This is an unapproved Kinectrics International Draft Report, subject to change D R A F T DRAFT

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1 This is an unapproved Kinectrics International Draft Report, subject to change To: HES Hacilar Electrik San. Ve Tic. Erciyes Mah. HES Cad. No: Hacilar, Kayseri Turkey 1.0 INTRODUCTION D R A F T KINECTRICS INTERNATIONAL INC. TEST REPORT FOR HES HACILAR ELEKTRIK SAN. VE TIC. (Ref. Stress-Strain Test on PHEASANT ACSR Conductor) Kinectrics International Inc. Report No.: December 22, 2009 C. Dimnik Transmission and Distribution Technologies Business 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 mm and is designated 1272 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, 2009 by Kinectrics North America Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4, Canada according to Kinectrics Quotation DIM R02 dated October 1, 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. Page 1 of 20

2 This is an unapproved Kinectrics International Draft Report, subject to change 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 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 m in length was terminated using epoxy-resin dead-ends. A steel core sample 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. Page 2 of 20

3 This is an unapproved Kinectrics International Draft Report, subject to change 4.0 TEST PROCEDURE The conductor was subjected to the loading schedule outlined in IEC 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 3,054 kg/minute (6,732 lb/minute). This is based on achieving 30% of RTS in two (2) minutes. Whole Conductor RTS= 20,357 kgf Step % RTS kgf lbf Hold (minutes) preload 2% % 6,107 13, % % 10,179 22, % % 14,250 31, % % 17,303 38, % 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 4,071 kg/minute (8,976 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 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 3,054 kg/minute lb/minute). (6,732 Page 3 of 20

4 This is an unapproved Kinectrics International Draft Report, subject to change Whole Conductor RTS= 20,357 kgf Whole Conductor Elongation, mm kgf lbs Hold (minutes) Step preload 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 stressstrain data while loading up to 30% RTS it was calculated that the corrected strain at preload was % for the conductor and % 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 PHEASANT ACSR conductor showing the plots for the whole conductor, the aluminium layers, and the steel core. The area of the conductor was mm 2 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 72,973 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 187,471 MPa. The MOE for the steel core (based on the area of the whole conductor) is approximately 21,077 MPa. Page 4 of 20

5 This is an unapproved Kinectrics International Draft Report, subject to change 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 60,779 MPa. The MOE for the aluminum layers (based on the area of the whole conductor) is approximately 53,946 MPa. The whole conductor failed at 22,286 kgf or 109.5% 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 = AX 3 +BX 2 +CX+D This equation is generated from a 3 rd 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 PHEASANT ACSR Whole Conductor Whole Conductor Polynomial Coefficients (MPa) A= E+08 B= E+06 C= E+04 D= E-01 Final Modulus of Elasticity MPa (before Knee-point) ** The knee-point is extracted from the 85% unloading curve. The R-squared value for this curve-fit was R 2 = Estimated Knee-point Load kn ** Breaking Load kgf 72, ,286 Table 2 Summary of Stress-Strain Test Results for PHEASANT ACSR Steel Core Steel Core Polynomial Coefficients (MPa) Final Modulus of Elasticity (based on area of Steel Only) MPa Final Modulus of Elasticity (area corrected for Consolidated Conductor) MPa A= E+07 B= E+05 C= E+04 D= E ,471 21,077 The R-squared value for this curve-fit was R 2 = Page 5 of 20

6 This is an unapproved Kinectrics International Draft Report, subject to change Table 3 Summary of Stress-Strain Test Results for PHEASANT ACSR Aluminum Layers Aluminum Polynomial Coefficients (MPa) Final Modulus of Elasticity (based on Area of Alum Only) MPa Final Modulus of Elasticity (area corrected for Consolidated Conductor) MPa A= E+08 B= E+06 C= E+04 D= E-03 60,779 53,946 The R-squared value for this curve-fit was R 2 = ACCEPTANCE CRITERIA As stated in IEC and BS EN 50182:2001, there are no acceptance criteria for the Stress- Strain test. As stated in IEC 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 and BS EN 50182:2001. Page 6 of 20

7 This is an unapproved Kinectrics International Draft Report, subject to change Prepared by: C. Dimnik Engineer Transmission and Distribution Technologies Business Reviewed by: C.J. Pon Principal Engineer Transmission and Distribution Technologies Business 2009 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., Page 7 of 20

8 This is an unapproved Kinectrics International Draft Report, subject to change Epoxy Deadend Page 8 of 20 Cylinder Mount Fixed to Strong Floor Hydraulic Cylinder Load Cell ACSR ACS Conductor Displacement Transducer Gauge length Data Aquisition System Figure 1 Set-up for Stress-Strain Test Stationary End Fixed to Strong Floor

9 Figure 2 Photo of Typical Test Sample Installed in Stress-Strain Test Facility. Page 9 of 20

10 Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor) 180 Page 10 of 20 Conductor Tension, kn kn Knee Point % 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, % Figure 3a Load (tension) vs. Conductor Strain

11 Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor) 80 Page 11 of 20 Core Tension, kn % 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, % Figure 3b Load (tension) vs. Steel Core Strain

12 Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor) Page 12 of 20 Conductor Stress, MPa %, MPa Conductor area = mm² %, MPa %, MPa %, MPa % 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% Conductor Strain, % Figure 4a Stress vs. Conductor Strain for Only Those Points That Contribute to the Stress-Strain Curve

13 Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor) Page 13 of 20 Core Stress, MPa %, MPa Conductor area = mm² %, MPa %, MPa %, MPa % 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% Core Strain, % Figure 4b Stress vs. Steel Core Strain for Only Those Points That Contribute to the Stress-Strain Curve

14 Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor) 250 Page 14 of 20 Stress, MPa Conductor area = mm² Core Area = mm² Final Steel % 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% Unit Strain, % Initial Steel Initial Composite Figure 5 Composite Stress-Strain Curve Final Composite Initial Aluminum Final Aluminum

15 APPENDIX A DESCRIPTION OF HES HACILAR ELEKTRIK SAN. VE TIC. CONDUCTOR (Ref mcm, mm 2, PHEASANT ACSR Conductor) Page 15 of 20

16 CONDUCTOR PROPERTIES CONDUCTOR PHEASANT 1272 MCM Stranding Direction Right Conductor OD mm Total Cross Section mm² Construction 1(St)+6(St)+12(St)+12(Al)+18(Al)+24(Al) Conductor Weight kg/km Conductor Tensile Strength kgf 20,357 Aluminum Cross Section mm² Aluminum Weight kg/km Steel Core Diameter mm 11.7 Steel Core Cross Section mm² Steel Core Weight kg/km A.C. Resistance at 25 C, 50 Hz ohm/km Xa at 50 Hz ohm/km X'a at 50 Hz Megaohm.km GMR 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 Tensile Strength(min) kg/mm² 16.5 DC Resistivity at 20 C (Max) n.ohm.m 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 128 Zinc Coating Weight g/m² 230 Page 16 of 20

17 Page 17 of 20 ISO-9001 Form: QF11-1 Rev 0, APPENDIX B INSTRUMENT SHEET HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor) Test Description: Stress-Strain Test Test Start Date: December 3, 2009 Project Number: K Test Finish Date: December 4, 2009 TEST DESCRIPTION Stress-Strain Test EQUIPMENT DESCRIPTION Datalogger Load Cell (MTS) Load Cell Conditioner Displacement Transducer Conditioner MAKE MODEL ASSET # or SERIAL # National Instruments PCI-6036E - B Lebow MTS Ametek Trans-tek DC PT-10AT-HT F KIN PWP #2 Measuring Tape Stanley FatMax (34-813) KIN Digital Meter Thermocouple Fluke Fluke 51 TC-K ACCURACY CLAIMED CALIBRATION DATE CALIBRATION DUE DATE TEST USE ±0.1% of Reading June 25, 2009 June 25, 2010 Data Acquisition ±1.0% of reading May 29, 2009 May 29, 2010 Stress Strain, Breaking Load ±0.1 mm October 7, 2009 October 7, 2010 Cable Strain KIN < 0.05% of Reading October 2, 2008 October 2, 2010 ±0.9 degree C ±0.5 degree C March 18, 2009 March 19, 2009 March 18, 2010 March 19, 2010 Cable and Gauge Length Cable Temperature

18 APPENDIX C KINECTRICS ISO 9001 QUALITY MANAGEMENT SYSTEM REGISTRATION CERTICATE Page 18 of 20

19 Page 19 of 20

20 DISTRIBUTION Mr. Asim Mercan (2) HES Hacilar Elektrik San. Ve Tic. Erciyes Mah. HES Cad. No: Hacilar, Kayseri Turkey Telephone: C. Dimnik (1) Transmission and Distribution Technologies KB223 Page 20 of 20