Composite Conductor 267-T16 ACCR. Deadend Strength Tests for 267-T16 ACCR

Transcription

1 Composite Conductor 267-T16 ACCR Deadend Strength Tests for 267-T16 ACCR Principal Investigator: Dr. Colin McCullough Reviewed by: Dr. Herve Deve Date of Report: March 24, 2010

2 Deadend Strength Tests for ACCR 267-T16 3M HCC Testing Laboratory March 24, 2010 Colin McCullough Name Signature Date Colin McCullough Principal Investigator Phu Trac Senior Quality Engineer Herve Deve Colin McCullough March 24, 2010 Phu Trac March 24, 2010 Technical Manager [xüäx Wxäx `tüv{ EG? ECDC

3 Deadend Strength Tests for ACCR 267-T16 Laboratory: 3M HCC Testing Laboratory, St Paul, MN, USA Date of Tests: February 19, 2010 Reference Documents: See section 5.0 Test Data: This report contains deadend strength data for 3M ACCR 267-T16. Accessories: Compression-style deadends for 267-T16 ACCR were supplied by ACA Conductor Accessories (Spartenburg, SC, USA) as part number SE0267T16HT. Reel Ref Number - hand-stranded conductor Manufacturing date: 1/29/2009 Requestor: 3M Test Ref Number. Test Numbers 359, 362, Summary A 267-T16 ACCR deadend assembly was successfully tested. It passed two test criteria; (i) no slip after a one hour load hold at 57% RBS, and (ii) supported > 95%. The final breaking loads were 105%, 107%, 99% RBS with all breaks in the gauge length. All test results passed the strength specification requirements under ANSI C119.4 and IEC Experimental 2.1 Conductor Short lengths (12 ft/3.6m) were stranded by hand on a stranding bench in the 3M ACCR development laboratory using lengths of core wire, core tape, and a spool of Al-Zr wire supplied by Southwire. The specification for the conductor is shown in Appendix A. 2.2 Deadend Pressing Core grips and full deadend assemblies were pressed using conventional pressing techniques and equipment. The die used to press the core was a 10014SH and for the outer aluminum a 10024AH. The specified minimum failure load (SMFL) rating for the deadend is 0.95 per IEC Testing Procedure The samples were prepared for tensile testing by using a full conductor in which a full deadend assembly was pressed onto one end of the sample, and then a resin fitting was applied to the

4 other end. These samples were tested per IEC Here the conductor was marked at the edge of the deadend to monitor for possible slip. Tensile loading involved loading to 57% RBS (i.e. 60% RBS x 95%) and then holding at this load for 1 hour (within ± 2% of load). The 95% factor is the specified minimum failure load (SMFL) rating for the deadend. After the load hold, the sample was then loaded until failure. The maximum load and the mode of failure was recorded. The equipment used for tensile testing is a Roberts Tensile Tester machine model number: RTE-LC13 (Serial Number 08142). The tester is capable of testing samples up to 150,000 lbs (670 kn). The load cell was recalibrated on 5/27/2009 by The Roberts Company. The load cell has accuracy better than 1%. Appendix B provides further information. 2.4 Passing Criteria Two criteria are required for full qualification of the deadend. Firstly, there should be no slip of the conductor after the one hour load hold, and secondly the conductor/deadend assembly should support greater than 95% RBS. Both these criteria then satisfy IEC 61284, and the latter criterion alone satisfies ANSI C Results The RBS (Rated Breaking Strength) of 267-T16 conductor is 10,500 lbs (46.7 kn). The SMFL (Sample Minimum Failure Load) for the deadend is 95% of the RBS (9975 lbs/44.4 kn). Table 1: Table showing all three test results and sample information. Max Sample 3M Test Number Sample Length in (m) Load lbs (kn) %RBS Failure Mode (2.65) 107 (2.72) 108 (2.74) (49.0) (49.9) (46.3) 104.9% 106.9% 99.1% Broke 5 (12 cm) from deadend Broke 27 (69 cm) from deadend Broke 51 (129 cm) from deadend All samples showed high strengths (105%, 107% and 99% RBS) which pass the ANSI C119.4 and IEC Standards. Figure 1a and 1b shows graphs of Load vs Elongation (from crosshead displacement). One is in English units and one in metric units. Figure 2 shows the Load vs Time graph for the deadend tests. Figures 3-5 show the details of the tests. For all three tests, the conductor was marked at the mouth of the deadend before testing and this was monitored for any slip arising from the onehour load hold. Figures 3a-b, 4a-b, and 5a-b show the before and after situations showing no slip occurs. The failure location for each test is shown in Figures 3c-d, 4c-d, and 5c-d. These show (i) test 359 (105% RBS) failed with the core and inner aluminum failing 5in (12 cm) from the deadend

5 and the outer aluminum strands 3.5in (9 cm) up inside the deadend, (ii) test 362 (107% RBS) failed 27in (69 cm) from the deadend, and (iii) test 363 (99% RBS) failed 51in (129 cm) from the deadend. Failure occurred by ductile rupture of the aluminum strands and by typical fracture of the core strands. 4.0 Conclusion A 267-T16 ACCR deadend assembly was successfully tested. It passed two test criteria; (i) no slip after a one hour load hold at 57% RBS, and (ii) supported > 95% RBS. The final breaking loads were 105%, 107%, 99% RBS with all breaks in the gauge length. Thus all test results passed the strength specification requirements under ANSI C119.4 and IEC Reference Documents IEC 61284, Overhead Lines Requirements and tests for fittings, section Tensile test ANSI C119.4, Connectors for Use between Aluminum-to-Aluminum or Aluminum-to-Copper Bare Overhead Conductors, section Tensile Strength Maximum Load 6.0 Figures Deadend Assembly: Load vs Elongation Load (lbs) Elongation (ins) Figure 1a. Load vs Elongation for the deadend samples. These exhibited high holding strengths. There is an inflection at approximately 5985 lbs due to the one-hour load hold.

6 Deadend Assembly: Load vs Elongation Load (kn) Elongation (mm) Figure 1b. Load vs Elongation (metric) for the deadend samples. These exhibited high holding strengths. There is an inflection at approximately 26.6 kn due to the one-hour load hold. Deadend Assembly: Load vs Time Load (lbs) Load (kn) Time (secs) Series4 Figure 2. Load vs Time for the deadend samples. This featured a one-hour load hold.

7 (a) edge of deadend before testing (b) edge of deadend after one hour load hold showing no slip (c) deadend in test (d) failure of core and inner aluminum 5 (12 cm) from deadend, and outer aluminum inside deadend Figure 3(a-d). Examination of test 359 showing the deadend sample

8 (a) edge of deadend before testing (b) edge of deadend after one hour load hold showing no slip (c) failure 27 (69cm) from deadend (d) broken strands of core & aluminum Figure 4(a-d). Examination of test 362 showing the deadend sample

9 (a) edge of deadend before testing (b) edge of deadend after one hour load hold showing no slip (c) failure 51 (129cm) from deadend (d) broken strands of core & aluminum Figure 5(a-d). Examination of test 363 showing the deadend sample

10 7.0 Disclaimer TECHNICAL INFORMATION AND DATA; PRODUCT USE. Technical information and data, recommendations, and other statements provided by 3M are based on information, tests, or experience which 3M believes to be reliable, but the accuracy or completeness of such information is not guaranteed. Some of the standard industry tests conducted by 3M were originally designed for conventional conductors and were adapted by 3M for use with composite conductors; references to such tests should be considered in light of this fact. Such technical information and data are intended for persons with knowledge and technical skills sufficient to assess and apply their own informed judgment to the information. No license under any 3M or third party intellectual property rights is granted or implied with this information. Buyer is responsible for evaluating and determining whether the 3M product is suitable and appropriate for Buyer s particular use and intended application. The conditions of evaluation, selection, and use of a 3M product can vary widely and affect the use and intended application of a 3M product. Because many of these conditions are uniquely within Buyer s knowledge and control, Buyer must evaluate and determine whether the 3M product is suitable and appropriate for a particular use and intended application. 3M products are sold or provided to Buyer solely for Buyer s internal manufacturing use or consumption and may not be repackaged, resold, or redistributed in any manner without the prior written consent of 3M. WARRANTY AND LIMITED REMEDY. Unless stated otherwise in 3M s product literature, packaging inserts or product packaging for individual products, 3M warrants that each 3M product meets the applicable specifications at the time 3M ships the product. Individual products may have additional or different warranties as stated on product literature, package inserts or product packages. 3M MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY IMPLIED WARRANTY ARISING OUT OF A COURSE OF DEALING, CUSTOM OR USAGE OF TRADE. User is responsible for determining whether the 3M product is fit for a particular purpose and suitable for user s application. If the 3M product is defective within the warranty period, your exclusive remedy and 3M s and seller s sole obligation will be, at 3M s option, to repair the product, replace the product, or refund the purchase price. LIMITATION OF LIABILITY. Except where prohibited by law, 3M and seller will not be liable for any loss or damage arising from the 3M product, whether direct, indirect, special, incidental or consequential, regardless of the legal theory asserted, including warranty, contract, negligence or strict liability.

11 Appendix A: Specification for 267-T16 ACCR Conductor Physical Properties Partridge 267 Partridge 267 Designation ACCR_257-T16 ACCR_257-T16 Stranding 26/7 26/7 Diameter indiv Core in mm 2.0 indiv Al in mm 2.5 Core in mm 5.9 Total Diameter in mm 16.0 Area Al in^ mm^2 130 Total Area in^ mm^2 152 Weight Core lbs/ft kg/m Aluminum lbs/ft kg/m Total Weight lbs/ft kg/m Strength Lbs 10,500 kgf 4,763 Core strength lbs 6,280 kgf 2,849 Final Modulus Core Msi 32.9 GPa 227 Aluminum Msi 8.8 GPa 61 Complete Cable Msi 12.2 GPa 84 Thermal Elongation Core 10^-6/C ^-6/C 6.3 Aluminum 10^-6/C ^-6/C 23.0 Complete Cable 10^-6/C ^-6/C 16.7 Heat Capacity Core W-sec/ft-C 7 W-sec/m-C 24 Aluminum W-sec/ft-C 106 W-sec/m-C 347 Conductor Electrical Properties Resistance 20C ohms/mile ohms/km C ohms/mile ohms/km C ohms/mile ohms/km C ohms/mile ohms/km C ohms/mile ohms/km C ohms/mile ohms/km C ohms/mile ohms/km Geometric Mean Radius ft mm Reactance (1 ft Spacing, 60hz) Inductive Xa ohms/mile ohms/km Capacitive X'a Mohms/mile ohms/km

12 Appendix B: Test Equipment Details 1) Roberts Tensile Tester 2) Calibration certificate