DC RESISTANCE TEST AND WEIGHT MEASUREMENT TEST … · and the conductor is stranded by PT KMI Wire...

To: Dr. Eric Bosze CTC Cable Corporation

2026 McGaw Avenue Irvine, CA 92614 USA

DC RESISTANCE TEST AND WEIGHT MEASUREMENT TEST ON “PRAGUE” ACCC/TW

CONDUCTOR STRANDED BY PT KMI WIRE AND CABLE Tbk COMPANY

Kinectrics North America Inc. Report No.: K-419220-RC-0001-R00

August 31, 2010

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

A DC Electrical Resistance Test and Weight Measurement Test were performed on a sample of 710 mm2 “Prague”, Aluminum Conductor, Composite Core/Trapezoidal Wire (ACCC/TW) conductor for CTC Cable Corporation (CTC). 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 is manufactured by CTC and the conductor is stranded by PT KMI Wire and Cable Tbk Company (Indonesia). The complete specification for the conductor is shown in Appendix A. The test conductor met the DC Electrical Resistance and Weight specification as tested. The test was performed between August 25, 2010 and August 26, 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 P.O. Number PO4437, dated August 6, 2010. The test was performed under Kinectrics ISO 9001 Quality Management System. A copy of Kinectrics ISO 9001 Accreditation Certificate is included in Appendix C.

TEST OBJECTIVE The objective of the DC Electrical Resistance Test is to verify the measured DC Resistance of the conductor against the manufacturer’s specified DC Resistance. The objective of the Weight Measurement Test is to verify the measured weight of the conductor against the manufacturer’s stated conductor weight.

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 6C4

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TEST STANDARD The DC Electrical Resistance Test was based test protocol described in ASTM B193-R92 Standard. The Weight Measurement Test was performed following Kinectrics test procedure.

TEST SET-UP

DC Electrical Resistance

A test sample, approximately 14 m in length, was installed in a hydraulically activated horizontal test machine and tensioned to about 4,390 lbf (1,991 kgf) corresponding to 15% of the conductor’s Rate Tensile Strength (RTS). Porcelain insulators were installed at each end of the conductor to electrical isolation purposes (see Figure 1). Small clamps five (5) meters apart were installed over copper foil on the conductor to act as equalizers for the voltage drop measurements (shown in Figure 2). DC electrical current was supplied approximately three (3) meters outboard from the equalizers. Weight Measurement

A test sample, approximately three (3) meters in length, was placed on the calibrated weight scale. The test was carried out in a temperature-controlled laboratory at 22ºC ± 2ºC. The instrumentation used to perform this test is listed in Appendix B.

TEST PROCEDURE


Current injection clamps were connected approximately three (3) meters outboard from the equalizer locations (5 meters apart) on the tensioned conductor. A calibrated current source of 10 DC Amperes was passed through the conductor. The potential drop between the equalizers was measured by a micro-Ohmmeter and displayed directly as micro-Ohms. This measurement was taken at five (5) different locations along the length of the test conductor. The DC resistance over one meter of the conductor was calculated. Temperature of the laboratory next to the conductor at the time of testing ranged within 23.3ºC-23.5ºC. Obtained resistance values were corrected to 20ºC by applying the following formula: R20 = Rm / [1+α(Tm-20)], where Rm is measured resistance, Tm is temperature of the conductor, α is temperature coefficient of resistance of the conductor. The temperature coefficient of resistance used for this conductor was:

α = 4.08 x 10-3 /°C (Aluminum 1350, 61.0% IACS), as specified in ASTM B193-R92 Standard.

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Weight Measurement A test sample, approximately 3 m in length, was prepared for the test. The sample length was verified with a calibrated measuring tape. The conductor sample was then placed on a weight scale, and the sample weight was recorded. The weight measurement was repeated five (5) times.

TEST RESULTS


Five (5) DC resistance readings collected during the test are shown in Table 1 below.

Table 1: DC Resistance Measurements

Reading Number

Measured DC Resistance / 5 m Gauge Length, in

micro-Ohm

DC Resistance / 1 m Conductor

Length, in micro-Ohm

Ambient Temperature, ºC

DC Resistance / 1 m Conductor

Length, Corrected to 20ºC, in micro-

Ohm

DC Resistance / 1 km

Conductor Length

Corrected to 20ºC, in Ohm

1 200.0 40.0 23.3 39.5 0.0395

2 210.0 42.0 23.3 41.4 0.0414

3 210.0 42.0 23.1 41.5 0.0415

4 210.0 42.0 22.5 41.6 0.0416

5 210.0 42.0 22.5 41.6 0.0416

Average Value 0.041102

Maximum DC Resistance at 20°C as Provided by Manufacturer, micro-Ohm 0.041100

Discrepancy (%) 0.0039

Weight Measurement Five (5) sample weight readings collected during the test are shown in Table 2 below.

Table 2: Conductor Weight Measurements

Reading Number

Total Sample Weight, kg

Conductor Core Weight,

kg

Aluminum Only Weight, kg

Sample Length, m

Complete Conductor

Linear density Corrected to 20ºC, kg/km

1 6.045 0.337 5.708 3.002 2013.49

2 6.045 0.337 5.708 3.002 2013.49

3 6.045 0.337 5.708 3.002 2013.49

4 6.045 0.337 5.708 3.002 2013.49

5 6.045 0.337 5.708 3.002 2013.49

Average Value 2013.49

Manufacturer’s Specified Conductor Linear Density, kg/km 2049.80

Discrepancy (%) 1.77

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CONCLUSIONS

The 710 mm2 “Prague”, ACCC/TW test conductor met the DC Electrical Resistance specification as tested. Prepared by:

________ ________________

Zs. Peter Principal Engineer Transmission and Distribution Technologies Business

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

___________ _________________

G. Brown Technologist Transmission and Distribution Technologies Business

Reviewed by:

___________ ______________________

C.J. Pon Department Manager Transmission and Distribution Technologies Business

Approved by:

__________ _____________

S. Zangeneh (Acting) General Manager Transmission and Distribution Technologies Business ZsP:DL: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: DC Resistance Test Set-up

Figure 2: Typical Equalizer Installed on Test Conductor

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APPENDIX A

DATA SHEET FOR “PRAGUE” ACCC/TW CONDUCTOR

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

APPENDIX B INSTRUMENT SHEET

(Ref. DC Resistance and Weight Measurement Tests on “Prague”, ACCC/TW Conductor)

Test Description: DC Resistance and Weight Measurement Tests Test Start Date: August 25, 2010

Project Number: K-419220-0001 Test Finish Date: August 26, 2010

TEST DESCRIPTION

EQUIPMENT DESCRIPTION

MAKE MODEL ASSET # or SERIAL #

ACCURACY CLAIMED

CALIBRATION DATE

CALIBRATION DUE DATE

TEST USE

DC Resistance

Test

Micro-Ohmmeter AEMC Model 6250 KIN -00644 ±1% of Reading

July 27, 2010 July 27, 2011 DC Resistance

Digital Meter

Thermocouple

Fluke

Fluke

51

TC-K

17616-0

KIN-00613

±0.9 deg C

±0.5 deg C

April 13, 2010

April 14, 2010

April 13, 2011

April 14, 2011 Temperature

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

October 2, 2008 October 2, 2010 Conductor Length

Weight Measurement

Test Digital Scale Mettler Toledo SB32000 10000640-0 ±5 grams April 14, 2010 April 14, 2011

Weight Measurements

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APPENDIX C

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

DC RESISTANCE TEST AND WEIGHT MEASUREMENT TEST … · and the conductor is stranded by PT KMI Wire...

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