1272mcm 726 79mm pheasant acsr 419148 hes ss on pheasant acsr draft report

8/20/2019 1272mcm 726 79mm Pheasant Acsr 419148 Hes Ss on Pheasant Acsr Draft Report

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

Page 1 of 20 K-419148-RC-0002-R00

To: HES Hacilar Electrik San. Ve Tic.

Erciyes Mah. HES Cad.No: 22 38210 Hacilar, KayseriTurkey

D R A F T

KINECTRICS INTERNATIONAL INC. TEST REPORTFOR HES HACILAR ELEKTRIK SAN. VE TIC.

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

Kinectrics International Inc. Report No.: K-419148-RC-0002-R00

December 22, 2009

C. DimnikTransmission 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 35.11 mm and is designated1272 MCM PHEASANT 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 3 and 4, 2009by 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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Page 2 of 20 K-419148-RC-0002-R00

2.0 TEST OBJECTIVE AND STANDARD

The objective of the test is to provide the stress-strain characteristics of the conductor to beused 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 layoverhead 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 conductorsample 13.95 m in length was terminated using epoxy-resin dead-ends. A steel core sample14.97 m in length was also terminated using epoxy-resin dead-ends. The prepared sample wasinstalled in a hydraulically-activated horizontal tension test facility. During the initial set-up andpre-loading steps, the sample was supported along its length to keep the sample as straight aspossible and to minimize the axial stress and sag. A pull-wire potentiometer was fixed to thesample 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. Aload cell located at the hydraulic end of the sample measured the tension. A photo of a typicaltest 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 thegauge length.

The test was carried out in a temperature-controlled laboratory at 20ºC ± 2ºC.

Instrumentation and Data Acquisi tion

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 loggingrate 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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Page 3 of 20 K-419148-RC-0002-R00

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. Theloads were applied at a rate of 3,054 kg/minute (6,732 lb/minute). This is based on achieving

30% of RTS in two (2) minutes.

20,357 kgf

St ep % RTS kgf lbf

Hold

(minutes)

preload 2% 407 898

1 30% 6,107 13,464 30

2 2% 407 898 1

3 50% 10,179 22,440 60

4 2% 407 898 1

5 70% 14,250 31,415 60

6 2% 407 898 1

7 85% 17,303 38,147 608 2% 407 898 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 loadreapplied at a rate of 4,071 kg/minute (8,976 lb/minute) until the conductor failed. The breakingload 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, 3and 5 for the steel core were determined by the elongation at the beginning of each hold periodobtained on the whole conductor at 30%, 50%, 70% and 85% RTS, respectively. That is, foreach load step, the tension was increased in the steel core until the % elongation was the sameas the whole conductor for the corresponding load step. This meant that the stress-strain testmust be performed on the whole conductor before the steel core. The steel core was tensionedaccording to the loading schedule on the following table. The loads were applied at a rate of3,054 kg/minute (6,732 lb/minute).


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Page 4 of 20 K-419148-RC-0002-R00

20,357 kgf

Step

Whole Con ductor

Elongation, mm kgf lbs

Hold

(minutes)

preload 0 407 898

1 11.79 - - 30

2 - 407 898 1

3 21.78 - - 60

4 - 407 898 1

5 35.95 - - 60

6 - 407 898 17 51.49 - - 60

8 - 407 898 1

Whole Conductor RTS=

The completion of Step 8 of the above loading schedule constituted the completion of theStress-Strain Test.

5.0 TEST RESULTS

The strain data for the conductor and core have been corrected because the elongationmeasurement 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+0.0032% for the conductor and +0.0291% for the steel core. After accounting for thesecorrections, the data was extrapolated to the Y-axis to zero. The corrected data was the actualconductor’s behaviour because the conductor will have zero elongation only when it is under zerotension.

Figures 3a and 3b show load (i.e. tension) plotted against all strain data for the whole conductorand 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 PHEASANT ACSR conductor showing the plots forthe whole conductor, the aluminium layers, and the steel core.

The area of the conductor was 726.79 mm2 according to the cable data sheet, included in Appendix A.

The stress-strain curve for the aluminium layers is calculated by subtracting corresponding datapoints 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 forthe conductor is approximately 72,973 MPa.

Similarly, the MOE of the steel core can also be determined from the unloading curve on thecore only Stress-Strain curve. The MOE for the steel core (based on the area of the steel coreonly) is approximately 187,471 MPa. The MOE for the steel core (based on the area of thewhole conductor) is approximately 21,077 MPa.


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Page 5 of 20 K-419148-RC-0002-R00

The MOE of the aluminum layers is calculated from the difference between the whole conductorand steel core, from the unloading at 85% to their intersection (knee-point). The MOE for thealuminum layers (based on the area of the aluminum only) is approximately 60,779 MPa. TheMOE for the aluminum layers (based on the area of the whole conductor) is approximately53,946 MPa.

The whole conductor failed at 22,286 kgf or 109.5% of the Rated Tensile Strength of theconductor.

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, steelcore 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 datapoints 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 PHEASANT ACSRWhole Conductor

Whole ConductorPolynomial Coefficients

(MPa)

Final Modulus ofElasticity

MPa(before Knee-point)

EstimatedKnee-point Load

kN **

Breaking Loadkgf

A= +4.0623 E+08B= -8.3710 E+06C= +7.5030 E+04D= -1.0032 E-01

72,973 46.5 22,286

** 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 PHEASANT ACSRSteel Core

Steel CorePolynomial Coefficients

(MPa)

Final Modulusof Elasticity

(based on area ofSteel Only)

MPa


(area corrected forConsolidated Conductor)

MPa

A= -2.3788 E+07B= -4.3890 E+05C= +2.2588 E+04D= +6.8298 E-03

187,471 21,077

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


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Page 6 of 20 K-419148-RC-0002-R00

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

AluminumPolynomial Coefficients

(MPa)


(based on Area of Alum Only)

MPa


(area corrected forConsolidated Conductor)

MPa

A= +4.2684 E+08B= -7.8971 E+06C= +5.2329 E+04D= -2.3784 E-03

60,779 53,946

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 shallwithstand, 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 theconductor 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.


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Page 7 of 20 K-419148-RC-0002-R00

Prepared by:C. DimnikEngineerTransmission and Distribution Technologies Business

Reviewed by:C.J. PonPrincipal EngineerTransmission and Distribution Technologies Business

Approved by:R. LingsGeneral ManagerTransmission and Distribution Technologies Business

CD:CJP:RL

DISCLAIMER

Kinectrics International Inc. (KII) has taken reasonable steps to ensure that all work performed meetsindustry standards as set out in KII Quality Manual, and that, for the intended purpose of this report, isreasonably free of errors, inaccuracies or omissions. KII DOES NOT MAKE ANY WARRANTY ORREPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THEMERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OF ANY INFORMATIONCONTAINED 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, consequentiallyor otherwise resulting from the use of this report.

Kinectrics International Inc., 2009


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

Figure 1 Set-up for Stress-Strain Test

Cylinder MountFixed to Strong Floor

Hydraulic Cylinder

Load Cell

Epoxy Deadend

ACS Conductor

Data Aquisition System

Gauge length

DisplacementTransducer P

a g e 8 of 2 0

K -4

1 9 1 4 8 -R C - 0 0 0 2 -R 0 0

ACSR Conductor


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Page 9 of 20 K-419148-RC-0002-R00

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. PHEASANT ACSR

0

20

40

60

80

100

120

140

160

180

0.00% 0.05% 0.10% 0.15% 0.20% 0.25% 0.30% 0.35% 0.40% 0.45%

Conductor Strain, %

C o n d u c

t o r T e n s i o n ,

k N

46.5 kN Knee

Figure 3a Load (tension) vs. Conductor Strain

P a g e1 0 of 2 0

K

-4 1 9 1 4 8 -R C - 0 0 0 2 -R 0 0


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0

10

20

30

40

50

60

70

80

0.00% 0.05% 0.10% 0.15% 0.20% 0.25% 0.30% 0.35% 0.40% 0.45%

Core Strain, %

C o r e

T e n s i o n ,

k N

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

P a g e1 1 of 2 0

K

-4 1 9 1 4 8 -R C - 0 0 0 2 -R 0 0


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0.584

0.4018%, 192.35 MPa

0.2390%, 137.41 MPa

0.1276%, 82.45 MPa

0

50

100

150

200

250

0.00% 0.10% 0.20% 0.30% 0.40%

Conductor Strain, %

C o n d u c

t o r S t r e s s ,

M P a

Conductor area = 726.79 mm²

Figure 4a Stress vs. Conductor Strain for Only Those Points That Contr ibute to the S

P a g e1 2 of 2 0

K

-4 1 9 1 4 8 -R C - 0 0 0 2 -R 0 0


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0.5567%,

0.3950%, 80.94 MPa

0.2487%, 53.06 MPa

0.1472%, 32.26 MPa

0

20

40

60

80

100

120

0.00% 0.10% 0.20% 0.30% 0.40%

Core Strain, %

C o r e

S t r e s s ,

M P a


Figure 4b Stress vs. Steel Core Strain for Only Those Points That Contr ibute to the S

P a g e1 3 of 2 0

K

-4 1 9 1 4 8 -R C - 0 0 0 2 -R 0 0


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0

50

100

150

200

250

0.00% 0.10% 0.20% 0.30% 0.40%

Unit Strain, %

S t r e s s ,

M P a

Initial Composite

Initial Steel

Final Steel


Core Area = 81.71 mm²

Figure 5 Composite Stress-Strain Curve

P a g e1 4 of 2 0

K

-4 1 9 1 4 8 -R C - 0 0 0 2 -R 0 0


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Page 15 of 20 K-419148-RC-0002-R00

APPENDIX A

DESCRIPTION OF HES HACILAR ELEKTRIK SAN. VE TIC. CONDUCTOR(Ref. 1272 mcm, 726.79 mm2, PHEASANT ACSR Conductor)


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Page 16 of 20 K-419148-RC-0002-R00

PHEASANTCONDUCTOR 1272 MCM

Stranding Direction Right

Conductor OD mm 35.11

Total Cross Section mm² 726.79Construction 1(St)+6(St)+12(St)+12(Al)+18(Al)+24(Al)

Conductor Weight kg/km 1783.8

Conductor Tensile Strength kgf 20,357

Aluminum Cross Section mm² 645.08

Aluminum Weight kg/km 1783.8

Steel Core Diameter mm 11.7

Steel Core Cross Section mm² 81.71

Steel Core Weight kg/km 639.7 A.C. Resistance at 25 ° C, 50 Hz ohm/km 0.00475

Xa at 50 Hz ohm/km 0.231

X'a at 50 Hz Megaohm.km 0.1363GMR 14.2

Conductor E-modulus (First) kg/mm² 5000

Conductor E-modulus (Final) kg/mm² 6000

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

Current Carrying Capacity A 1160

Drum Length m 1600

Aluminum Wires

Nominal OD mm 3.9

Nominal Cross Section mm² 11.93Tensile Strength(min) kg/mm² 16.5

DC Resistivity at 20 ° C (Max) n.ohm.m 28.264

Linear Thermal Coefficient / °C 23*10-6

Steel Wires

Nominal OD mm 2.34

Nominal Cross Section mm² 4.29

Tensile Strength After Stranding kg/mm² 138

Tensile Strength at 1% Elongation (Min.) kg/mm² 128Zinc Coating Weight g/m² 230

CONDUCTOR PROPERTIES


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ISO-9001

Form: QF11-1Rev 0, 97-10

APPENDIX B

INSTRUMENT SHEETHES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT AC

Test Description: Stress-Strain Test Test Start Da

Project Number: K-419148 Test Finish Da

TESTDESCRIPTION

EQUIPMENTDESCRIPTION

MAKE MODEL ASSET # or

SERIAL # ACCURACY

CLAIMEDCALIBRATION

DATE

DataloggerNationalInstruments PCI-6036E - B

±0.1% ofReading June 25, 2009 Ju

Load Cell (MTS)

Load CellConditioner

Lebow

MTS

3156

493.01DC

17356-0

10000686-0±1.0% ofreading May 29, 2009 M

DisplacementTransducer

Conditioner

Ametek

Trans-tek

PT-10AT-HT

1002-000F

KIN-00658PWP #2

19698-0 ±0.1 mm October 7, 2009 O

Measuring Tape Stanley FatMax (34-813) KIN-00723< 0.05% ofReading October 2, 2008 O

Stress-StrainTest

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

M

M

P a g e1 7 of 2 0

K

-4 1 9 1 4 8 -R C - 0 0 0 2 -R 0 0


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APPENDIX C

KINECTRICS ISO 9001 QUALITY MANAGEMENT SYSTEM REGISTRATIONCERTICATE


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P 20 f 20 K 419148 RC 0002 R00

DISTRIBUTION

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

Erciyes Mah. HES Cad.No: 22 38210 Hacilar, KayseriTurkey

Telephone: 90 352 207 45 00Email: [email protected]

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

1272mcm 726 79mm pheasant acsr 419148 hes ss on pheasant acsr draft report

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