419148 - HES SS on CARDINAL ACSR - DRAFT Report · Figure 5 shows the stress-strain curve for the...

This is an unapproved Kinectrics International Draft Report, subject to change

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To: HES Hacilar Electrik San. Ve Tic.

Erciyes Mah. HES Cad. No: 22 38210 Hacilar, Kayseri Turkey

D R A F T

KINECTRICS INTERNATIONAL INC. TEST REPORT FOR HES HACILAR ELEKTRIK SAN. VE TIC.

(Ref. Stress-Strain Test on CARDINAL ACSR Conductor)

Kinectrics International Inc. Report No.: K-419148-RC-0001-R00

December 22, 2009

C. Dimnik Transmission and Distribution Technologies Business

1.0 INTRODUCTION A Stress-Strain Test was performed on a conductor manufactured by HES Hacilar Elektrik San. Ve Tic. of Turkey. The outside diameter of the conductor is 30.42 mm and is designated 954 MCM CARDINAL ACSR. The data sheet for this conductor is included in Appendix A. The cable was received in good condition. The test was performed on December 8, 2009 by Kinectrics North America Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4, Canada according to Kinectrics Quotation DIM-419-0910-068-R02 dated October 1, 2009. The testing was videotaped and reviewed by Mr. Asim Mercan of HES. A copy of Kinectrics ISO 9001 Certificate is included in Appendix C.

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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2.0 TEST OBJECTIVE AND STANDARD The objective of the test is to provide the stress-strain characteristics of the conductor to be used in the calculation of sags and tensions during the design of overhead transmission lines. The test was performed in general compliance to IEC 61089 Round wire concentric lay overhead electrical stranded conductors, Annex B; and BS EN 50182:2001 Conductors for overhead lines – Round wire concentric lay stranded conductors, Annex C. 3.0 TEST SET-UP – for Whole Conductor and Steel Core The set-up for the Stress-Strain Tests is shown schematically in Figure 1. A whole conductor sample 14.19 m in length was terminated using epoxy-resin dead-ends. A steel core sample 14.04 m in length was also terminated using epoxy-resin dead-ends. The prepared sample was installed in a hydraulically-activated horizontal tension test facility. During the initial set-up and pre-loading steps, the sample was supported along its length to keep the sample as straight as possible and to minimize the axial stress and sag. A pull-wire potentiometer was fixed to the sample to measure elongation over a gauge length of about 10 m, centered midway between the dead-ends. The actual gauge length for the test was measured at the first pre-load step. A load cell located at the hydraulic end of the sample measured the tension. A photo of a typical test sample installed in the test facility is shown in Figure 2. A thermocouple was installed on the conductor and core samples during the test, outside the gauge length. The test was carried out in a temperature-controlled laboratory at 20ºC ± 2ºC. Instrumentation and Data Acquisition The conductor elongation and tension, as measured by the pull wire potentiometer and load cell respectively, were monitored continuously using a digital data logging system. The data logging rate during loading was every one (1) second and during holds every ten (10) seconds. Temperature measurements were manually recorded at the end of each hold period. The measuring instruments and equipment used in this test are listed in Appendix B.

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4.0 TEST PROCEDURE The conductor was subjected to the loading schedule outlined in IEC 61089 Annex B. Step 1 – Whole Conductor The conductor was tensioned according to the loading schedule on the following table. The loads were applied at a rate of 2,338 kg/minute (5,155 lb/minute). This is based on achieving 30% of RTS in two (2) minutes.

15,589 kgf

Step % RTS kgf lbfHold

(minutes)

preload 2% 312 6871 30% 4,677 10,310 302 2% 312 687 13 50% 7,795 17,184 604 2% 312 687 15 70% 10,912 24,057 606 2% 312 687 17 85% 13,251 29,212 608 2% 312 687 1

Whole Conductor RTS=

The completion of Step 8 of the above loading schedule marked the completion of the Stress-Strain Test. The pull wire potentiometer was removed from the conductor, and the load reapplied at a rate of 3,118 kg/minute (6,874 lb/minute) until the conductor failed. The breaking load of the conductor was recorded. Step 2 – Steel Core The stress-strain test on the steel core was also performed according to IEC 61089 Annex B. The procedure was similar as for the whole conductor except the tension levels for Steps 1, 3 and 5 for the steel core were determined by the elongation at the beginning of each hold period obtained on the whole conductor at 30%, 50%, 70% and 85% RTS, respectively. That is, for each load step, the tension was increased in the steel core until the % elongation was the same as the whole conductor for the corresponding load step. This meant that the stress-strain test must be performed on the whole conductor before the steel core. The steel core was tensioned according to the loading schedule on the following table. The loads were applied at a rate of 2,338 kg/minute (5,155 lb/minute).

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15,589 kgf

StepWhole ConductorElongation, mm kgf lbs

Hold(minutes)

preload 0 312 6871 11.96 - - 302 - 312 687 13 22.26 - - 604 - 312 687 15 36.26 - - 606 - 312 687 17 51.28 - - 608 - 312 687 1

Whole Conductor RTS=

The completion of Step 8 of the above loading schedule constituted the completion of the Stress-Strain Test. 5.0 TEST RESULTS The strain data for the conductor and core have been corrected because the elongation measurement was taken to be zero at the preload. Using a straight-line regression of the stress-strain data while loading up to 30% RTS it was calculated that the corrected strain at preload was +0.0072% for the conductor and +0.0270% for the steel core. After accounting for these corrections, the data was extrapolated to the Y-axis to zero. The corrected data was the actual conductor’s behaviour because the conductor will have zero elongation only when it is under zero tension. Figures 3a and 3b show load (i.e. tension) plotted against all strain data for the whole conductor and steel core, respectively. Figures 4a and 4b show stress plotted against strain (%) for only those points that contribute to the stress-strain curve for the whole conductor and steel core, respectively. Figure 5 shows the stress-strain curve for the CARDINAL ACSR conductor showing the plots for the whole conductor, the aluminium layers, and the steel core. The area of the conductor was 547.34 mm2 according to the cable data sheet, included in Appendix A. The stress-strain curve for the aluminium layers is calculated by subtracting corresponding data points of the steel core from the whole conductor. The Modulus of Elasticity (MOE) of the conductor can be determined from the Stress-Strain curve. The MOE is the slope of the unloading segment of the 85% RTS curve. The MOE for the conductor is approximately 74,734 MPa. Similarly, the MOE of the steel core can also be determined from the unloading curve on the core only Stress-Strain curve. The MOE for the steel core (based on the area of the steel core only) is approximately 191,536 MPa. The MOE for the steel core (based on the area of the whole conductor) is approximately 21,980 MPa.

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The MOE of the aluminum layers is calculated from the difference between the whole conductor and steel core, from the unloading at 85% to their intersection (knee-point). The MOE for the aluminum layers (based on the area of the aluminum only) is approximately 61,207 MPa. The MOE for the aluminum layers (based on the area of the whole conductor) is approximately 54,183 MPa. The whole conductor failed at 17,043 kgf or 109.3% of the Rated Tensile Strength of the conductor. The key results for the Stress-Strain Tests are shown in Tables 1, 2, and 3. The general form of the equation of the loading curve for each of the whole conductor, steel core and outer aluminum layers is:

y = AX3+BX2+CX+D This equation is generated from a 3rd order polynomial least-squares curve-fit based on the data points at the end of each hold period. This is the formula used by the Alcoa Sag10 program.

Table 1 Summary of Stress-Strain Test Results for CARDINAL ACSR Whole Conductor

Whole Conductor Polynomial Coefficients

(MPa)

Final Modulus of Elasticity

MPa (before Knee-point)

Estimated Knee-point Load

kN **

Breaking Load kgf

A= +2.8999 E+08 B= -7.0860 E+06 C= +7.2275 E+04 D= -1.0908 E-01

74,734 34.6 17,043

** The knee-point is extracted from the 85% unloading curve. The R-squared value for this curve-fit was R2 = 1.0000.

Table 2 Summary of Stress-Strain Test Results for CARDINAL ACSR Steel Core

Steel Core Polynomial Coefficients

(MPa)


(based on area of Steel Only)

MPa


(area corrected for Consolidated Conductor)

MPa

A= -9.9753 E+07 B= +1.6546 E+05 C= +2.1801 E+04 D= +1.3489 E-02

191,536 21,980

The R-squared value for this curve-fit was R2 = 1.0000.

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Table 3 Summary of Stress-Strain Test Results for CARDINAL ACSR Aluminum Layers

Aluminum Polynomial Coefficients

(MPa)


(based on Area of Alum Only)

MPa


(area corrected for Consolidated Conductor)

MPa

A= +3.8620 E+08 B= -7.2123 E+06 C= +5.0346 E+04 D= -2.3399 E-03

61,207 54,183

The R-squared value for this curve-fit was R2 = 1.0000. 6.0 ACCEPTANCE CRITERIA As stated in IEC 61089 and BS EN 50182:2001, there are no acceptance criteria for the Stress-Strain test. As stated in IEC 61089 and BS EN 50182:2001, the breaking strength of the conductor shall withstand, without fracture of any wire, not less than 95% of the rated tensile strength. 7.0 CONCLUSION The primary purpose of the Stress-Strain Test is to provide stress-strain characteristics of the conductor to be used in sag-tension calculations. The conductor, as tested, met the requirements for the Tensile Test as specified in IEC 61089 and BS EN 50182:2001. DRAFT


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Prepared by:

C. Dimnik Engineer Transmission and Distribution Technologies Business

Reviewed by:

C.J. Pon Principal Engineer Transmission and Distribution Technologies Business

Approved by: R. Lings General Manager Transmission and Distribution Technologies Business CD:CJP:RL

DISCLAIMER Kinectrics International Inc. (KII) has taken reasonable steps to ensure that all work performed meets industry standards as set out in KII Quality Manual, and that, for the intended purpose of this report, is reasonably free of errors, inaccuracies or omissions. KII 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. KII does not accept any liability for any damages, either directly, consequentially or otherwise resulting from the use of this report. Kinectrics International Inc., 2009

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Figure 1 Set-up for Stress-Strain Test

Cylinder MountFixed to Strong Floor

Hydraulic Cylinder

Load Cell

Epoxy Deadend

Stationary EndFixed to Strong Floor

ACS Conductor

Data Aquisition System

Gauge length

DisplacementTransducerP

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ACSR Conductor

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Figure 2 Photo of Typical Test Sample Installed in Stress-Strain Test Facility.

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Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. CARDINAL ACSR Conductor)

0

20

40

60

80

100

120

140

0.00% 0.05% 0.10% 0.15% 0.20% 0.25% 0.30% 0.35% 0.40% 0.45% 0.50% 0.55% 0.60%

Conductor Strain, %

Co

nd

uct

or

Ten

sio

n, k

N

34.6 kN Knee Point

Figure 3a Load (tension) vs. Conductor Strain

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0

10

20

30

40

50

60

70

0.00% 0.05% 0.10% 0.15% 0.20% 0.25% 0.30% 0.35% 0.40% 0.45% 0.50% 0.55% 0.60%

Core Strain, %

Co

re T

ensi

on

, kN

Figure 3b Load (tension) vs. Steel Core Strain

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0.5809%, 237.52 MPa

0.4059%, 195.62 MPa

0.2461%, 139.75 MPa

0.1333%, 83.86 MPa

0

50

100

150

200

250

0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60%

Conductor Strain, %

Co

nd

uct

or

Str

ess,

MP

a

Conductor area = 547.34 mm²

Figure 4a Stress vs. Conductor Strain for Only Those Points That Contribute to the Stress-Strain Curve

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0.5562%, 109.21 MPa

0.3964%, 82.88 MPa

0.2525%, 54.40 MPa

0.1495%, 32.71 MPa

0

20

40

60

80

100

120

0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60%

Core Strain, %

Co

re S

tre

ss, M

Pa

Conductor area = 547.34 mm²

Figure 4b Stress vs. Steel Core Strain for Only Those Points That Contribute to the Stress-Strain Curve

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0

50

100

150

200

250

0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60%

Unit Strain, %

Str

ess

, MP

a

Initial Composite

Initial Aluminum

Final AluminumInitial Steel

Final Steel

Final Composite

Conductor area = 547.34 mm² Core Area = 62.81 mm²

Figure 5 Composite Stress-Strain Curve

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APPENDIX A

DESCRIPTION OF HES HACILAR ELEKTRIK SAN. VE TIC. CONDUCTOR (Ref. 954 mcm, 547.34 mm2, CARDINAL ACSR Conductor)

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CARDINALCONDUCTOR 954 MCM

Stranding Direction RightConductor OD mm 30.42Total Cross Section mm² 547.34Construction 1(St)+6(St)+12(Al)+18(Al)+24(Al)Conductor Weight kg/km 1829Conductor Tensile Strength kgf 15,589Aluminum Cross Section mm² 484.5Aluminum Weight kg/km 1339.6Steel Core Diameter mm 10.14Steel Core Cross Section mm² 62.81Steel Core Weight kg/km 490.2A.C. Resistance at 25 ° C, 50 Hz ohm/km 0.00622 Xa at 50 Hz ohm/km 0.242 X'a at 50 Hz Megaohm.km 0.1287GMR 12.25Conductor E-modulus (First) kg/mm² 5000Conductor E-modulus (Final) kg/mm² 6000

Linear Thermal Coefficient / °C 19,3*10-6

Current Carrying Capacity A 961Drum Length m 2100

Aluminum Wires

Nominal OD mm 3.38Nominal Cross Section mm² 8.96Tensile Strength(min) kg/mm² 16.5DC Resistivity at 20 ° C (Max) n.ohm.m 28.264

Linear Thermal Coefficient / °C 23*10-6

Steel Wires

Nominal OD mm 3.38Nominal Cross Section mm² 8.96Tensile Strength After Stranding kg/mm² 138Tensile Strength at 1% Elongation (Min.) kg/mm² 124Zinc Coating Weight g/m² 245

CONDUCTOR PROPERTIES

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

APPENDIX B INSTRUMENT SHEET

HES Hacilar Elektrik San. Ve Tic. (Ref. CARDINAL ACSR Conductor)

Test Description: Stress-Strain Test Test Start Date: December 8, 2009 Project Number: K-419148-1 Test Finish Date: December 8, 2009

TEST DESCRIPTION

EQUIPMENT DESCRIPTION

MAKE MODEL ASSET # or

SERIAL # ACCURACY

CLAIMED CALIBRATION

DATE CALIBRATION

DUE DATE TEST USE

Datalogger National Instruments PCI-6036E - B

±0.1% of Reading June 25, 2009 June 25, 2010 Data Acquisition

Load Cell (MTS) Load Cell Conditioner

Lebow MTS

3156 493.01DC

17356-0 10000686-0

±1.0% of reading May 29, 2009 May 29, 2010

Stress Strain, Breaking Load

Displacement Transducer Conditioner

Ametek Trans-tek

PT-10AT-HT 1002-000F

KIN-00658 PWP #2 19698-0 ±0.1 mm October 7, 2009 October 7, 2010 Cable Strain

Measuring Tape Stanley FatMax (34-813) KIN-00723 < 0.05% of Reading October 2, 2008 October 2, 2010

Cable and Gauge Length

Stress-Strain Test

Digital Meter Thermocouple

Fluke Fluke

51 TC-K

17616-0 KIN-00613

±0.9 degree C ±0.5 degree C

March 18, 2009 March 19, 2009

March 18, 2010 March 19, 2010

Cable Temperature

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APPENDIX C

KINECTRICS ISO 9001 QUALITY MANAGEMENT SYSTEM REGISTRATION CERTICATE

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DISTRIBUTION Mr. Asim Mercan (2) HES Hacilar Elektrik San. Ve Tic.

Erciyes Mah. HES Cad. No: 22 38210 Hacilar, Kayseri Turkey Telephone: 90 352 207 45 00 Email: [email protected]

C. Dimnik (1) Transmission and Distribution Technologies – KB223

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