Press Releases:

December 2012 - download the newsletter - with this link

Eurolls Group News

Additional and Very Important Use for ACSR

By this time you have seen hundreds of pictures of the total devastation caused by Hurricane Sandy on the East Coast of the United States. Entire coast lines have been reshaped. Houses were swept away. Hundreds of powers lines were destroyed and millions of people were without power.

Our hearts and prayers go out to all that were affected by this terrible storm. However, there is always some positive that comes from tragic events. People bond together to help their neighbors, random acts of kindness spring up before your eyes and sometimes, just sometimes, your trust in humanity is restored.

While I ventured out through the neighborhood after Sandy had passed through, I could not help but feel sorry for people who had lost so much and how it could have been so much worse.

Thankfully we have ACSR. ACSR, what the heck does that have to do with this you may ask. As you travel around in the older neighborhoods, where telephone poles are still used, you cannot help but notice how many trees were being held up by the ACSR power lines. In many cases they prevented these mammoth trees from crushing cars, houses and maybe even people. They even managed to keep the trees off the roads so emergency responders could get to people in need. So the next time you ask yourself, why do I need all this steel in my cable or why do the specifications require so much wasted material, remember Sandy and the tree that did not come crushing down because it was held up by a piece of ACSR.

Remember those who were less fortunate!

Eurolls Tube and Pipe

Eurolls Spa would like to announce that they have been chosen by TUPER of Brasil, to be TUPER’s roll tooling vendor for their latest expansion project.

Eurolls Spa - Eurolls Spa recently partnered up with TUPER of Brasil, by supplying all of the roll tooling for TUPER’s new mill installation for the production of API tubes. This mill was recently installed at
TUPER’s new unit, Óleo e Gás, which held its “Grand Opening” on September 14th at Sao Bento
do Sul/SC.

This customer, with whom Eurolls Spa has had a long term relationship, has expressed great appreciation on the timing and quality with which Eurolls has delivered their roll tooling, and has effectively awarded Eurolls Spa, a “Preferential Supplier Certificate”.

roll tooling for API and structural tubingEurolls Spa also completed the design, production and timely supply of roll tooling, for another important customer in Turkey. The value of this order was for several million dollars.

In addition to this, Eurolls SPA, has also been recently awarded contracts in the United States and Mexico for the production of roll tooling for API and structural tubing, respectively. Important orders have been also recently signed with Italian customers who reconfirmed their long term confidence towards Eurolls products and service. A recent appointment of a new agent in Germany has also resulted in an incredible increase in sales in this country!

Vitari Announces the Production of The New NR-300 Straight & Cut Machine

Vitari is proud to announce the production of their latest in their line of Vitari Automatic Straightening and Cutting Machines for mild steel wires. The NR-300 produces perfectly straightened bars in the wire range of 3.0– 10.0 mm. Wire feeding and straightening are accomplished through carbide or casted straightening dies assembled in a spinner (rotating body). The cutting device is operated via a hydraulic clutch / brake unit. This device can be equipped with either a flying or fixed shear. The option with flying shear allows customers to obtain a constant and true production output as opposed to a theoretical one, because the wire does not stop during the cutting operation. Wire overheating and straightened bar torsion are also reduced. The fixed shear solution with a provides an easier production of bars with lengths as low as 1m. by giving customers a better tolerance on the bar length. The tolerance on the bar length can vary from +/- 1 to +/- 2 mm depending on the machines actual feed speed.

The Wire Feed Speed on the NR300 goes up to 180m/min, depending on the wire diameter, the expected wire quality and the desired bar length. You can expect an output of up to 160 cuts per minute, with a standard measuring device, or up to 380 with a continuous cut. All Vitari Straightening and Cutting machines can come equipped with an automated cutting bench complete with piece counter , which allows customers to customize their bar bundles as they desire.

Italy’s Economic Crisis

Italy’s main employers’ association revised downwards its forecasts for the country’s economy on Thursday, predicting a deeper ongoing recession and the subsequent failure in balancing the budget by 2013. Confindustria expects that the Italian economy, the third largest in the euro zone, will contract 2.4 per cent in 2012, down from the minus 1.6 per cent figure published in December and double the 1.2 per cent fall predicted by the government.

The gloomy report also predicts the economy shrinking 0.3 per cent next year, significantly down from the last forecast for growth of 0.6 per cent. Luca Paolazzi, chief economist, explained that “previous forecasts were based on the expectation of more contained debt financing costs. As the bond yields have risen again, we had to revise down our projection.” “The second quarter showed deterioration in the whole euro region, with Italy being negatively affected by the earthquakes in the Emilia region. Investments fell and households have changed their spending and saving behaviors as available income fell,” he added.

In a sign of the growing nervousness surrounding the country’s debt, Italy on Thursday was forced to pay the highest interest rates since December in a €5.24bn auction of five- and 10-year government bonds. Rome sold its 10-year debt at an average rate of 6.19 per cent, up from 6.03 per cent at last month’s auction, while the five-year paper priced at a rate of 5.84 per cent, compared with 5.66 per cent in May.

February 2012 - download the newsletter - with this link

Electric Power: The Engine That Drives Economic Growth

OVERHEAD ALUMINUM CONDUCTORS: MARKET TENDENCY & HOW CORTINOVIS SICTRA IS
RESPONDING TO THE INCREASE IN DEMAND

February 2012 - download the newsletter - with this linkDeveloping nations, in order to grow their economies, need reliable and economic solutions to their energy requirements. Unfortunately, the road to energy independence is not always easy. Laws need to be written, regulations need to be put in place, environmental concerns need to be considered and sound engineering solutions need to be developed in order to get the energy where it is required in the most efficient manner.

This discussion will concentrate on the specific cables utilized to distribute this energy, the developments in cable designs and the equipment required to produce these cables. We will describe the current trend in the overhead conductor market and how CORTINOVIS MACHINERY and SICTRA, companies, which belong the same group (EUROLLS GROUP), have developed technologies proven to increase the production capabilities of manufactures already present in the market and also provide know how to companies that are considering entering the market but have been reluctant due to deficiencies in market knowledge and production capability. We will describe the two essential processes that are required to produce these conductors; Wire Drawing and Stranding.

Product Solutions:
From the beginning of the 20th century AAC (All Aluminum Conductor) was the only solution used for overhead conductor. This remained constant until just before WWII when the use of AAC was exceeded by AAAC (All Aluminum Alloy Conductor). The change was brought about because of the need for a higher conductivity conductor with higher strength. Unfortunately, it was determined that the strength of the conductor was the real limit.

This remained the limitation until the introduction of ACSR (Aluminum Conductor Steel Reinforced) and ACAR (Aluminum Conductor Aluminum Alloy Reinforced).

Today’s market is demanding even higher performance conductors, and the research is concentrated in the following areas:
1. Smaller diameter conductors with the same conductivity value
2. Lower resistance conductor material for higher conductivity
3. Higher strength for conductors reducing the conductor’s weight with the same conductivity
level We will attempt to explain how the constructions have evolved, the reasons for the evolution, and finally the equipment required to manufacture these products.

There are five major types of overhead conductors used for electrical transmission and distributionThere are five major types of overhead conductors used for electrical transmission and distribution:
1. AAC All Aluminum Conductor
2. AAAC All Aluminum Alloy Conductor
3. ACSR Aluminum Conductor Steel Reinforced
4. ACAR Aluminum Conductor Aluminum Alloy Reinforced
5. ACCR Aluminum Conductor Composite Reinforced

AAC – All Aluminum Conductors

Stranded 1350 aluminum conductors are classified, as follows:
• Class AA: For bare conductors usually used in overhead lines.
• Class A: For conductors to be covered with weather‐resistant materials and for bare conductors where greater flexibility is required.
• Class B: For conductors to be insulated with various materials and for conductors indicated under Class A where greater flexibility is required.
• Class C: For conductors where greater flexibility is required. Compact strand conductor for use in bare overhead applications or for use with weather‐resistant coverings or insulations are also available.

AAC – All Aluminum Alloy Conductors

Used as bare overhead conductor for primary and secondary distribution. Designed utilizing a high strength aluminum alloy to achieve a high strength‐to‐weight ratio; affords better sag characteristics. Aluminum alloy gives AAAC higher resistance to corrosion than ACSR.

ACSR – Aluminum Conductor Steel Reinforced

ACSR is a high‐capacity, high‐strength concentric‐lay‐stranded conductor consisting of a single core wire or a stranded steel central core with one or more layers of 1350 H19 stranded aluminum wires typically used in overhead power lines. The outer strands are aluminum, chosen for its excellent conductivity, low weight and low cost. The center strand is of steel for the strength required to support the weight without stretching the aluminum due to its ductility. This gives the cable an overall high tensile strength.

ACAR – All Conductor Alloy Reinforced

Used as bare overhead transmission cable and as primary and secondary distribution cable. A good strengthto‐ weight ratio makes ACAR applicable where both ampacity and strength are prime considerations in line design. For equal weight ACAR offers higher strength and ampacity than ACSR.


ACSR‐TW ‐ ACSR with Trapezoidal Aluminum

ACSR/TWD is ideal for replacement of existing conductor: it offers the same diameter for ice and wind but loading at higher ampacity than traditional ACSR designs. Angle and deadened structures must be carefully evaluated because of the greater weight of the conductor. The same tangent structures may normally be used in installation.

Zinc (Zn) Coated Steel Wire Core

The steel wires are coated with zinc to improve corrosion resistance. The technology used is either “hot dip galvanizing” or “electro‐galvanizing”. Hot dip plating involves passing the steel wire through a molten zinc bath whereas electro‐galvanizing involves electroplating.

Galfan, which is Zn‐5% AL, is the most rapidly growing hot dip process and provides improved corrosion resistance over conventional Zn. Once coated, the wire can be used as is or can be redrawn. The wires are stranded to produce a single wire, 7‐wire or 19‐wire core.

Using ACSR & ACCR with Shaped Conductors

The latest evolution in overhead conductors since the introduction of conventional Aluminum Steel Reinforced Conductor (ACSR) is the development of a strand using shaped wire instead of round wire aluminum conductors in combination with composite core. Due to its light weight and high strength, this core, patented by 3M, can provide a cable with transmission capacities from two to three times greater than those of existing systems. The high‐performance 3M brand composite conductor is known as ACCR (Aluminum Conductor Composite Reinforced). In addition, regarding the current carrying material, the tendency nowadays is to use Aluminum Alloy. However, more often we find customers using Aluminum Zirconium Alloy which has a greater thermal limit.

It does not matter if the project is in an industrialized area or big city, most of the points that are pushing the companies into shaped wire conductors can be summarized in using the following points:

1. Very high cost to install new power line
2. Too difficult to acquire new tower sites and right of way
3. Time constraints where for some projects there is not enough time to build a new site
4. Popular feeling against construction of high voltage overhead lines in urban and suburban areas

Why Shaped Wires:
Each trapezoidal segment must be specifically designed for each cross section and each layer within the cross section. If you then consider the geometries of the numerous strands, the manufacturing cost to produce these trapezoidal segments is higher than producing conventional round wires.

So why would you do it?
The objective is to manufacture strands with max possible reduction of interstices, the free space between the wires. Traditionally this is accomplished by compacting the strand after it is formed. Unfortunately, this process is limited to compacting ratios of 90‐92%. To achieve these compaction rates, capstans which can produce sufficient pull to compact the strands are required. Furthermore, while the smaller cross sections can be produced efficiently the larger cross sections become problematic.

Therefore, since the objective is to reduce the space between the wires by deforming them, it stands to reason that if you start with a deformed, trapezoidal wire the amount of work needed to produce the compacted conductor is reduced significantly.

But why shaped conductors? The answer becomes obvious if you consider the following: If you produce a given cross section, and you use trapezoidal wire, the diameter is smaller. This in turn means that all the downstream equipment which is diameter sensitive can be reduced. For example: If the product requires insulation, you will use less plastic. If the cable is eventually cabled into a triplex or a quad it will also be smaller in diameter. See the example below:

Construction 1 - Equivalent Diameter Construction 1 - Equivalent Diameter

EQUIVALENT DIAMETER
Instead of manufacturing a smaller diameter conductor for the “equivalent” circular area, the design of the trapezoidal shapes can be enlarged and yield a greater cross‐sectional area of aluminum and matching the diameter of the original conventional round conductor.

The resulting conductor has the same diameter as the conventional conductor, but with a much larger Aluminum cross‐sectional area, this means you can increase the Aluminum content by 20‐25%, decreasing the AC resistance by 15 to 20% and significantly increase the current carrying capacity of an existing line.

However, if the objective is to increase current carrying capacity and you are not attempting to decrease diameter you can increase the cross section while maintaining the same diameter. See the example below:

Construction 2 - Equivalent Area Construction 2 - Equivalent Area

EQUIVALENT AREA
Trapezoidal conductors utilize aluminum pre‐shaped wires prior to stranding to provide a smooth outer surface and fit together to reduce the interstitial empty space and finally to allow a smaller overall diameter of the conductor.

Trapezoidal conductor has the same Aluminum cross‐sectional area as the Conventional conductor, but with smaller overall diameter. The result is a conductor that has a diameter approximately 10% smaller.

Therefore you can increase the cross section and increase the current carrying capacity and still maintain the same diameter.

Traditional conductors, ACSR (Aluminum conductor steel reinforced) using round conductors are being substituted with newly developed products such as:
• ACSR/TW (Aluminum conductors steel reinforced/trapezoidal wires with internal gap)
• ACSS/TW (Aluminum conductors steel supported/trapezoidal wires)
• ACCR (Aluminum conductors composite reinforced)

Trapezoidal Gap Design “Self‐dampening” Alcan Cables
Trapezoidal Gap Design “Self‐dampening” Alcan Cables
Trapezoidal Gap Design “Self‐dampening” Alcan Cables

 

In some cases, a high performing material with extra high conductivity Al Alloy, composite wires with oriented Alumina fibers in AL matrix (3M patented product can be used.

What Benefit do you get from ACCR?

Electric power is the engine that drives economic growth. As utilities continue to expand the electrical grid the demand for more power is ever increasing. In some cases additional power is required in mature areas where the replacement of existing infrastructure is just not economically feasible. But what if you could increase the amount of power you could deliver by changing the cable without having to change the towers.

The 3M ACCR core is stranded from wires that are composed of Alumina fibers which are embedded into high purity aluminum. Compared to conventional ACSR, which has a steel core, the ACCR cable exhibits half the thermal expansion therefore less sag at high energy levels and has twice the strength to weight ratio.

This enables you to produce a cable with the characteristics that result in two or more times the current carrying capacity in a cable that puts less stress on the structures. Also since the core is lighter, you can increase the amount of current carrying conductor and eliminate the need for new towers, land acquisition and the inherent problems with environmental impact by maintaining the same cable weight but increasing the current carrying to weight ratio.

ACCR ‐ Aluminum Conductor Composite Reinforced

Compared to the same diameter steel core conductor 3M ACCR can offer as much as:
• Half the thermal expansion for less sag at high energy levels
• Twice the strength to weight ratio
• Operating temperatures up to 210°C continuous and 240°C emergency for up to 1,000 hours
cumulative
• More conductivity

These properties allow you to triple the capacity of your transmission line without adding tension or weight to your structures – maximum amps with no compromises.

3M ACCR is an advanced transmission conductor3M ACCR is an advanced transmission conductor designed to replace ACSR on existing structures, giving you up to two to three times the capacity without the risks of a major construction project.
• Reduce construction outages
• Speed up and simplify permitting
• Reduce project schedule
• Increase budget certainty
• Minimize new environmental impacts on existing rights of way

Now that we have introduced the available solutions we need to understand the reason why the market is moving into trapezoidal Aluminum shape wire conductors. When considering an upgrade to an existing infrastructure or the installation of new power line, several constants are always present; the demand for more electricity in the most efficient way and the least amount of environmental impact must be considered.

The solution for the above problem, in most cases, is RE‐CONDUCTORING of existing lines with high temperature & low sag conductors carrying higher power. This enables you to utilize the existing tower and in most cases the existing clamping, while still being able to have more power transmission capacity.

Sictra Wire Drawing:

SICTRA is well known worldwide for its experience in the field of the wire drawing of non‐ferrous materials. Sictra has been part of The EUROLLS Group since 2008

In January 2011 Cortinovis Machinery integrated Sictra into the Cortinovis Company making it a separate wire drawing division within Cortinovis Machinery S.p.A. At this time we also took this opportunity to change our historical logo to a new one combining the two brands and their logos into a unique one while maintaining the brand and individual experience of each company.

This continuity of the new division was maintained by retaining the original Sictra management and technical staff headed by Mr. Giorgio Monti. Mr. Monti is the original founder of Sictra with more than 40 years experience in the field. Today the new division continues the innovation of products enabling SICTRA to offer high quality practical solutions which have become a benchmark in the NON‐FERROUS wire industry. This continued commitment to the industry has resulted in numerous innovative solutions to the manufacturing equipment we produce for the wire and cable industry. Our main products include:

Rod break down, drawing machines for single or dual wires, pay‐offs, annealers, and a variety of take‐ups for various solutions.

For all types of the overhead conductors, the initial process will be wire drawing. The Sictra division has a full range of non‐ferrous wire drawing machines working successfully in the wire & cable industry all around the globe.

In this writing we will present a new concept of Rod Break Down machine designed specifically for Aluminum and Aluminum Alloy for round, trapezoidal and shaped wire.

Cortinovis Machinery Stranding:
Cortinovis was established in 1881. In the early years, the company’s core business was a foundry for bronze and cast iron; the company also had a workshop where mechanical work was done as a subcontractor, mainly for manufacturing tools for small industries and for the agricultural industry.

In the early part of the 20th century the company started to develop and design its own products and technology. From the 20’s to the beginning of World War II, the foundry and the workshop continued to develop, making the Company one of the most renowned foundries and mechanical workshops in the area.

Immediately after World War II, Cortinovis took advantage of the close vicinity of one of the largest cable manufacturers, which was based in Milan and entered into the cable machinery business, a sector, which the Company would never leave.

Cortinovis has introduced numerous new solutions, earning the reputation as a machinery producer of innovative designs and machines to fulfill customer production requirements. Cortinovis went on to establish worldwide presence in markets such as South East Asia, North and South America, Europe, and the Middle East. In order to serve these markets better we have established Cortinovis companies in the local markets such as Cortinovis Machinery America, Cortinovis Do Brazil and a service center in Cairo providing service to our customers in the Middle East. Recently we have set up an after sales organization in China in order to be able to provide a more efficient service to our Chinese and South East Asian customers.

Together, our companies are able to supply a complete solution for upgraded the overhead conductor solution.
􀂓 Systems integration & responsibility to provide total systems solutions
􀂓 Total technical capabilities providing innovative high‐quality products and services
􀂓 In‐house experienced cable process engineers and manufacturing engineers
􀂓 Short decision chain ‐ to anticipate and take advantage of changes in the market
􀂓 Products tailored for the market

TOTAL PROJECT MANAGEMENT:

 

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CORTINOVIS MACHINERY AMERICA, Inc.

A Eurolls Group Company
1014A Route 173
Bloomsbury, New Jersey
08804 U.S.A.

Tel.: +1 (908) 479-9818
Fax: +1 (908) 479-1644
E-Mail: cortinovis

 

 

 

 

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