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
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
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, 363 1.0 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 61284. 2.0 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 61284. 2.3 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
other end. These samples were tested per IEC 61284. 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 C119.4. 3.0 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 1 359 2 362 3 363 104.5 (2.65) 107 (2.72) 108 (2.74) 11016 (49.0) 11227 (49.9) 10403 (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 61284 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
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 61284. 5.0 Reference Documents IEC 61284, Overhead Lines Requirements and tests for fittings, section 11.5.1 Tensile test ANSI C119.4, Connectors for Use between Aluminum-to-Aluminum or Aluminum-to-Copper Bare Overhead Conductors, section 7.3.4 Tensile Strength Maximum Load 6.0 Figures 12000 Deadend Assembly: Load vs Elongation 10000 8000 Load (lbs) 6000 4000 2000 0 0 0.5 1 1.5 2 Elongation (ins) 359 362 363 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.
Deadend Assembly: Load vs Elongation 60.0 50.0 40.0 Load (kn) 30.0 20.0 10.0 0.0 0.0 10.0 20.0 30.0 40.0 50.0 Elongation (mm) 359 362 363 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 12000 10000 50.0 40.0 Load (lbs) 8000 6000 4000 30.0 20.0 Load (kn) 2000 10.0 0 0.0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 Time (secs) 359 362 363 Series4 Figure 2. Load vs Time for the deadend samples. This featured a one-hour load hold.
(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
(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
(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
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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 0.077 mm 2.0 indiv Al in 0.100 mm 2.5 Core in 0.232 mm 5.9 Total Diameter in 0.630 mm 16.0 Area Al in^2 0.202 mm^2 130 Total Area in^2 0.235 mm^2 152 Weight Core lbs/ft 0.050 kg/m 0.074 Aluminum lbs/ft 0.244 kg/m 0.364 Total Weight lbs/ft 0.294 kg/m 0.438 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 6.3 10^-6/C 6.3 Aluminum 10^-6/C 23.0 10^-6/C 23.0 Complete Cable 10^-6/C 16.7 10^-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 DC @ 20C ohms/mile 0.3403 ohms/km 0.2115 AC @ 25C ohms/mile 0.3484 ohms/km 0.2165 AC @ 50C ohms/mile 0.3829 ohms/km 0.2379 AC @ 75C ohms/mile 0.4174 ohms/km 0.2594 AC @ 100C ohms/mile 0.4519 ohms/km 0.2808 AC @ 210C ohms/mile 0.6037 ohms/km 0.3751 AC @ 240C ohms/mile 0.6450 ohms/km 0.4008 Geometric Mean Radius ft 0.0191 mm 7.4615 Reactance (1 ft Spacing, 60hz) Inductive Xa ohms/mile 0.481 ohms/km 0.2797 Capacitive X'a Mohms/mile 0.1080 ohms/km 0.0645
Appendix B: Test Equipment Details 1) Roberts Tensile Tester 2) Calibration certificate