorsbutwaslaterremovedtoprotectthecommonconsumeragainst problems related to the use of aluminumconductors such as oxidation, creep, and availability ofsuitableconnectingdevicesthathaveconsiderablesafetyissues.Thus,aluminumwiresusedforresidentialhousesareconsideredaspotentialfirehazards.CCAconductorswere not mentioned as an approved material for thisapplication.

The localPhilippineElectricCodeallowstheuseofCCAwires and cables with ampacity rating and conditionsof installation same as those of aluminum cables. Foraluminum wires, the required aluminum alloy is theAA-8000serieselectricalgrade.However, forCCAthereisnoprescribedaluminumalloy tobeusedas thecoreconductor. This condition raises doubt on the possiblequality and performance of the aluminum conductorusedasthecorematerial.

REFERENCES

1. ASTM Organization, ASTM B 566, StandardSpecification forCopper-CladAluminumWire, BookofStandards,Volume02.03,2004

2. Underwriters Laboratories, UL 83 Standard ofThermoplasticInsulatedWiresandCables,September1998

3. Bureau of Product Standards – DTI, PhilippineNationalStandard,PNS35-12004,ElectricWireandCablesRated600volts–Part1:GeneralSpecification

4. BureauofProductStandards–DTI,PhilippineNationalStandard,PNS2602004,ElectricWireandCables–AnnealedCopperWires-Specification

5. Institute of Integrated Electrical Engineers of thePhilippines, 2009 Philippine Electrical Code Part 1,Volume1

Why should we pay attention to the price of acommodity such as ‘Renewable Energy’ in the firstplace? That shouldbea commonpracticalnotion forany customer who certainly expends an amount forelectrical energy on a regular consumption. Becausethe planet that we have inhabited is planted withlimitedphysicalresources,itisthereforealsologicaltopronouncethataconsistentextractionandutilizationofthesefossilfuelresourcesisproofenoughthattheyareboundforextinction.

Quiteastronomically,humanexplorationhasledtotheproliferation of inventions and theoretical formulastranslated into concrete structures interwoven withengineering knowledge. This capability has grown tothe discovery of a unique commodity later on coinedaselectricitywhichwasthenunderstandablytheobjectof demand to power up the advanced technology ofelectricalgeneratingfacilities.

SowhatisthedealwiththisRenewableEnergybeinganessentialarticleoftrade?Fromwhatitsbrandimplies,arenewableenergyisaproductfromaprocessderivedfromanaturallybuddingsourcethatisreplenishedatafasterratethan it isconsumed.Commontypesof thisenergylistshydro,wind,solar,biomassandgeothermal.Basically, the process utilizes the free advantage ofnatural phenomenon in order to fuel up a system ofmechanical machineries to generate a non-physicalcommoditymorefamiliarlyreferredtoaselectricity.

Soitwasaproductofcriticalthinkingandingenuitythatsetofftheelectricalpowerindustry.Aheavyinvestmentto conventional power generating plants ensued fromtheexponentialclimbofcustomerdemandtoelectricalenergy.Withamathematicalplayofallsourcesinvolvedcognizantofinflationandthescarcityofrawmaterials,thecostofelectricitytothebuyingconsumersisnotassimpleaspayingtheworthofanendproductcoherentwithitspracticaluse.

Simplyput intoaneconomistperspective, renewablesreducethecountry’sfuelimportsfromoil-richcountriesthat have control and an upbeat advantage over theprice swings driving the market. It bears no financialobligations toexternal supplierswherea considerableamountoftimeandbudgetcouldhavebeenneedlesslylostonwastage.Agoodwaytoputitisthathavingtheseavailable resources somehow insulates the economyfromscarcityandexcessivecostsoffossilfuels.

Agrowingawarenessofthecriticalityoftheenvironmenthas also led to an equivalent inner state panic tomost clean energy advocates encouraging alternativemeans rather than the insatiable exploitation of fossilfuels. Experts as well as practical science enthusiastsare convinced that these human inflicted exploratoryexcavations are major contributions of detrimentalconsequences to the environment. Tomanifest a few,the explicit shifting of climate phenomenon and theexcessive precipitation experienced just lately in thecountryareadverseeffectsofnegligenceandpecuniaryinterestsofthehumannature.

Market-wise,thesaleofelectricityisprobablytheonlycommodity that is somewhat visibly intangible andcomplicatedly quantified. Although difficulty is lackingabettertermtodescribe it, theexistenceofstatutorypolicies and regulatory bodies deal with the dilemmaofhavingtoensurethedeliveranceofpowertoeveryhouseholdatthelowestpricepracticable.

From the latest release of the approved rates forrenewable energy by the country’s Energy RegulatoryCommission (ERC), it may seem that developing arenewableenergypowerplantwouldcostmorethantheratesimposedbyconventionalenergypowerplants.Thisiswherewespeculateandassessthesituationcarefully.Eventually,thestretchedoperationalandmaintenanceexpenses relative to these plants are significantly low

from the Member’s point of view

The Clean Cost of Renewable EnergyBy: Engr. Glynn Andy O. Gayman


comparedtoconventional types.Addingtothat is thenaturaltendencyoffossilfuelstodepleteintimewhichmeans the conventional plants would be mountingexpensestosustainoperation.Evenmorepositiveeffectis the reduction in the emission of greenhouse gasescontributingtopollution.

So, having a secured investment not to mention theother upsides of developing clean energy sourcesintoaproductiveexploit could turndispleasedenergyconsumersintoall-over-ithappyclients.Itnowbecomesaquestionofrunningabusinessordrivingit.

Member’s Point of View

Engr. Andy Glynn O. Gaymanis a graduate of Saint LouiseUniversity with the course ofBachelor of Science in ElectricalEngineering in 2008. He is aRegister Electrical Engineer andcurrently connected with the GridManagement Committee - Energy

RegulationsCommissionasaSeniorDesignEngineer.

2012 IIEE 3rd Quarter Magazine

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