THERMO-MECHANICAL CYCLE TEST ON 540 mm 2 ACCC/TW … · 2019-01-22 · THERMO-MECHANICAL CYCLE TEST ON 540 mm2 ACCC/TW CONDUCTOR Kinectrics North America Inc. Report No.: K-419506-RC-0001-R00

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 5G5

To: CTC Global

2026 McGaw Avenue Irvine, CA 92614, USA

THERMO-MECHANICAL CYCLE TEST ON 540 mm2 ACCC/TW CONDUCTOR

Kinectrics North America Inc. Report No.: K-419506-RC-0001-R00

October 2, 2013

Zsolt Peter Transmission and Distribution Technologies Business

1.0 INTRODUCTION

A Thermo-Mechanical Cycle Test was performed on a sample of 1.108 inch (28.15 mm), 540 mm2, “Dublin”, Aluminum Conductor, Composite Core/Trapezoidal Wire (ACCC/TW) conductor for CTC Global Corporation (CTC). The Dublin/Drake (Dublin is the metric size equivalent to Drake in US customary units) conductor consists of a single composite glass and carbon fiber core covered by two (2) layers of twenty two (22) annealed, trapezoidal-shaped aluminum alloy wires. The composite core is manufactured by CTC Global (CTC) from California (USA) and the conductor is stranded by Lamifil N.V., from Belgium. The specification for the conductor is shown in Appendix A.

Sufficient length of test conductor and dead-end assemblies were received on April 16th, 2013 in a good condition from CTC Global. The test was performed from April 25th through August 1, 2013 in accordance with a proposed test procedure described in CIGRE Guide 426, Section 4.17, and in accordance with Kinectrics ISO 9001 Quality Management System. All work was performed by Kinectrics North America Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 5G5, Canada, under CTC Global Corporation’s Purchase Order No. 6831. A copy of Kinectrics ISO 9001 Accreditation Certificate is included in Appendix C.

The ACCC/TW Dublin/Drake conductor successfully met all requirements of the test protocol developed by EPRI and in accordance with GIGRE 426, Section 4.17, Temperature Cycle Test methods. The Thermo-Mechanical Cycle Test was very similar to previous tests performed on organic composite core conductors and documented in Kinectrics North America Test Report No K-419212-RC-0001-R00. The test consists of five hundred (500) thermo-mechanical cycles and five (5) holds at 70% of the conductor’s rated tensile strength (RTS) at room temperature. The maximum test temperature during the thermo-mechanical cycles was approximately 200 ˚C measured on the surface of the test conductor.

Two (2) conductors were tested: one tensioned test conductor and one non-tensioned dummy conductor. Both tensioned and dummy conductors used standard field rated dead-ends for electrical and mechanical connection throughout the thermo-mechanical cycling. At the end of the cycling test, breaking load tests were performed on both conductors to assess the remaining tensile strength. Both conductors were pulled apart well above the conductor’s Rated Tensile Strength with the test conductor reaching 111.6% of conductor’s RTS and the dummy conductor reaching 112.3% of the conductor’s RTS.

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2.0 TEST OBJECTIVE AND STANDARD The primary objective of the Thermo-Mechanical Cycle Test was to subject a CTC glass/carbon fiber composite core HTLS (high-temperature low-sag) conductor to thermal and mechanical loads simulating those encountered in actual operation. The test protocol was based on a proposed test procedure described in CIGRE Guide 426, Section 4.17, Temperature Cycle Test. However, no industry explicit test standard is available for evaluating the combined effects of thermal and mechanical cycles on HTLS conductors.

3.0 TEST SET-UP

Test Conductors The selected conductor size for the test was 1.108 inch (28.15 mm), 540 mm2, Aluminum Conductor, Composite Core/Trapezoidal Wire (ACCC/TW) “Drake/Dublin” conductor. The Conductor is produced by LAMIFIL in Belgium and has the reel number LAM 384 and has a core reel number 4316. The conductor consists of a single composite glass and carbon fiber core covered by two (2) layers of twenty two (22) annealed, trapezoidal-shaped aluminum alloy wires. The complete specification for the conductor is shown in Appendix A. CTC supplied a sufficient length of conductor in good condition for testing. Two (2) approximately 47.5 ft (14.5 m) lengths of conductor were cut from the supplied reel. One conductor was used in the tensioned span, and the second one served as a dummy return conductor. All conductor ends were terminated with Burndy high temperature dead-end connectors, P/N 5600-1060. A photo of the conductor termination with the compression connector is shown in Figure 1. The effective conductor length between the dead-end assemblies was approximately 42.5 ft (13 m). The compression connectors, manufactured by Burndy, were installed by Chris Wong of CTC with the assistance of Peter Chan from Burndy and KNAI personnel. CTC also provided appropriate compression dies, and KNAI supplied a 60-ton press for the installation. The mouth of each dead-end assembly was marked with orange paint to permit tracking of any conductor slip. Porcelain insulators were connected to each compression dead-end in order to electrically isolate the energized test conductors from the rest of the test setup. Test Apparatus The test was carried out in Kinectrics’ Mechanical Testing Laboratory. Three (3) tests were performed:

i) Thermo-Mechanical Cycling Test, ii) Sustained Load Test at 70% RTS (Rated Tensile Strength), iii) Breaking Load Test to measure the remaining tensile strength of the test

assembly.

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i) Thermo-Mechanical Cycling Test Figure 2a provides the test setup schematics. A photo taken from the actual test setup is shown in Figure 2b. A test machine having a load accuracy of ± 2% was used for this test. The test conductor was loaded using a hydraulic piston on one end and a cantilever beam weight system on the opposite end. The conductor was located in a thermally isolated box in order to assure thermal stability and consistency between thermal cycles, but the compression dead ends were located outside the heated part of the isolated box. The thermally isolated box was equipped with five (5) large industrial fans. The fans were switched on during the cooling cycles in order to shorten the cooling period by forced convection. A dummy conductor shown in Figure 2c, running in parallel to the test conductor under tension, was also installed in order to measure conductor temperature at various locations. The dummy conductor was not under tension, but passed through the same current and underwent the same temperature cycles as the test conductor. The dummy conductor was also used as the return conductor to the power transformer. An AC current transformer (Figure 3) and a contactor provided necessary current to increase the temperature in the conductor to the desired temperature. The AC current transformer supplied the current in the test conductor through jumper terminals that were attached to the test conductor with compressed dead-ends. A typical photo taken from the jumper conductors is shown in Figure 4. ii) Sustained Load Test at 70% RTS This test was performed using the same test setup as the Thermo-Mechanical Cycling Test. At the end of the Thermo-Mechanical Cycling Test, the cantilever tray was loaded with additional weight and the hydraulic piston was used again to increase the tension to 70% RTS. iii) Breaking Load Test on Compression Dead-end Connectors This test was performed at the end of the five hundred (500) thermo-mechanical cycles and five (5) holds at 70% RTS. On completion of the Thermo-Mechanical Cycling Test, the test and dummy conductors were cut at the center span and only half of the span length was used for Breaking Load Test. The half-length of the conductor used for testing was prepared by bonding the cut end of the conductor into tensioning grips. The remaining half length of test and dummy conductors was sectioned and sent back to CTC Global for further evaluation. The dummy and test conductor samples were installed in a hydraulically-activated horizontal test machine and individually tested. The pin-to-pin distance between the compression dead-end connector and epoxy resin dead-end loading point was approximately 7.55 m, while the effective conductor length was approximately 6.2 m. A schematic of the test set-up is shown in Figure 5a. A photo of a test conductor installed in the Tension Test Facility is shown in Figure 5b.

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Instrumentation Conductor Tension for Thermo-Mechanical Cycling and Sustained Load Test at 70% RTS A strain gauge load cell (see Appendix B) measured the tension in the test conductor at the north end of the test span during the test. The load cell was installed between the insulator and the dead-end structure so that it would be electrically isolated from the conductor. The signals from the load cell were amplified to provide a 0 to 5 V signal for the data acquisition system (see Appendix B). Temperature Measurements A total of twenty-seven (27) thermocouples were located on the conductors, dead-end and jumper terminal compression connectors. The temperature of the conductors was measured at multiple locations along the length of the conductors. Six (6) thermocouples were placed in outer strands of each test conductor and dummy return conductor to monitor surface temperature of the conductors. Typical thermocouple installation in outer layer of the conductors is shown in Figure 6. Each thermocouple measuring surface temperature of conductors was pinned into a small hole drilled in one of the outer conductor strands. The location of thermocouples installed in the outer layers is detailed in Table 1. Three (3) additional thermocouples were placed in the dummy return conductor: i) in the composite core at the center of the test span; ii) in the composite core 1.5 m north from the center; and iii) between first and second aluminum layers near center of the test span. One of the compression dead-end connectors on each test conductor and dummy return conductor had four (4) thermocouples installed as shown in Figure 7. A thermocouple installed at the electrical crimp area is shown in Figure 8. Ambient temperature was measured at two (2) locations: near the south end and near the north end of the isolated test box. Glass isolated thermocouples of J-type were used to measure the temperature of the conductors. All thermocouples were electrically isolated from other instrumentation to prevent electrical interference into the data acquisition system. Table 1 summarizes the positions of all installed thermocouples for Thermo-Mechanical Cycling Test.

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Table 1: Locations of Thermocouples

Positioned in Thermocouple (TC) Number

Location

Thermal Box TC1 Box temperature near south end

TC2 Box temperature near north end

Tensioned Test Conductor

TC3 0.5m south of centre, Outer Layer, Test Conductor

TC4 3.5m south of centre, Outer Layer, Test Conductor

TC5 0.5m from south thermal barrier, Outer Layer, Test Conductor

TC6 0.5m north of centre, Outer Layer, Test Conductor

TC7 3.5m north of centre, Outer Layer, Test Conductor

TC8 0.5m from north thermal barrier, Outer Layer, Test Conductor

TC9 North end, Dead End Terminal Pad

TC10 North end, Dead End Eyebolt Crimp

TC11 North end, Dead End Electrical Crimp

TC12 North end, Dead End Sleeve

TC13 South end, Dead End Terminal Pad

Non-Tensioned Dummy

Conductor

TC14 Centre, Between first and second aluminum layers

TC15 Centre, in the composite core -A

TC16 1.5m north of centre, in the composite core -B

TC17 0.5m south of centre, Outer Layer, Dummy Conductor

TC18 3.5m south of centre, Outer Layer, Dummy Conductor

TC19 0.5m from south thermal barrier, Outer Layer, Dummy Conductor

TC20 0.5m north of centre, Outer Layer, Dummy Conductor

TC21 3.5m north of centre, Outer Layer, Dummy Conductor

TC22 0.5m from north thermal barrier, Outer Layer, Dummy Conductor

TC23 North end, Dead End Terminal Pad

TC24 North end, Dead End Eyebolt Crimp

TC25 North end, Dead End Electrical Crimp

TC26 North end, Dead End Sleeve

TC27 South end, Dead End Terminal Pad

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Conductor Tension for Breaking Load Test A load cell located at the hydraulic end of the sample measured the tension. The data logging rate during loading was a minimum of every ten (10) seconds. Control of Current in Loop and Data Acquisition The data acquisition system (DAQ) recorded the conductors’ temperature and tension, and controlled the contactor. The data were sampled and recorded periodically (typically every 2 minutes). Continuous AC current of ~1440 amperes was circulated in the conductors. A closed-loop system was used to maintain the target temperature of the test conductor. The data acquisition system (DAQ) recorded the maximum outer temperature of the tensioned and non-tensioned conductors and controlled the motor-driven variac. The variac varied the supply voltage to the current transformer. The target test current was slightly adjusted (using a variac) to maintain the maximum outer temperature of the conductor at 200 ˚C ±5 ˚C. The controller instructed the transformer to shut off and wait, if any thermocouple readings were higher than 210˚C. 4.0 TEST PROCEDURE It is intended to subject the test conductor to a total of 500 thermo-mechanical cycles and 5 holding periods at 70% RTS for 24 hours. The conductor tension of 20% (± 2%) of the conductor’s RTS at ambient temperature is chosen for the thermo-mechanical cycling test. The cantilever weight system allows a decrease in tension to occur during the high-temperature range of the cycling test to simulate the expected field tensions. 20% RTS is considered an upper limit for tension at extreme conductor temperatures. Sustained Load Test at 70% RTS hold for 24 hours is intended to simulate high wind and/or ice conditions. The test was carried out according to the following test procedure: i) The conductor in the thermally isolated box at room temperature is tensioned to

approximately 20% of the rated tensile strength (corresponds to 8260 lb or 36.76 kN). This initial tension is allowed to change ±2% RTS during the test due to ambient temperature variations. The percentage variation corresponds to tensions from 7430 lb to 9090 lb (33.1 kN to 40.4 kN). The entrance of tensioned dead-end connectors is marked with paint to monitor conductor slip after the conductor is brought to 20% RTS.

ii) At 20% RTS, the tensioned and dummy conductors were also marked with radial

markings. These markings, which are painted rings spaced approximately 0.5 m (north and south) and 3.5 m (north and south) from the center of the span are used to determine if there is any movement of the individual surface strands relative to each other. Later, pictures of these rings are taken periodically during the test program whenever there is a significant change in conductor tension. Also, the tensioned and dummy conductor’s outer diameter is measured where the radial rings are located.

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iii) 100 thermo-mechanical cycles are applied on the test conductor from room temperature to 200°C ± 5°C maximum conductor temperature measured in the outer layer of the test conductor. A typical thermo-mechanical cycle is shown in Figures 9a and 9b for test and dummy conductors, respectively. Each thermo-mechanical cycle is performed as follows: A. Starting at room temperature (nominally 20˚C - 30˚C), the temperature in the

conductor is increased by circulating a constant alternating current (AC) supplied by a current transformer.

B. The data logger monitors temperatures along the length of test and dummy conductors at various locations and records data every two (2) minutes. The highest value of all thermocouples readings measured in outer layer of tensioned and non-tensioned conductors is selected and logged as maximum outer temperature. The target test current was slightly adjusted (using a variac) to maintain the maximum outer temperature of the conductor at 200 ˚C ± 2.5 ˚C.

C. After 10 min heating period, the controller instructs the transformer to shut off. Industrial fans are switched on automatically to cool the conductors and connectors by forced convection to the ambient temperature.

D. After the conductors and all connectors are cooled to, and stabilized, at room temperature (within ± 5˚C), the fans are switched off and the transformer is switched on.

E. The cycle is repeated for accumulating total of hundred (100) cycles. After all hundred (100) cycles are completed, the controller instructs transformer to shut off.

iv) On completion of one hundred (100) thermo-mechanical cycles, the electrical connections were removed. The test conductor was then tensioned to 70% RTS by placing weights on the cantilever tray. This tension was maintained for twenty four (24) hours. The data acquisition system (DAQ, see Appendix B) recorded the conductor tension periodically. On completion of 24 hour hold period at 70% RTS, the load is reduced to 20% RTS gradually and compression dead-end are inspected for any slippage or movement.

v) Pictures of the radial rings of the tensioned conductor are taken before and after the hold period. Also, the outer diameter of the tensioned and dummy conductor’s are measured at the same locations where the radial rings were painted.

vi) DC resistance is measured across compression dead-end connectors after each 100 thermo-mechanical cycles and 70% RTS loading.

vii) Steps from i) to vi) are repeated four (4) more times (for a total of five (5) times). viii) At the end of the test, the test and dummy conductors were cut in the middle

separating the conductors into two (2) equal sections. One (1) half of each conductor (dummy and test) was sent to CTC Global for further evaluation.

ix) The remaining half sections of dummy and test conductors were re-terminated with epoxy resin dead-ends. Therefore, both conductors (test and dummy) had one (1) compression dead-end on one end, and one (1) epoxy resin dead-end on another end. The Breaking Load Test was performed on the remaining parts of the test and dummy conductors.

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5.0 TEST RESULTS AND DISCUSSION Large amounts of temperature data were recorded by the data logger for the duration of each thermo-mechanical cycle. To facilitate the reduction and management of the data, only every ten (10) cycles were reported in table format and every cycle steady-state data are presented in figures. Table 2a and 2b contain the steady-state temperatures of the test and dummy conductors after every ten (10) thermo-mechanical cycles. Table 3a and 3b contain the steady-state temperatures of the tensioned dead-end attached to test and dummy conductors. The data in table format are also plotted as follows:

a) Figure 10: Steady-State Temperatures Measured along the Tensioned Test Conductor during Thermo-Mechanical Cycling Test

b) Figure 11: Steady-State Temperatures Measured along the Dummy Non-tensioned Conductor during Thermo-Mechanical Cycling Test

c) Figure 12: Steady-State Temperatures of Tensioned Dead-end during Thermo-Mechanical Cycling Test

d) Figure 13: Steady-State Temperatures of Non-Tensioned Dead-end during Thermo-Mechanical Cycling Test

Temperature Variations during the Thermo-Mechanical Cycling Test: During the first 100 thermo-mechanical cycles the tensioned test conductor and non-tensioned dummy conductors had very similar temperatures as shown in Figures 10 and 11, respectively. Due to the end effects of the test setup, the temperature close to the thermal barriers at south and north ends was about 10 °C lower. This is also shown in Figures 10 and 11. After the first 70% RTS hold period (first 100 thermo-mechanical cycles), the test conductor had some loosened outer strands (due to high tension and annealed aluminium) while no loosened aluminium layer could be observed for non-tensioned dummy conductor. This resulted in test conductor temperatures to be slightly lower than dummy conductor temperature. As shown in Figure 11, the dummy conductor surface temperature was kept very close to the target test temperature (200 °C). More loosened outer layer strands were noticed for the tensioned test conductor after the second 70%RTS loading and this resulted in slightly more temperature drop as shown in Figure 10. The slight temperature differences between dummy and test conductor and temperature variations along the length of the conductors did not impact the test objectives since the middle section of test conductor was always kept close to the target temperature. Performance of Compression Connectors during Thermo-Mechanical Cycling Test: One (1) dead-end installed on tensioned test conductor (at north end of the span) and one (1) dead-end installed on non-tensioned dummy conductor were instrumented with thermocouples along its length. The thermocouple locations are detailed in Table 1. The compression connectors were located outside the heated section of the thermal box. A barrier was used to separate the connectors from the heated test section of the setup.

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Figures 12 and 13 show the temperature measurements at the end of each cycle for dead-end connectors installed on test and dummy conductors, respectively. As it was expected, the highest temperature was measured at the electrical crimp area for both monitored dead-end connectors. The results show while the conductor test temperature was ~200°C, the dead-end installed on non-tensioned conductor was below 100°C and the dead-end installed on tensioned conductor stayed below 120°C during the Thermo-Mechanical Cycling Test. As shown in Figure 13, temperatures measured along the length of the dead-end installed on non-tensioned dummy conductor were fairly stable, and the small temperature changes were following the temperature change in the thermal box. The tensioned dead-end connector had very similar temperature as the non-tensioned dead-end at the early stage of the test (~first 100 cycles). As the test progressed, some temperature increase can be noticed at the electrical crimp of the tensioned dead-end as shown in Figure 12. The DC resistance at ambient temperature was also measured across the compression dead-end connectors. These measurements were started only after 200 thermo-mechanical cycles were performed and thereafter were taken after each significant change in tension. Table 4a shows DC resistance measurements across tensioned dead-end connector. Table 4b shows DC resistance measurements across non-tensioned dead-end connector. The results presented in aforementioned tables indicate that the performances of the electrical contact interfaces were not affected due to Thermo-Mechanical Cycling Test. Table 5a shows the conductor movement at the entrance of the tensioned dead-end connectors. The entrance of tensioned dead-end connectors was marked in order to detect any slippage and/or conductor movement. No movement or slippage could be noticed until the first 70%RTS holding period. After completing the first 70% RTS hold, 3.9 mm and 4.6 mm movement was noticed at the tensioned compression dead-ends. According to the manufacturer this movement is due to additional seating of the collet system under high load conditions and is not due to slippage. This explanation was confirmed by four (4) additional loadings to 70% RTS later in the test plan without any significant conductor movement beyond what was experienced during the first 70% RTS hold. Conductor Condition:

Figure 2c shows the test and dummy conductors before the start of the test program. Since the compression dead-end connectors were reverse (i.e. backward) crimped, not much slack was noticed in the test and dummy conductors before starting the test program. After each 70% RTS loading period more slack was introduced to the test conductor due to elongating annealed aluminum wires under high tension. Figures 14a and 14b show the outer surface of the test conductor after completing the Thermo-Mechanical Cycling Test. Significantly less loosened aluminum wires were noticed on the dummy conductor. After completing the Thermo-Mechanical Cycling Test, the conductors were cut at the middle and the core was examined. Darker color of the outer surface of the epoxy shell was noticed, but this darkening was not noticed at the cross-section of the core. The condition of the core is shown in Figure 14c.

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Table 2a: Measured Steady-State Conductor Temperatures and Tensions during Thermo-Mechanical Cycling

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Table 2b: Measured Steady-State Conductor Temperatures and Tensions during Thermo-Mechanical Cycling

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Table 3a: Measured Steady-State Connector Temperatures during Thermo-Mechanical Cycling

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Table 3b: Measured Steady-State Connector Temperatures during Thermo-Mechanical Cycling

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Table 4a: Measured DC Resistance across Dead-end Connectors Terminating

Tensioned Test Conductor

DC Resistance Measurement on Tensioned Dead-end Connectors

After Cycle

After Tension

North Dead-end South-Dead-end Ambient

Temperature

# %RTS micro-Ohm micro-Ohm °C

200 70% 26.0 26.6 24.2

300 20% 27.3 28.0 24.2

300 70% 26.2 28.8 23.9

400 20% 27.8 28.1 24.9

400 70% 27.2 27.4 25.2

500 20% 34.2* 36.8* 24.9

500 70% 31.9* 32.1* 23.3

*Loosened outer aluminium strands may influence the measurement

Table 4b: Measured DC Resistance across Dead-end Connectors Terminating Non-Tensioned Dummy Conductor

DC Resistance Measurement on Tensioned Dead-end Connectors

After Cycle

After Tension

North Dead-end South-Dead-end Ambient

Temperature

# %RTS micro-Ohm micro-Ohm °C

200 N/A 29.8 22.3 24.2

300 N/A 30.5 22.3 24.2

400 N/A 30.3 21.9 24.7

500 N/A 29.6 19.8 23.1

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Table 5a: Test Conductor Outer Diameter Measurements and Connectors Movements

After Cycle

After Tension

Conductor Outer Diameter Measurements Dead-end

Movement* 0.5m South

3.5m South

0.5 m North

3.5 m North

North South

# %RTS mm mm mm mm mm mm

0 2.5% 28.96 28.90 29.09 28.80 0 0

0 20% 28.50 28.55 28.50 28.61 0 0

100 20% 28.94 28.84 28.41 28.54 0 0

100 70% 30.90 31.44 30.61 30.09 4.6 3.9

200 20% 31.07 31.17 30.47 31.35 4.9 3.9

200 70% 31.87 32.18 31.11 31.86 4.9 4.3

300 20% 31.48 31.79 31.37 32.08 4.9 4.3

300 70% 31.42 31.84 31.32 32.14 4.9 4.3

400 20% 31.24 31.63 31.15 32.10 4.9 4.3

400 70% 31.48 31.33 31.10 32.21 4.9 4.3

500 20% 32.15 31.48 31.35 31.91 4.9 4.9

500 70% 31.46 31.50 31.28 31.99 4.9 4.9

*Dead-end movement is believed to occur due to seating of the collet system during application of high tension

Table 5b: Dummy Conductor Outer Diameter Measurements

After Cycle

Conductor Outer Diameter Measurements

0.5m South

3.5 South 0.5 m North

3.5 m North

# mm mm mm mm

0 28.92 28.92 29.18 29.20

100 29.46 29.42 29.49 29.79

200 29.59 29.19 29.40 29.90

300 29.47 29.30 29.35 30.02

400 29.31 29.70 29.25 30.05

500 29.35 29.46 29.55 30.09

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Conductor Breaking Load

The following observations were made with regards to the Breaking Load Test:

i. The aluminum wires of the dummy conductor sample before starting the Breaking Load Test were loose, but this loosening disappeared once the tension reached ~30% RTS. The dummy conductor broke near the middle of the test assembly as shown in Figure 16a. A close up photo showing the broken strands of the dummy conductor is presented in Figure 16b.

ii. The dummy conductor (non-tensioned during Thermo-Mechanical Cycling Test) breaking load was at 46,359 lb which corresponds to 112.3% of conductor’s RTS.

iii. The aluminum wires of the test conductor sample before starting the Breaking Load Test were loose as shown in Figure 15. It was noticed that the strands settled in and loosening disappeared once the tension exceeded ~70% RTS. The test conductor broke about 1m from the south compression dead-end as shown in Figure 17a. A close up photo showing the broken strands of the dummy conductor is presented in Figure 17b.

iv. The test conductor (tensioned during Thermo-Mechanical Cycling Test) breaking load was at 46,089 lb which corresponds to 111.6% of conductor’s RTS. This breaking load was very close (within 1%) what was measured for the non-tensioned dummy conductor. This result indicates no degradation in strength of conductor, as tested, occurred as a result of the Thermo-Mechanical Cycling.

v. At the end of the Breaking Load Tests on both the Test and Dummy conductors, a ~4-6 mm movement was noticed at the compression dead-ends. Figures 18a and 18b show the movement of the compression dead-end connectors attached to dummy and test conductors, respectively. According to the manufacturer this movement is due to additional seating of the collet system under high load conditions. The test results indicate that the mechanical and electrical performance of the connectors was not affected by this movement.

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ZsP:PF:MK:AR:CP: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., 2013.

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Figure 1: High Temperature Compression Dead-end Connector Installed on ACCC “Dublin” Conductor

Figure 2a: Typical Test Setup for Thermo-Mechanical Cycling Test (Current Supply not shown)

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Figure 2b: Insulated Box for Thermo-Mechanical Cycling (Current Supply not shown)

Figure 2c: Photo of Tensioned Conductor and Dummy Conductor Installed in Insulated Box for Thermo-Mechanical Cycling

Test Conductor

Dummy Conductor

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Figure 3: AC Current Transformer and Variac

Figure 4: Jumper Terminal Used as Current Supply Connector

Jumper Conductors

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Figure 5a: Schematics of Test Setup for Breaking Load Test

Figure 5b: Photo of Test Conductor Installed in Tension Test Facility for Breaking Load Test (actual test sample)

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Figure 6 Typical Thermocouple Installations in Outer Layer of the Conductor

Figure 7 Schematic of Thermocouple Locations at Compression Dead-End Connector

Figure 8 Typical Thermocouple Installation in Dead-end Connector (at Electrical Crimp)

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Figure 9a: Typical Thermo-mechanical Cycle on Test Conductor before the First 70% RTS Loading

Figure 9b: Typical Thermo-mechanical Cycle on Dummy Conductor before the First 70% RTS Loading

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Figure 10: Steady-State Temperatures Measured along the Tensioned Test Conductor during Thermo-Mechanical Cycling Test

Figure 11: Steady-State Temperatures Measured along the Dummy Non-tensioned Conductor during Thermo-Mechanical Cycling Test

Insulation at North End was Temporary Removed

Insulation at North End was Temporary Removed

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Figure 12: Steady-State Temperatures of Tensioned Dead-end during Thermo-Mechanical Cycling Test

Figure 13: Steady-State Temperatures of Non-Tensioned Dead-end during Thermo-Mechanical Cycling Test

Insulation at North End was Temporary Removed

Insulation at North End was Temporary Removed

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Figure 14a: Condition of Test and Dummy Conductors after Thermo-Mechanical Cycling Test

Figure 14b: Close Up Photo of Test Conductor after Thermo-Mechanical Cycling Test

Dummy Conductor

Test Conductor

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Figure 14c: Core after Thermo-Mechanical Cycling Test (Close Up Photo)

Figure 15: Condition of Test Conductor prior to the Breaking Load Test

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Figure 16a: Dummy Conductor after the Breaking Load Test

Location of Failure

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Figure 16b: Dummy Conductor after the Breaking Load Test (close up photo)

Figure 17a: Test Conductor after the Breaking Load Test

Location of Failure

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Figure 17b: Test Conductor after the Breaking Load Test (close up photo)

Figure 18a: Connector Attached to Dummy Conductor after the Breaking Load Test

Conductor Movement

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Figure 18b: Connector Attached to Test Conductor after the Breaking Load Test

Conductor Movement

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APPENDIX A

DATA SHEET FOR 540 mm2 ACCC/TW “DUBLIN” CONDUCTOR RECEIVED FROM CTC GLOBAL

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

APPENDIX B INSTRUMENT SHEET

(Ref. Thermo-Mechanical Cycling Test on “Dublin”, ACCC/TW Conductor)

Test Description: Thermo-Mechanical Test on “Dublin”, ACCC/TW Conductor Test Start Date: April 16, 2013

Project Number: K-419506-0001 Test Finish Date: August 1, 2013

TEST DESCRIPTION

EQUIPMENT DESCRIPTION

MAKE MODEL ASSET # or

SERIAL # ACCURACY

CLAIMED CALIBRATION

DATE CALIBRATION

DUE DATE TEST USE

Thermo-Mechanical

Cycling Test

Data Logger National

Instrument PCI-6221 KIN-01698

±0.1% of Reading

July 20, 2012 July 20, 2013 Data Acquisition

Load Cell

Load Conditioner

Aries

Daytronics

FTU-B-172-60K( 60k lbs)

3170

17649-0

#10 162122-0

±1% of Reading

April 16, 2012 April 16, 2014 Tensile Load

Current Transformer

Flex Core 126-52 KIN-01559 ±0.3% FS June 28, 2012 June 28, 2014 Electrical Current

Current Transducer

Flex Core ACT-005-CX5 KIN-01270 - Sept. 19, 2012 Sept. 19, 2013 Electrical Current

Thermocouple Omega Type J (30AWG) KIN-01688 ±1% of Reading

Sept. 21, 2012 Sept. 21, 2013 Temperature

Thermocouple Omega Type J (30AWG) KIN-01685 ±1% of Reading

July 5, 2012 July 5, 2013* Temperature

Digital Caliper Mitutoyo CD-6” CSX KIN-00898 0.02 mm July 9, 2012 July 9, 2013 Conductor Diameter

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

November 30, 2012 November 30, 2014 Conductor Length

Breaking Load Test

Load Cell (MTS)

Conditioner

Lebow

MTS

3156 (100,000 lbs)

493.01DC

17356-0

KIN-01724

±1% of Reading

October 11, 2012 October 11, 2014 Conductor Tension

Data Logger National

Instrument PCI-6221 KIN-01836

±0.1% of Reading

January 11, 2012 January 11, 2014 Data Acquisition

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

November 30, 2012 November 30, 2014 Conductor Length

Temperature Transmitter

Thermocouple

Omega TX-13

Type T

KIN-00918

KIN-00919

±1% of Reading

September 15, 2012

September 15, 2014

Temperature

*1 month extension awarded

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APPENDIX C

KINECTRICS ISO 9001 QUALITY MANAGEMENT SYSTEM REGISTRATION

CERTIFICATE

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DISTRIBUTION Mr. Eric Bosze (2) CTC Global

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 5G5 Canada