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Novinium Connector / Adapter Evaluation

NEETRAC Project Number: 06-009

Final Report August 15, 2006

Requested by: Mr. Glen Bertini Novinium

Principal Investigator:

T. L. McKoon

Reviewed by:

Rick Hartlein

AGeorgia In

Research Center of thestitute of Technology

NEETRAC 06-009 Final Report – August 15, 2006 of 76

Novinium Connector / Adapter Evaluation

NEETRAC Project Number: 06-009 Final Report

SUMMARY Novinium requested that NEETRAC evaluate the performance of two sizes of adapter barrels designed to facilitate the injection of underground cables with restoration fluid. The goal of the test program was to establish the current loading and mechanical performance characteristics of various length elbow connectors installed on Novinium adapter barrels installed with a special crimping tool as compared to standard elbow connectors installed with a standard crimping tool. The tests were conducted on cables with 1/0 AWG and 1,000 kcmil aluminum conductor sizes.

The test procedure followed was patterned after the Current Cycle Submersion Test and the Tensile Test outlined in ANSI C119.4, 2004, “American National Standard for Electric Connectors for use Between Aluminum-to-Aluminum or Aluminum-to-Copper Bare Overhead Conductors”. While this standard is for bare conductors, the test protocol is also useful for testing insulated conductors.

The test results show that all connectors met the maximum temperature, temperature stability and resistance stability requirements of the ANSI C119.4 standard. Additionally, all connectors met the minimum tension requirement of the standard.

SAMPLES TESTED Novinium supplied the following:

• 1/0 AWG, Elastimold compression elbow connectors catalog # 02500240

• 1,000 kcmil, Elastimold compression conductor lugs catalog # 03700410

• 1/0 AWG injection adapters Novinium part # 3-2

• 1,000 kcmil injection adapters Novinium part # 12-12

• One 45-ton swaging tool with appropriate dies

• Approximately 225 feet of 1,000 kcmil unfilled strand aluminum conductor with 260 mils of XLPE insulation.

NEETRAC supplied the following:

• Approximately 70 feet of 1/0 AWG, unfilled strand conductor with 175 mils of XLPE insulation.

• Tooling and dies to perform the standard connector installation on both size connectors • All instrumentation and testing equipment to perform the electrical and mechanical tests


INSTALLATION PROCEDURE

Twenty, 1/0 AWG connector samples were installed on the 15 kV class cable with a 1/0 AWG, Class B, unfilled, stranded aluminum conductors. The jacket and metallic shield of the cable was removed, but the insulation and insulation shield remained in place. The connectors were installed using the following procedures:

• Four standard elbow connectors installed with a standard 9/16 die and standard compression tool

• Four standard connectors were cut to accommodate 1.00 inch of conductor. The injection adapter was installed over the elbow connectors with 45-ton swage tool.

• Four standard connectors were cut to accommodate 0.75 inches of conductor. The injection adapter was installed over the elbow connectors with 45-ton swage tool.



Figure 1 is a photograph of a typical connector cut to length along with swage adapter connector before compression. The connector shown is cut to accommodate 0.50 inches of conductor. Twelve, 1000 kcmil connector samples were installed on the 25 kV class cable with a 1000 kcmil, Class B, unfilled, stranded aluminum conductors. The jacket and metallic shield of the cable were removed, but the insulation and insulation shield remained in place. The connectors were installed using the same procedures as the 1/0 AWG cable. However, the 1000 kcmil adapters required a different compression tool than the 1/0 AWG connectors.

• Four standard compression connectors installed with a standard 1 3/4 hex die with a standard compression tool with 3.5 inches of conductor inserted into the barrel.

• Four standard connectors were cut to accommodate 2.5 inches of conductor. The injection adapter was installed over the compression connectors with 45-ton swage tool.


Figure 4 is a photograph of the completed 1000 kcmil connector adapters.

Connector cut to 0.5 inches

Figure 1: Shortened Connector with Injection Adapter – Before Installation

The conductor was inserted into the elbow connector. The adapter barrel was installed over the elbow connector and the first swage was made on the aluminum portion of the elbow. The last swage was made over the portion of the adapter located over the insulation. Figure 2 is a photograph of an injection adapter swaged to the elbow connector. Figure 3 shows the injection adapter with all swages completed.

First Compression Made Here

Figure 2: Injection Adapter Swaged on Elbow Connector


Figure 3: Completed Installation – 1/0 AWG Connector/Adapters

Figure 4: Completed Installation - 1000 kcmil Connector/Adapters


CURRENT CYCLE TESTS The ANSI C119.4, 2004 100 Cycle Current Cycle Submersion Test was used to evaluate all conductor / connector combinations. The performance criteria included maximum temperature, temperature stability and resistance stability. The maximum temperature measurements were used to determine the temperature of the connector relative to the temperature of the control conductor. This evaluation was performed at the end of each current loading cycle. The temperature and resistance stability criteria establish the stability of the connectors over the 100 cycle test period.

Heat Cycle Tests

The connectors and conductors were assembled in a series loop with equalizers. The equalizers are used to provide an equipotential contact point for resistance measurements. All connector testing was performed on insulated conductors. However, the insulation was removed from the control conductors. Thermocouples were installed at the first swage in each connector. The control conductor was monitored with one thermocouple in the center portion of the conductor. The 1/0 AWG control required a 24 inch length. The 1000 kcmil required a 72 inch control conductor. Figure 5 is a photograph of a typical connector with thermocouple installed. Figure 6 shows the test loop installed over the current cycle submersion test tank typical for both loops.

Figure 5: Typical Thermocouple Location (1000 kcmil Connector Shown)


Figure 6: 1000 kcmil Test Loop Installed over Current Cycle Submersion Tank

Sufficient current was applied to each loop to achieve a control conductor temperature of 100 degrees Celsius above ambient temperature. The 1/0 AWG loop consisted of a 60 minute “current on” period followed by a 30 minute “current off” period. The 1000 kcmil loop required a 120 minute “current on” followed by a 30 minute “current off” period. At the end of the current on period, the connectors and control conductor were submerged in water chilled to approximately 4 °C.

It should be noted that the 1/0 AWG test loop was first tested in a test cell that was recently “upgraded” with new temperature and resistance monitoring equipment. After this 100 cycle test was complete, the resistance data was found to be erratic and was ultimately determined to be inaccurate. With the permission of Novinium, the 100 cycle test was repeated in a test cell with measuring equipment that was known to be accurate. The data in this report is from the second test performed on the 1/0 AWG connectors.

Mechanical Tests

Three connectors of each assembly combination were tested to Section 7.3, Pullout Test of ANSI C119.4. The connectors tested are Class 3 connectors and are required to hold 5% of the conductor’s rating. The samples were pulled using the NEETRAC 150,000 MTS tensile machine. The connector end of each test sample was connected to the machine using appropriate hardware. The opposite end was held using a wire “basket” grip.



The ultimate tensile strength was determined to be 2,160 pounds for the 1/0 AWG conductor and 17,700 pounds for the 1000 kcmil conductor. The 1/0 AWG samples were pulled at a loading rate 1,000 pounds per minute. The 1000 kcmil samples were pulled at a loading rate of 2,000 pounds per minute. Results of the tensile test and failure mode for the 1/0 AWG samples are shown in Table 1. Results of the tensile test and failure mode for the 1000 kcmil samples are shown in Table 2. A photograph of a sample under test is shown in Figure 7.

Table 1

Tensile test results and failure mode for 1/0 AWG samples

Sample Number Conductor

Rating (lbs.)

Failure (lbs.)

% of Rating Failure Mode

#1 Standard Connector 2,160 1,731 80 Conductor broke at mouth of connector



#1-0.25” Connector w/Adapter 2,160 1,835 85 Connector pulled out of end fitting

#2-0.25” Connector w/Adapter 2,160 1,225 57 Conductor pulled out of end fitting



#2-0.50” Connector w/Adapter 2,160 1,846 85 Conductor broke at mouth of connector








TABLE 2

Tensile test results and failure mode for 1000 kcmil samples

Sample Number Conductor

Rating lbs.

Failure

Lbs. % of

Rating Failure Mode

#1 Standard Connector 17,700 3,140 18 Connector eye pulled through



#1-1.5” Connector w/Adapter 17,700 3,120 18 Connector eye pulled through






Figure 7: Tensile Test Setup - 1000 kcmil Cable with Connector/Adapter



CONCLUSIONS All connectors tested in this project met the thermal, electrical and mechanical acceptance criteria of ANSI C119.4, 2004. It should be noted that the 1/0 AWG met the thermal and electrical performance criteria after being subjected to two current cycle submersion tests. Graphs detailing the thermal and electrical performance of each connector are included in the Appendix.

REFERENCES

ANSI C119.4, 2004 American National Standard for Electric Connectors, Connectors for Use Between Aluminum-to-Aluminum or Aluminum-to-Copper Bare Overhead Conductors

EQUIPMENT USED

• HP 3421A Data Acquisition System, Control Numbers CQ 0226 and CQ 0218 (temperature data)

• AVO Ducter DLR0, Control Number CQ 1083 (resistance data)

• Current Cycle Submersion Test Fixture and AC Current Loading Power Supply

• MTS Control Number CQ 0195


APPENDIX

GRAPHS FOR 1/0 AWG CONNECTORS

06-009 NOVINIUM CONNECTOR ADAPTOR EVALUATIONCONNECTOR #1

TESTED ON 1/0 AWG 25 kV INSULATED CONDUCTORMAXIMUM TEMPERATURE AT END OF CYCLE ( STANDARD )

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06-009 NOVINIUM CONNECTOR ADAPTOR EVALUATION

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