To: AFL 104 Hidden Lake Circle Duncan, SC 29334 USA 4 HIGH TEMPERATURE SUSTAINED LOAD TEST ON A COMPRESSION DEAD-END CONNECTOR INSTALLED ON 1020 KCMIL, ACCC/TW DRAKE CONDUCTOR Kinectrics North America Inc. Report No.: July 30, 2015 Dmitry Ladin Transmission and Distribution Technologies Business A High Temperature (200 C maximum conductor temperature) Sustained Load Test was performed on one (1) compression dead-end connector for AFL. An ambient temperature Maximum Load Test was performed on the dead-end connector after completion of the High Temperature Sustained Load Test. The test connector was installed on 1020 kcmil, Aluminum Conductor, Composite Core, Trapezoidal Wire, (ACCC/TW), Drake conductor. The catalogue number stamped on the tested connector is AFL B11381-A. The tested dead-end connector is rated as Class AA, Extra Heavy Duty connector. AFL provided the test sample in fully assembled condition for testing. Kinectrics received the test sample in good condition on January 22, 2015. The tests were performed in general accordance with ANSI C119.4-2011, American National Standard for Electric Connectors Connectors for Use Between Aluminum-to- Aluminum and Aluminum-to-Copper Conductors Designed for Normal Operation at or Below 93 C and Copper-to-Copper Conductors Designed for Normal Operation at or Below 100 C, Clauses 7.3.3.1 and 7.3.4. The tested dead-end compression connector, as tested, met the High Temperature Sustained Load Test acceptance criteria as specified in ANSI C119.4-2011. The tests were performed under Kinectrics ISO 17025 Quality Management Program. A copy of Kinectrics ISO 17025 Registration Certificate is included in Appendix A. The test was carried out from March 10, 2015 to March 18, 2015 by Kinectrics North America Inc. (KNAI) personnel at 800 Kipling Avenue, Unit 2, Toronto, Ontario, M8Z 5G5, Canada, under AFL Purchase Order # 487067, dated December 3, 2014. PRIVATE INFORMATION Contents of this report shall not be disclosed without authority of the client. Kinectrics North America Inc., 800 Kipling Avenue, Unit 2, Toronto, Ontario M8Z 5G5.
1.0 TEST STANDARD AND OBJECTIVE The High Temperature Sustained Load and Maximum Load Tests were performed in general accordance with ANSI C119.4-2011, American National Standard for Electric Connectors Connectors for Use Between Aluminum-to-Aluminum and Aluminum-to- Copper Conductors Designed for Normal Operation at or Below 93 C and Copper-to- Copper Conductors Designed for Normal Operation at or Below 100 C, Clauses 7.3.3.1 and 7.3.4. The tested dead-end connector is rated as Class AA, Extra Heavy Duty connector for ACCC/TW Drake conductor. The objective of the test was to determine long term tensile load carrying capacity, at elevated temperature, of the dead-end connector installed on 1020 kcmil, ACCC/TW Drake conductor. The purpose of this custom designed test is to give a reasonable assurance to the user that the tested connector is meeting ANSI C119.4-2011 Sustained Load Test requirements and will perform in a satisfactory manner, provided the connector has been properly selected for the intended application and is installed with the manufacturer s recommendation. 2.0 DESCRIPTION OF TEST COMPONENTS, PREPARATION AND SET-UP Dead-end Connector Assembly The compression dead-end connector was installed by AFL on approximately 13 m length of 1020 kcmil, ACCC/TW Drake conductor. At the opposite (free) end of conductor, Kinectrics personnel terminated conductor using a high temperature epoxy resin deadend. Both the compression dead-end connector and the epoxy resin dead-end mouth were marked with paint at the test start to monitor conductor slippage during the test. The effective conductor length between compression dead-end and epoxy resin dead-end was 12.44 m, and the exposed conductor length was 11.22 m. Test Apparatus Test schematic for the High Temperature Sustained Load Test is shown in Figure 1, and the general arrangement used for the High Temperature Sustained Load is shown in Figures 2 through 8. The test span is designated as Golden Span and located in room KB019 of the Main Mechanical Laboratory of Kinectrics. During the initial set-up and preloading steps, the sample was supported along its entire length to keep the sample as straight as possible and to minimize creep during the set-up of the test. A current transformer, shown in Figure 4, was configured to provide the circulating current to increase the temperature of the test conductor. A 600 Volt variable transformer (variac) supplied the current to the power transformer. The motor-driven variac was controlled by a data acquisition system (DAQ) in order to provide the necessary current to increase the temperature in the test loop to the desired test temperature. Also, capacitor banks were connected to the primary side of the power transformer in order to balance the impedance of the test loop. Page 2 of 16
Conductor Tension One (1) strain gauge load cell measured tension in the conductor assembly during the test. The signals from the load cell were amplified to provide a 0 to 5 volt signal for the data acquisition system. Tension data was collected and recorded continuously throughout the entire length of the test. Connector and Conductor Temperatures The temperature of the tested compression dead-end connector and conductor was measured at several locations on the assembly using calibrated thermocouples. Conductor thermocouples were located at the center of the span. The thermocouples were positioned in the outer layer of the conductor assembly as seen in Figure 6. The thermocouples were electrically isolated from other instruments to prevent electrical interference in the data acquisition system. Data Acquisition and Control A Labview-based data logging system (DAQ) recorded the measurements from the thermocouples and the load cell. To achieve the target conductor temperature, the circulating current was adjusted by the DAQ using a 600 Volt variac on the primary side of the current transformer. Maximum Load Test Upon completion of 168 hours of the High Temperature Sustained Load Test, the test assembly installed on ACCC Drake Conductor was placed in a 100 kip hydraulicallyactivated horizontal test machine, located on the strong floor of the Main Mechanical Laboratory of Kinectrics, to measure the connector s remaining tensile strength (see Figure 9). Both compression dead-end and epoxy dead-end paint marks were verified to detect conductor slippage during the test. The measuring instruments and equipment used in this test are listed in Appendix B. 3.0 TEST PROCEDURE The test assembly was subjected to a total of 168 hours of constant tensile load at elevated conductor temperature. Initially, the test assembly was pre-tensioned to approximately 824 lb or 2% of the conductor s Ultimate Tensile Strength (UTS) of 41,208 lb. Once the test conductor was loaded to 2% UTS, the heating process was started. Electric current was injected in the conductor to heat it by Joule-effect. The conductor temperature was increased gradually up to 200 C temperature, allowing the temperature to stabilize for a minimum of ten (10) minutes. During the heating, the conductor tension was manually maintained at 2% UTS. Conductor and connector temperatures were recorded continuously. The conductor was then loaded to achieve the target tension of 8,241 lb or 20% of the conductor s UTS in five (5) minutes. Once the target tension was achieved, a servo- Page 3 of 16
controlled tensioning system ensured near constant tension for the duration of the test. The rate of loading was kept linear to avoid impacting or overloading of the conductor sample. Conductor tension was also measured and recorded continuously. The conductor then stabilized at a temperature of 200 ± 5 C for the 168 hours test period. After the 168 hour of thermal exposure under tensile load, the A/C transformer was disconnected, and test assembly was allowed to cool down to ambient temperature. The tensile load was dropped as well. Maximum Load Test On completion of the High Temperature Sustained Load Test (i.e. 168 hours), the test assembly was subjected to a Maximum Load Test (i.e. Breaking Load) as per ANSI C119.4-2011, Clause 7.3.4. Once the sample was installed in the hydraulically activated horizontal test machine, it was pre-loaded to 824 lb or 2% of the conductor s UTS and dead-end connector and epoxy dead-end mouth paint marks were verified. The load was then increased at a steady rate until the failing load was reached. The steady loading rate for the UTS Test was 8,242 lb/min and was chosen based on achieving 100% UTS in five (5) minutes. 4.0 TEST RESULTS The test sample remained at the specified load and elevated temperature for 168 hours. There was no slippage detected at either dead-end compression connector or the epoxy resin dead-end, and the conductor condition remained unchanged. Figure 7 depicts a typical connector mouth condition after the test. Maximum Load Test The test sample broke at 36,353 lb or 88.2% of the conductor s UTS. The failure occurred off the epoxy dead-end (test setup is shown in Figure 9). Tested compression dead-end condition after the test is shown in Figure 10, and the conductor core appearance after failure is shown in Figure 11. Slippage measurements at the compression dead-end connector were also taken. There was no slippage observed in the tested dead-end connector. 5.0 ACCEPTANCE CRITERIA Following acceptance criteria should be met by all full tension (Class AA) compression connectors in accordance with ANSI C119.4-2011: High Temperature Sustained Load Test The sustained load test is classified as a failure if slippage or breakage of the conductor occurs during the test. Page 4 of 16
Maximum Load Test The pullout strength of connector/wire assembly shall be equal or greater than 95% of the conductor s RTS. The RTS of 1020 kcmil, ACCC/TW Drake conductor is 41,208 lb. 6.0 CONCLUSIONS Sustained Load Test The High Temperature Sustained Load performed on AFL compression dead-end connector installed on 1020 kcmil, ACCC/TW Drake conductor met the ANSI Std. C119.4-2011 test criteria, as tested. The test assembly maintained the 20% of the conductor s RTS tension at elevated conductor temperature (200 ± 5 C) for 168 hours (7 days) without any slippage. Maximum Load Test In the Maximum Load Test performed on AFL compression dead-end connector installed on 1020 kcmil, ACCC/TW Drake conductor, conductor failed at the epoxy resin dead-end prior to reaching 95% of conductor s RTS. At the maximum load - 88.2% of the conductor s UTS there was no slippage observed on the AFL dead-end connector. Page 5 of 16
Prepared by: D. Ladin Engineer/Scientist Transmission and Distribution Technologies Business P. Adams Senior Technologist Transmission and Distribution Technologies Business Reviewed by: P. Fong Lead Technologist Transmission and Distribution Technologies Business A. Rizzetto Engineer/Scientist Transmission and Distribution Technologies Business Approved by: _ Zsolt Peter, PhD Department Manager Line Asset Management Dept. Transmission and Distribution Technologies Business DL:PA:PF:AR:ZsP 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., 2015. Page 6 of 16
Figure 1 High Temperature Sustained Load Test Schematic Figure 2 Typical High Temperature Sustained Load Test Set-Up, Span View Page 7 of 16
Figure 3 High Temperature Sustained Load Test Set-Up, Cantilever Weight Arm System View Capacitor Bank Current Transformer 600 V Variac Figure 4 AC Current Transformer and Variable Transformer Page 8 of 16
Figure 5 Load Cell Connected to Insulator Figure 6 Thermocouple Installed in Outer Conductor Layer Page 9 of 16
Figure 7 Mouth of Connector Marked with Orange Paint to Monitor Slippage Figure 8 Mouth of Epoxy Resin Dead-end Marked with Orange Paint to Monitor Slippage Page 10 of 16
Figure 9 Test Sample Located in Hydraulically Activated Horizontal Test Machine for Maximum Load Test Figure 10 Test Connector after Maximum Load Test Page 11 of 16
Figure 11 Conductor Failure at Epoxy Resin Dead-end after Maximum Load Test Page 12 of 16
APPENDIX A KINECTRICS ISO 17025 QUALITY MANAGEMENT SYSTEM REGISTRATION CERTIFICATE Page 13 of 16
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ISO-9001 Form: QF11-1 Rev 0, 97-10 APPENDIX B INSTRUMENT SHEET (Ref. HT SUSTAINED LOAD TEST ON ACCC/TW DRAKE DEAD-END CONNECTOR) Test Description: High Temperature Sustained Load Test on ACCC/TW Drake Dead-end Connector Test Start Date: March 10, 2015 Project Number: K-419652-0002 Test Finish Date: March 18, 2015 TEST DESCRIPTION EQUIPMENT DESCRIPTION MAKE MODEL ASSET # or SERIAL # ACCURACY CLAIMED CALIBRATION DATE CALIBRATION DUE DATE TEST USE Data Logger Agilent 34970A KIN-02721 ±1% of Reading May 2, 2014 May 2, 2015 Data Acquisition Page 15 of 16 High Temperature Sustained Load Test Maximum Load Test Load Cell Conditioner Aries Daytronics 10000 TRC (10,000 kgf) 3170 17647-0 #3 10715-0. Thermocouple Omega 5TC GG J 24 36 KIN-01687 Current Transformer (CT) Current Transducer Measuring Tape A/D Datalogger Load Cell (MTS) 100 KIP Conditioner Flex Core 125-502 Ratio 5000 to 5 A ±1% of Reading < 0.1% of Reading April 1, 2014 April 1, 2015 September 16, 2014 September 16, 2015 KIN-01558 ±0.25% of FS May 29, 2014 May 29, 2016 Flex Core ACT-005CX5 KIN-01268 ±0.5% of FS December 8, 2014 December 8, 2015 Mastercraft 57-7190-0 KIN-00314 National Instruments Lebow MTS PCI-6221 3156 (100,000 lbs) 494.26 DC Channel: S2-J2A KIN-01836 I KIN-03727 KIN-01724 < 0.1% of Reading ±0.1% of Reading ±1% of Reading April 30, 2014 April 30, 2015 Conductor Tension Temperature Current Measurements Current Measurements Conductor Length January 28, 2015 January 28, 2016 Data Acquisition September 25, 2014 September 25, 2016 Breaking Load
DISTRIBUTION Mr. Ben Freeman (2) AFL 104 Hidden Lake Circle Duncan, SC 29334 USA Mr. Dmitry Ladin (1) Kinectrics North America Inc., Unit 2 800 Kipling Ave, KB 223 Toronto, Ontario, M8Z 5G5 Canada Page 16 of 16