heat cycling test on “london” accc/tw … · heat cycling test on “london” accc/tw...

To: Dr. Eric Bosze CTC Cable Corporation

2026 McGaw Avenue Irvine, CA 92614 USA

HEAT CYCLING TEST ON “LONDON” ACCC/TW CONDUCTOR UNDER TENSION AT A

MAXIMUM DEPARTURE ANGLE THROUGH A PLP AGS SUSPENSION ASSEMBLY

Kinectrics North America Inc. Report No.: K-419205-RC-0002-R00

September 29, 2010

Zsolt Peter, Dmitry Ladin, Michael Kastelein, Greg Brown Transmission and Distribution Technologies Business

A Heat Cycling Test was performed on a tensioned sample of 33.40 mm, “London”, Aluminum Conductor, Composite Core/Trapezoidal Wire (ACCC/TW) conductor, and on a modified PLP AGS suspension assembly P/N AGS-5518-MODIFIED, for CTC Cable Corporation (CTC). National Grid Company (UK) requested CTC to perform a test in which the “London” ACCC/TW conductor is tensioned through a modified PLP AGS suspension assembly at a 15˚ departure angle, and thermally cycled forty (40) times at 215°C conductor core temperature. The goal of the testing program was to determine the effect of accelerated laboratory aging on the conductor and the suspension assembly when the conductor is bent at the maximum departure angle through a PLP AGS suspension assembly and thermally cycled. According to the National Grid’s probabilistic approach the maximum temperature of the 9.78 mm composite core of the “London” ACCC/TW conductor is expected to reach 215°C during its service life. The test was performed between July 16, 2010 and September 9, 2010 in accordance with Kinectrics ISO 9001 Quality Management System by Kinectrics North America Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4, Canada under CTC Cable Corporation’s Purchase Order No. 4301. The test was performed under Kinectrics ISO 9001 Quality Management System. Applicable measuring instruments calibration certificates are shown in Appendix C. A copy of Kinectrics ISO 9001 Accreditation Certificate is included in Appendix D.

PRIVATE INFORMATION Contents of this report shall not be disclosed without authority of the client.

Kinectrics North America Inc., 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4

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1.0 TEST OBJECTIVE AND STANDARD The objective of the Heat Cycling Test was to subject the CTC glass/carbon fiber composite core High Temperature Low Sag (HTLS) conductor and a modified PLP AGS suspension assembly to thermal and mechanical loads, simulating those encountered in actual operation, when it’s tensioned, bent at the maximum departure angle through a PLP AGS suspension assembly, and thermally cycled at the maximum core temperature. Currently, no industry standard or definite test protocol is available for evaluating the combined effects of thermal and mechanical cycles on HTLS conductors and accessories.

2.0 TEST SET-UP

Conductor Assemblies The selected conductor size for the test was 33.40 mm, “London”, Aluminum Conductor, Composite Core/Trapezoidal Wire (ACCC/TW) conductor. The conductor consists of a single composite glass and carbon fiber core covered by three (3) layers of thirty-six (36) annealed, trapezoidally-shaped aluminum alloy wires. The composite core (CTC P/N 200-009, Manufacturing Order # 0001689) is manufactured by CTC and the conductor is stranded by LAMIFIL N.V. Safety Rated Tensile Strength (RTS) of the conductor is 180.1 kN or 18,380 kgf. The complete specification for the conductor is shown in Appendix A. CTC supplied sufficient length of conductor in brand new condition. Two (2) approximately 11 m lengths of conductor were cut from the supplied reel for testing. One conductor was used in tensioned span, and the second one served as a dummy return conductor. All conductor ends were terminated with Burndy high temperature dead-end connectors P/N YTW451-ACCC4. A photo of typical conductor termination with the compression connector is shown in Figure 1. The compression connectors, manufactured by Burndy, were installed by Mr. Chip White of CTC with the assistance of Kinectrics North America Inc. (KNAI) personnel. CTC also provided appropriate compression dies, and KNAI supplied a 60-ton press for the installation. Suspension Assemblies Preformed Line Products Co. (PLP) has supplied two modified AGS unit suspension assemblies (PLP P/N AGS-5518-MODIFIED) in brand new condition. The suspension assemblies have been redesigned with shorter armor rods to meet the National Grid standards for corona and noise reduction. One of the AGS assemblies was installed in the center of the tensioned and bent span, and the second one was placed in the center of the straight dummy return conductor. Distance between the dead-end connector’s mouth and the opposed end of armor rod was approximately 4 m. Test Apparatus The test was carried out in Kinectrics’ Mechanical Testing Laboratory. The following tests were performed: A) Heat Cycling Test, and B) Breaking Load Tests.

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A. Heat Cycling Test Figure 2a provides the test setup schematics. Photo taken from the test setup are shown in Figures 2b and 2c. A test machine having a load accuracy of ± 2% was used for this test. The test conductor was loaded using a hydraulic piston and the tension was kept at the target level using a cantilever weight system, and raised to a height providing the maximum conductor departure angle through the AGS suspension assembly of 15 ± 1˚. The suspension clamp was mounted on an elevated steel frame bolted to a concrete structure anchored to the concrete floor (see Figure 2d). A porcelain insulator electrically isolated the steel frame and the suspension assembly. The test was performed in a room free of excess drafts in order to assure thermal stability and consistency between thermal cycles. During the cooling period of each test cycle, the conductor/connector assembly temperature reduced gradually by natural convection. A dummy conductor shown in Figure 2c, running in parallel to the test conductor under tension, was also installed in order to monitor conductor core temperature. The dummy conductor was not under tension, but passed through the same current and underwent the same temperature cycles as the test conductor and, therefore, provided, direct composite core temperature measurements. The dummy conductor was also used as the return conductor to the power transformer. An AC current transformer (Figure 3) and a variable transformer (variac) provided necessary current to increase the temperature in the conductor to the desired temperature. The AC current transformer supplied the current in the test conductor through jumper terminals that were attached to the test conductor with compressed dead-ends. A typical photo taken from the jumper terminal connector is shown in Figure 4. Instrumentation Conductor Tension for Heat Cycling Test A strain gauge load cell (shown in Figure 4) measured the test conductor tension at the north end of the test span during the test. The load cell was installed between the insulator and the dead-end structure so that it would be electrically isolated from the conductor. The signals from the load cell were amplified to provide a 0 to 5 V signal for the data acquisition system (see Appendix B). Temperature Measurements Total of thirty (30) thermocouples were located on the conductors, suspension assembly components, and dead-end compression connectors (see representative thermocouple images in Figures 5a-5g). Temperature readings were collected and recorded automatically every five (5) minutes. The temperature of the conductors was measured at multiple locations along the test loop length. Also, several thermocouples were located at various places across the radius of the dummy conductor: i) in the composite core; ii) between first and second aluminum layers, and iii) in the second (outer) aluminum layer between two (2) adjacent strands. Several additional thermocouples were installed on the AGS suspension assembly components. Numerous thermocouples were also attached to the dead-end compression connectors.

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Ambient temperature was measured at two locations: around the tensioned test conductor, and around the dummy conductor. Table 1 summarizes the thermocouple positions at each location. Glass isolated thermocouples of J-type were used to measure the temperature of the conductors. All thermocouples were optically isolated from other instrumentation to prevent electrical interference into the data acquisition system.

Table 1: Locations of Thermocouples

Conductor Thermocouple Number (TC)

Location

Tensioned Test

Conductor

TC1 Ambient air around tensioned conductor

TC2 Jumper pad/jumper terminal interface, north tensioned dead-end

TC3 Mouth of north dead-end

TC4 Outer layer, 150 mm from mouth of north dead-end

TC5 Outer layer, 600 mm from north dead-end

TC6 Outer layer, 2.4 meters from middle of conductor

TC7 On the armor rod, at the end facing north dead-end

TC8 Between suspension clamp rubber bushing and conductor (Figure 5c)

TC9 On bolt of suspension clamp

TC10 Surface of conductor between end of suspension clamp rubber bushing and armor rod touching the conductor (Figure 5d)

TC11 600 mm from center of conductor, on armor rod, facing south dead-end (Figure 5b)

TC12 Outer layer, 2.4 meters from center of conductor

TC13 Mouth of south dead-end (Figure 5e)

TC14 Surface of south dead-end, mounted above collet housing (Figure 5f)

TC15 Eye-bolt of south dead-end

Non-Tensioned Dummy

Conductor

TC16 Ambient air around dummy conductor

TC17 Jumper pad/jumper terminal interface, north dummy dead-end (Figure 5g)

TC18 Mouth of north dead-end

TC19 Outer layer, 150 mm from mouth of north dead-end

TC20 Outer layer, 600 mm from north dead-end

TC21 Outer layer, 2.4 meters from middle of conductor facing the north dead-end (Figure 5a)

TC22 Between aluminum layers 2 and 3 of dummy conductor, 2.4 meters from middle of conductor facing the north dead-end (Figure 5a)

TC23 Touching core, 2.4 meters from middle of conductor facing the north dead-end (driving TC) (Figure 5a)

TC24 Between suspension clamp rubber bushing and conductor

TC25 Touching core, 2.4 meters from middle of conductor facing south dead-end (driving TC)

TC26 Between aluminum layers 2 and 3 of dummy conductor, 2.4 meters from middle of conductor facing south dead-end

TC27 Outer layer, 2.4 meters from middle of conductor facing south dead-end

TC28 On the armor rod, at the end facing south dead-end

TC29 Mouth of south dead-end

TC30 Surface of south dead-end, mounted above collet housing

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Control of Current in Loop and Data Acquisition Constant AC current was circulated in the conductors. The data acquisition system (DAQ) recorded the conductors’ temperature and tension, and controlled the contactor. The data were sampled and recorded periodically. A closed-loop system was used to maintain the target temperature of the test conductor. As the control core temperature increases or decreases with ambient temperature and current variations the DAQ adjusted the voltage of the Variac (variable transformer) to keep a constant target temperature in the core. Upon completion of the Heat Cycling Test, the tensioned test conductor was unloaded, tension reduced to zero, and conductor lowered to the ground. The AGS suspension assemblies were dismounted from both tensioned and dummy conductors. All suspension assembly components as well as the conductor under the suspension clamps were visually inspected.

B. Breaking Load Tests Exposed conductor core samples were terminated by Darrin Witt from CTC at KNAI facility using CTC supplied epoxy dead-end. The exposed core length was approximately 1 m between epoxy dead-ends. Once epoxy resin has cured, each core test sample assembled with epoxy dead-ends was installed in the vertical tensile machine. One compression dead-end sample attached to approximately 1.5 m of free conductor length was taken from each tensioned and dummy conductor assembly. The dead-end connectors were selected from the north side of the test loop. These connectors did not have thermocouples installed on the aluminum sleeve surface. Each test sample was installed in a hydraulically-activated horizontal test machine (see Figure 6). Typical dead-end connector prior to the test is shown in Figure 7 and typical epoxy resin dead-end in Figure 8, respectively. Both compression dead-end connector and epoxy dead-end were marked with paint to detect conductor slippage during the test. Instrumentation and Data Acquisition The conductor tension was measured by a load cell located at the hydraulic end of the sample. The signals from the load cell were amplified to provide a 0 to 5 V signal for the data acquisition system. The controller for the hydraulically activated horizontal test machine recorded the peak tension. 3.0 TEST PROCEDURE The intent was to subject the test conductor to a total of forty (40) thermo-mechanical cycles. The conductor tension of 20% (± 2%) of the conductor’s RTS (using safety rating RTS value) is chosen for the Thermo-Mechanical Cycle Test.

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A. Heat Cycling Test The test was carried out according to the following test procedure:

i) One AGS unit suspension clamp (PLP P/N AGS-5518-MODIFIED) is installed in the centre of the tensioned/bent test conductor and one in the centre of the dummy conductor as well.

ii) The test conductor is attached to the test frame, with the suspension clamp mounted on an elevated steel fixture, raising the test conductor to a height that provides the maximum departure angle through the suspension clamp of 15 ± 1˚.

iii) 30 thermocouples are installed at the test loop locations listed in Table 1. iv) Once the angle is achieved, conductor is tensioned to approximately 20% RTS (8,098

lbf or 3,676 kgf), using safety rating RTS value according to the Lamifil “London” ACCC/TW specification (see Appendix A).

v) Compression jumper terminals (see Figure 9), supplying current to the jumper pads of the compression dead-ends on the test conductor and dummy conductor, are installed. The electrical current path is from the transformer, through the tensioned conductor, through the dummy conductor and back to the transformer, as shown in Figure 2a.

vi) Forty (40) heat cycles are applied on the test and dummy conductor from room temperature to 215°C maximum conductor core temperature. A typical heat cycle is shown in Figure 5a. Each heat cycle is performed as follows:

a. Starting at room temperature (nominally 20˚C - 30˚C), the temperature in the conductor is increased by circulating alternating current (AC) supplied by a current transformer. The motor driven variac adjusts the electrical current in order to heat the conductor core up to the test temperature (215˚C) and maintain this temperature for eight (8) hours.

b. A data logger (see Appendix B) monitors temperatures of the conductor at two (2) locations. The highest value of two (2) thermocouple readings in the core of dummy conductor, i.e. of thermocouples TC #23 and TC #25 is selected and logged as maximum conductor core temperature. The current is automatically adjusted to heat the conductor core up to the test temperature of 215˚C ± 1˚C, and maintain this temperature for 8 hours.

c. The tension in the test conductor is not constant, but is allowed to change with temperature. The tension is monitored at all times to record how the tensions decrease and increase with temperature cycling.

d. Once the target temperature soak time (8 hours) is achieved, the contactor is instructing the transformer to shut power off, and the conductor is allowed to naturally cool down.

e. Once the test loop temperature is reduced below 60˚C ± 1˚C, the transformer is switched on, and the temperature of the conductor will be ramped back up to the core temperature of 215˚C ± 1˚C and held for another 8 hours.

f. The cycle is repeated for accumulating total of forty (40) cycles. After all cycles are completed, the controller instructs transformer to shut off.

vii) Once all heat cycles are complete, the load and angle are removed from the test conductor.

Upon completion of the Heat Cycling Test, the tensioned test conductor was unloaded, tension reduced to zero, and conductor lowered to the ground. All suspension assembly components as well as the conductor under the suspension clamps were visually inspected for possible markings, damage or other artifacts left over from the heat cycling testing.

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B. Breaking Load Tests Each core sample was inserted into the hydraulic activated vertical test machine and tensioned to failure. The load was applied gradually and the rate of loading was 5 mm/min (0.2 in/min) until failure, according to ASTM D3716. The maximum force during testing was recorded. The test is performed in a temperature controlled laboratory at 20°C ± 2°C. Each dead-end assembly was installed in the horizontal tensile machine as shown in Figure 6, and the load was gradually increased at the rate of 9,226 lbf/min (4,185 kgf/min) until the test sample was tensioned to 90% of RTS (18,831 kgf). This load was maintained for 1 min, and after that the tension was increased to the breaking point. The maximum force and conductor slippage during the test was recorded. The test was performed in a temperature controlled laboratory at 20°C ±2 °C. Measuring instruments and equipment used in all tests is listed in Appendix B. 4.0 TEST RESULTS AND DISCUSSION

A. Heat Cycling Test Large amounts of temperature data were recorded by the data logger for the duration of the test. Tables 2a to 2c contain the steady-state temperatures and conductor tension data of the test conductor, dummy conductor, suspension assembly, and compression connectors installed in the test loop. The temperature and tension data contained in Tables 2a to 2c are also plotted in Figures 10 and 11 as follows:

Figure 10a: Typical Heat Cycle, Conductor Core Temperatures Figure 10b: Typical Heat Cycle, Suspension Assembly Temperatures Figure 10c: Typical Heat Cycle, Test Conductor Temperatures Figure 10d: Typical Heat Cycle, Dummy Conductor Temperatures Figure 11a: Steady-State Conductor Core Temperatures during Heat Cycling Figure 11b: Steady-State Suspension Assembly Temperatures during Heat Cycling Figure 11c: Steady-State Test Conductor Temperatures during Heat Cycling Figure 11d: Steady-State Dummy Conductor Temperatures during Heat Cycling Figure 11e: Steady-State Temperatures of Test Conductor Connectors during Heat Cycling Figure 11f: Steady-State Temperatures of Dummy Conductor Connectors during Heat

Cycling Temperature Variations Figures 10a-10d illustrate typical heat cycle as experienced by the tensioned test conductor, non-tensioned dummy conductor, and the suspension assembly. The thermal stability was achieved approximately 100 minutes into the cycle. Noticeable, for the test conductor (Figure 13c), the highest temperature (approximately 190-200 °C) was recorded 2.4 m north of the suspension assembly, while the conductor section close to bushing of the suspension assembly remained at a much lower temperature (approximately 110-120 °C). This fact points out to efficient heat dissipation in the suspension assembly area. It’s also evident from the low temperature recorded in the bushing of suspension assembly, and a much lower temperature at the suspension assembly bolt on top of the clamp (Figure

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10b). No significant steady state temperature variation between the heat cycles was noticed at any of the thermocouple locations. Heat dissipation from the suspension assembly armor rods resulted in lower conductor temperatures in the vicinity of the suspension assembly. Tension Variations

Figure 10a shows typical test conductor tension reduction due to the heat cycling. The tension in every cycle was reduced from the initial 8,098 lbf to under 7,000 lbf once the conductor temperatures reached steady state. Once the power in the test loop was shut off, the tension returned to the initial setting. No significant variation in the steady state test conductor tension was observed for the duration of the test (see Figure 10a). Performance of Compression Connectors

Figures 11e and 11f summarize temperature measurements taken from the compression connectors used in the test. All the connectors were able to achieve steady state temperature. The highest temperatures were recorded at the mouth of each dead-end connector, while the lowest temperature was at the dead-end eye-bolt. Those temperatures remained stable from cycle to cycle. After completion of 40 heat cycles, the conductor was visually examined. There were no signs of physical damage to the conductor strands. No breaks, cracks, failure, bird-caging or discoloration of any conductor components was detected. The AGS Suspension Assemblies were dismounted from the tensioned and dummy conductors and also inspected for signs of breaks or component failure. Figures 12a to 12c and Figures 13a to 13c show details of the examination. First, the armor rods were taken off, and then suspension clamp was opened and removed to expose the rubber bushing. Finally, the rubber bushing halves were dismounted to expose the bare conductor. No visible mechanical damage was detected on those parts.

B. Breaking Load Tests Tests on Core Sections under the Suspension Clamps: Retained Tensile Load Test results obtained on core samples under the suspension assembly are summarized in Table 3. Conductor core sections, which were located directly under the suspension assembly, have retained strength exceeding 100% of the core RTS value (16,529 kgf or 162.1 kN). These core sections seem to be the least affected by thermal ageing due to effective heat dissipation from the armor rods and suspension clamp. Tests on Dead-end Assemblies: It was observed that in the tensioned conductor test sample, at the end of the breaking load test, conductor broke approximately in the middle of conductor span, while in the dummy conductor test sample failure occurred at the dead-end connector mouth (see Figures 14a and 15a). In the tensioned conductor, conductor slippage (approximately 2 cm) was noticed at the compression connector mouth. In both test samples conductor failure occurred due to the conductor’s composite core failure. Figures 14b and 15b represent magnified views of conductor’s aluminum strands with the symptomatic overextension “necking” of the strands.

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The breaking load values recorded were as follows:

• 20,462 kgf (97.8% of the conductor’s RTS) for the tensioned conductor test sample,

• 20,158 kgf (96.3% of the conductor’s RTS) for the dummy conductor test sample.

Table 2a: Measured Steady-State Temperatures during Heat Cycling

Cycle Number

Steady-State Temperatures

Cond. Core Suspension Assembly Test Conductor Ambient

˚C

TC23 TC25 TC7 TC28 TC11 TC24 TC8 TC4 TC5 TC6 TC10 TC1 TC16

1 214.0 210.0 160.0 168.0 147.0 129.0 130.0 152.0 176.0 196.0 123.0 25.0 24.0

2 215.0 208.0 159.0 166.0 138.0 128.0 124.0 153.0 175.0 195.0 121.0 25.0 24.0

3 215.0 211.0 160.0 167.0 134.0 129.0 125.0 151.0 173.0 196.0 123.0 25.0 25.0

4 215.0 207.0 162.0 165.0 131.0 128.0 122.0 149.0 174.0 194.0 120.0 25.0 25.0

5 215.0 207.0 165.0 167.0 129.0 129.0 121.0 152.0 176.0 198.0 118.0 25.0 25.0

6 214.6 208.0 162.1 164.6 128.3 127.5 117.2 150.1 175.5 196.1 115.0 24.8 24.4

7 215.2 204.9 158.8 166.3 126.8 128.5 116.3 150.9 176.2 194.3 113.2 24.4 24.3

8 215.4 209.6 158.3 164.9 126.8 127.9 115.3 152.0 176.8 196.2 112.5 24.7 24.2

9 214.8 213.3 161.9 159.9 125.0 126.6 115.2 152.1 176.2 198.2 113.6 24.6 24.3

10 214.3 208.9 157.6 167.9 127.6 128.0 113.9 152.2 177.7 197.4 111.3 24.2 23.6

11 215.5 210.9 157.7 163.2 125.2 126.6 112.4 152.0 177.6 195.7 109.2 24.6 24.3

12 214.7 208.8 155.3 165.5 125.6 126.9 111.5 153.5 179.1 195.6 108.5 24.3 23.8

13 215.9 212.0 156.7 161.8 124.9 126.5 112.7 151.1 175.8 196.6 110.5 24.8 24.4

14 215.1 209.0 153.1 165.0 126.1 126.3 110.4 153.0 177.9 195.0 106.6 24.4 23.9

15 215.4 211.4 154.5 161.8 126.1 126.6 111.6 152.0 177.0 196.6 109.0 24.8 24.4

16 211.8 214.3 158.5 169.6 136.6 130.0 116.5 154.1 181.7 201.4 113.5 25.7 25.0

17 215.0 214.6 156.2 165.9 130.0 129.0 114.5 153.2 177.8 195.2 110.1 25.3 24.8

18 214.6 212.6 154.2 161.9 127.9 127.4 112.3 152.8 177.5 196.4 108.1 25.3 25.2

19 214.6 214.9 155.9 166.6 130.7 128.6 114.3 152.0 175.7 197.1 109.9 25.9 25.2

20 214.5 213.6 153.5 162.5 127.9 127.4 112.2 151.0 174.2 194.9 107.7 25.6 24.8

21 213.8 214.6 158.3 167.5 125.3 130.0 113.0 151.7 174.0 197.9 111.4 25.6 25.2

22 215.1 212.6 153.1 162.2 124.6 127.1 110.5 152.7 174.1 194.2 107.9 25.0 25.1

23 209.8 214.7 160.0 171.7 135.6 131.4 118.8 151.0 171.3 191.4 114.7 26.3 25.9

24 215.6 213.5 155.8 165.8 129.0 129.3 114.4 152.5 172.3 191.9 111.5 25.5 25.3

25 214.4 215.4 160.5 169.1 131.7 130.2 117.3 153.8 175.5 193.9 113.1 26.0 25.6

26 214.0 214.3 161.2 168.8 130.5 130.1 116.8 152.8 173.2 194.8 114.1 26.3 25.7

27 214.5 215.2 163.6 169.7 129.8 130.4 117.3 153.8 175.7 196.7 115.0 26.1 25.6

28 213.6 214.4 158.9 167.7 132.1 130.2 118.0 153.9 174.9 193.2 114.1 26.0 25.9

29 214.9 210.2 158.6 166.0 130.4 128.8 116.2 154.6 176.8 191.5 113.0 25.4 25.5

30 215.5 213.8 159.6 170.7 137.3 131.3 121.3 149.3 169.5 193.1 116.0 26.7 26.6

31 215.4 212.2 157.3 167.2 131.8 130.2 116.5 155.6 178.1 190.7 113.1 25.4 25.5

32 214.5 215.0 159.1 168.7 134.1 129.9 119.2 154.1 176.2 189.4 114.8 26.0 25.8

33 214.4 211.1 157.4 165.4 130.7 129.2 117.0 152.8 175.3 190.6 113.5 25.7 25.6

34 212.3 215.4 157.4 170.1 135.6 130.6 119.7 154.7 176.9 187.9 115.1 25.8 25.6

35 215.1 212.5 157.3 166.8 131.4 129.7 117.2 155.3 177.5 193.8 113.8 25.6 25.6

36 215.1 213.4 160.4 166.5 130.9 128.2 117.0 154.3 174.7 189.1 114.2 25.6 25.5

37 215.7 212.9 163.4 168.4 132.2 129.9 118.6 157.2 177.2 190.9 115.1 25.8 25.8

38 214.9 211.8 160.3 166.6 130.4 128.3 116.4 156.1 177.0 186.4 113.3 25.2 25.5

39 214.7 214.0 161.7 168.7 132.1 129.7 118.7 155.0 174.7 193.4 115.3 26.1 25.9

40 215.1 211.4 158.1 162.4 131.3 126.0 115.6 156.4 179.1 182.9 112.6 25.6 25.0

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Table 2b: Measured Steady-State Temperatures during Heat Cycling

Cycle Number

Steady-State Temperatures,

Dummy Conductor Connectors on Test Conductor

˚C

TC19 TC20 TC21 TC22 TC26 TC27 TC2 TC3 TC13 TC14 TC15

1 167.0 194.0 207.0 212.0 206.0 202.0 111.0 123.0 127.0 97.0 52.0

2 166.0 192.0 207.0 212.0 204.0 200.0 111.0 123.0 126.0 96.0 52.0

3 165.0 192.0 207.0 212.0 206.0 203.0 112.0 123.0 126.0 97.0 52.0

4 165.0 191.0 206.0 212.0 203.0 200.0 111.0 122.0 125.0 96.0 52.0

5 163.0 190.0 207.0 213.0 202.0 199.0 112.0 125.0 133.0 107.0 58.0

6 161.2 186.6 206.2 212.0 204.0 200.5 110.2 124.1 132.4 106.8 58.4

7 163.3 190.1 206.3 212.6 200.5 196.8 111.1 123.7 133.0 106.3 57.3

8 161.9 188.6 206.5 213.0 205.5 202.2 111.6 124.6 133.7 107.6 58.6

9 162.8 190.4 206.1 212.4 209.4 206.1 112.2 123.6 133.3 108.2 57.0

10 161.0 187.5 206.3 212.2 204.9 201.7 109.8 125.6 135.7 110.6 59.2

11 163.1 189.9 206.7 213.0 207.1 203.8 110.8 124.6 134.9 109.5 58.1

12 161.5 188.0 205.8 212.6 204.8 201.3 111.1 125.2 134.7 109.7 58.5

13 162.9 189.1 207.2 213.7 208.3 204.6 109.5 123.8 135.0 109.8 58.6

14 161.7 188.3 206.8 213.0 205.2 201.7 111.9 125.4 134.4 109.5 58.5

15 163.7 190.8 206.4 213.3 207.9 204.7 110.8 124.5 135.1 109.8 58.4

16 166.1 192.0 205.1 210.6 210.0 206.1 111.4 125.8 141.2 114.7 63.7

17 166.3 193.9 206.5 212.7 211.2 208.3 112.2 125.8 135.0 111.1 60.5

18 166.2 193.1 206.1 212.3 208.9 205.5 113.9 125.5 136.8 110.9 60.2

19 165.8 194.3 206.3 212.2 211.8 208.8 112.5 125.5 135.8 111.8 60.5

20 165.7 192.6 206.1 212.2 210.4 207.3 112.6 124.4 136.4 110.9 59.8

21 166.1 193.4 205.9 211.4 211.5 208.8 113.0 124.7 130.1 105.6 58.8

22 164.4 191.8 208.7 213.2 208.7 205.6 111.6 127.1 132.6 106.7 58.1

23 166.6 195.5 203.4 207.9 211.7 208.8 117.1 126.5 131.5 107.1 60.7

24 165.7 194.0 209.1 213.7 209.9 206.9 112.3 127.7 134.1 107.6 58.8

25 167.8 196.9 207.5 212.2 211.6 208.9 115.8 128.9 135.1 108.0 60.0

26 166.8 195.7 207.3 211.9 210.9 208.1 114.7 127.6 135.8 108.7 58.1

27 168.3 196.6 207.1 211.9 212.2 209.6 115.7 127.6 136.4 108.9 58.8

28 167.6 194.7 206.8 211.3 211.0 208.4 113.6 128.1 134.8 108.3 60.4

29 166.1 192.7 207.8 212.5 206.9 204.1 113.4 128.6 134.1 107.8 58.9

30 166.1 193.8 199.9 204.5 210.4 207.5 115.2 124.7 132.1 107.4 60.8

31 167.7 194.7 208.4 213.0 208.2 205.5 113.5 129.7 136.0 108.8 59.9

32 167.3 195.1 207.4 211.8 211.1 208.2 114.2 129.0 135.9 108.7 59.6

33 165.9 192.9 207.0 212.0 207.3 204.4 112.5 130.4 135.6 108.5 59.9

34 167.5 196.1 205.6 209.7 212.1 209.3 116.6 128.8 136.1 109.2 59.5

35 167.3 194.5 208.0 212.5 209.2 206.5 112.5 130.1 135.9 108.8 58.4

36 166.6 194.1 206.9 212.1 209.8 207.0 114.5 129.0 134.5 107.4 58.7

37 168.3 195.7 208.9 213.1 209.6 207.1 114.6 130.0 136.0 108.8 60.1

38 166.8 193.3 207.3 212.0 208.4 205.6 114.3 129.0 134.9 107.9 58.3

39 168.7 196.0 206.8 211.6 211.0 208.6 115.2 129.5 136.2 108.9 59.4

40 165.8 198.0 207.4 211.6 207.8 204.8 113.8 128.3 142.9 109.9 64.9

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Table 2c: Measured Steady-State Temperatures and Conductor Tension during Heat

Cycling

Cycle Number

Steady-State Temperatures, Connectors on Dummy Conductor

Test Conductor Tension ˚C

TC17 TC18 TC29 TC30 lbf

1 126.0 134.0 129.0 99.0 6856

2 124.0 132.0 128.0 98.0 6818

3 125.0 132.0 128.0 99.0 6848

4 124.0 132.0 128.0 98.0 6798

5 122.0 130.0 128.0 97.0 6749

6 120.9 128.9 126.9 95.9 6811

7 123.1 130.3 127.2 96.3 6770

8 122.6 129.3 126.7 95.6 6826

9 123.1 130.2 127.1 96.6 6739

10 121.4 129.2 126.8 95.8 6794

11 122.3 129.7 126.9 96.9 6894

12 121.3 128.9 126.4 95.5 6888

13 122.5 129.8 127.1 96.8 6861

14 121.6 129.1 126.4 95.7 6888

15 122.8 130.2 126.8 96.4 6864

16 124.5 132.5 128.5 98.1 6828

17 125.6 133.2 129.2 98.4 6821

18 126.5 133.1 128.4 97.7 6833

19 125.3 133.1 129.4 98.4 6797

20 127.5 132.9 128.8 98.5 6858

21 128.0 134.6 131.4 98.9 6766

22 125.4 132.6 130.0 97.3 6815

23 128.2 135.2 131.4 98.6 6759

24 126.3 133.5 131.4 99.2 6822

25 127.7 135.1 131.8 98.8 6749

26 127.1 134.8 132.2 100.0 6795

27 128.9 135.6 132.3 100.0 6802

28 126.1 134.4 131.9 100.3 6797

29 126.2 133.6 131.4 99.9 6802

30 126.1 134.1 131.0 99.6 6737

31 126.1 134.3 132.3 100.4 6839

32 126.9 134.4 131.8 99.8 6784

33 125.2 133.7 131.8 98.9 6815

34 127.7 134.9 132.2 100.0 6813

35 125.4 133.8 132.1 100.0 6808

36 126.8 133.9 131.4 99.0 6785

37 127.7 135.5 133.1 100.7 6807

38 127.4 134.1 131.7 100.2 6818

39 128.3 135.6 132.8 100.6 6766

40 124.6 134.2 132.8 101.9 6745

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Table 3: Retained Tensile Load Testing of Aged Composite Core Samples

Conductor Assembly

Core Section under the Suspension Assembly

Conductor Core Breaking Load

Tensioned Conductor

17,488 kgf (106.0% of core’s RTS)

Dummy Conductor

18,444 kgf (111.6 % of core’s RTS)

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Prepared by:

______________ __________ Zs. Peter Principal Engineer Transmission and Distribution Technologies Business

___________________________________________ D. Ladin Engineer/Scientist Transmission and Distribution Technologies Business

___________ _______ M. Kastelein Lead Technologist Transmission and Distribution Technologies Business ___________________________________________

G. Brown Technologist Transmission and Distribution Technologies Business

ZsP:DL:MK:GB:CP:SZ:JC

DISCLAIMER Kinectrics North America, Inc (KNAI) has taken reasonable steps to ensure that all work performed meets industry standards as set out in Kinectrics Quality Manual, and that, for the intended purpose of this report, is reasonably free of errors, inaccuracies or omissions. KNAI DOES NOT MAKE ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THE MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OF ANY INFORMATION CONTAINED IN THIS REPORT OR THE RESPECTIVE WORKS OR SERVICES SUPPLIED OR PERFORMED BY KNAI. KNAI does not accept any liability for any damages, either directly, consequentially or otherwise resulting from the use of this report.

Kinectrics North America Inc., 2010.

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Figure 1: High Temperature Compression Dead-end Being Installed on CTC Conductor

Figure 2a: Test Setup Schematics for Heat Cycling Test

Compression Dead-end Connector

60-ton Press

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Figure 2b: Test Setup Schematics for Heat Cycling Test

Figure 2c: Dummy Conductor in Heat Cycling Test

Dummy Conductor

Test Conductor

Suspension Assembly on Test Conductor

Suspension Assembly on Dummy Conductor

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Figure 2d: Modified AGS Suspension Assembly on Tensioned Part of Test Loop

Figure 3: AC Current Transformer and Variac

Suspension Clamp Rubber Bushing

Armor Rod Bolt

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Figure 4: Load Cell Measuring Test Conductor Tension

Figure 5a: Thermocouples Installed in Dummy Conductor (Thermocouples #21, #22, and #23)

Load Cell

of 54 K-419205-RC-0002-R00

Figure 5b: Thermocouple Installed in Armor Rod (Thermocouple #11)

Figure 5c: Thermocouple Installed between Suspension Assembly Rubber Bushing and Tensioned Conductor (Thermocouple #8)

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Figure 5d: Thermocouple Installed on Tensioned Conductor between End of Suspension Assembly Rubber Bushing and Armor Rod (Thermocouple #10)

Figure 5e: Thermocouple Installed at the Mouth of a Dead-end Connector (Thermocouple #13)

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Figure 5f: Thermocouple Installed on Surface of Dead-end above Collet Housing (Thermocouple #14)

Figure 5g: Thermocouple Installed on Dead-end Pad (Thermocouple #17)

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Figure 6: Breaking Load Test Set-up

Figure 7: Compression Dead-end Connector Prior to Breaking Load Test

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Figure 8: Epoxy Dead-end Prepared for Breaking Load Test

Figure 9: Jumper Terminal Used for Current Supply to Test Connector

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Figure 10a: Typical Heat Cycle, Conductor Core Temperatures

Figure 10b: Typical Heat Cycle, Suspension Assembly Temperatures

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Figure 10c: Typical Heat Cycle, Test Conductor Temperatures

Figure 10d: Typical Heat Cycle, Dummy Conductor Temperatures

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Figure 11a: Steady-State Temperatures of Conductor Core during Heat Cycling

Figure 11b: Steady-State Suspension Assembly Temperatures during Heat Cycling

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Figure 11c: Steady-State Temperatures of Test Conductor during Heat Cycling

Figure 11d: Steady-State Dummy Conductor Temperatures during Heat Cycling

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Figure 11e: Steady-State Temperatures of Test Conductor Connectors during Heat Cycling

Figure 11f: Steady-State Temperatures of Dummy Conductor Connectors during Heat Cycling

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Figure 12a: Tensioned Conductor Suspension Assembly after 40 Heat Cycles

Figure 12b: Tensioned Conductor Suspension Assembly after 40 Heat Cycles

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Figure 12c: Tensioned Conductor Suspension Assembly after 40 Heat Cycles, Rubber Bushing

Figure 13a: Dummy Conductor Suspension Assembly after 40 Heat Cycles

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Figure 13b: Dummy Conductor Suspension Assembly after 40 Heat Cycles, Clamp Removed

Figure 13c: Dummy Conductor Suspension Assembly after 40 Heat Cycles, Rubber Bushing

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Figure 14a: Breaking Load Test on North Compression Dead-end Installed on Tensioned Conductor

Figure 14b: Breaking Load Test on North Compression Dead-end Installed on Tensioned Conductor, Magnified Conductor View

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Figure 15a: Breaking Load Test on North Compression Dead-end Installed on Dummy Conductor

Figure 15b: Breaking Load Test on North Compression Dead-end Installed on Dummy Conductor, Magnified Conductor View

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APPENDIX A

DATA SHEET FOR

“LONDON” ACCC/TW CONDUCTOR

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ISO-9001 Form: QF11-1 Rev 0, 97-10

APPENDIX B INSTRUMENT SHEET

(Ref. Heat Cycling Test on “London”, ACCC/TW Conductor)

Test Description: Heat Cycling Test Test Start Date: July 16, 2010

Project Number: K-419205-0001 Test Finish Date: September 9, 2010

TEST DESCRIPTION

EQUIPMENT DESCRIPTION

MAKE MODEL ASSET # or SERIAL #

ACCURACY CLAIMED

CALIBRATION DATE

CALIBRATION DUE DATE

TEST USE

Thermo-Mechanical Cycling Test

Load Cell

Conditioner w/READOUT

Eaton

Daytronic

3124 (10,000 lbs)

3270

3362

X01207

±1.0% of reading

April 14, 2010 April 14, 2011 Conductor Tension

Current Transformer

(CT) Flex Core

125-402 Ratio 4000 to 5 A

002208231 ±0.3% FS May 4, 2010 May 4, 2011 Electrical Current

Current Transducer

Flex Core ACT-005CX5 6032515 ±0.5% FS May 3, 2010 May 3, 2011 Electrical Current

Thermocouple Omega Type J KIN-01308 ± 1 degree C June 15, 2010 June 15, 2011 Temperature





Measuring Tape Stanley FatMax (34-813) KIN-00723 < 0.05% of Reading

October 2, 2008 October 2, 2010 Conductor Length

Breaking Load Test on Two (2) Dead-

End Connectors

Load Cell (MTS)

Conditioner

Lebow

MTS

3156 (100,000 lbs)

493.01DC

17356-0

10000686-0

±1% of Reading

May 27, 2010 May 27, 2011 Conductor Tension

of 5

4

K-419205-RC-0001-R01

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APPENDIX C

CALIBRATION CERTIFICATES FOR MEASURING INSTRUMENTS USED IN THE

TESTS

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APPENDIX D

KINECTRICS ISO 9001 QUALITY MANAGEMENT SYSTEM REGISTRATION CERTIFICATE

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DISTRIBUTION Dr. Eric Bosze (3) CTC Cable Corporation

2026 McGaw Avenue Irvine, CA 92614 USA

Mr. Zsolt Peter (1) Kinectrics North America Inc., Unit 2

800 Kipling Ave, KB 223 Toronto, Ontario

M8Z 6C4 Canada

heat cycling test on “london” accc/tw … · heat cycling test on “london” accc/tw...

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