ROOM TEMPERATURE SUSTAINED LOAD TEST ON 1572 KCMIL BITTERN ACCC/TW CONDUCTOR FOR COMPOSITE TECHNOLOGY CORPORATION

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1 To: Mr. Dave Bryant Composite Technology Corporation 2026 McGaw Avenue Irvine, CA USA ROOM TEMPERATURE SUSTAINED LOAD TEST ON 1572 KCMIL BITTERN ACCC/TW CONDUCTOR FOR COMPOSITE TECHNOLOGY CORPORATION Kinectrics North America Inc. Report No.: September 9, 2005 C.J. Pon, M.J. Kastelein, M. Colbert 1.0 INTRODUCTION A Room Temperature Sustained Load Test was performed on a sample of inch (34.17 mm), 1572 kcmil, Bittern Aluminum Conductor, Composite Core/Trapezoidal Wire (ACCC/TW) conductor for Composite Technology Corporation (CTC). The conductor consists of a single composite glass and carbon fiber core covered by 3 layers of 39 annealed, trapezoidally-shaped aluminum alloy wires. The composite core is manufactured by CTC and the conductor is stranded by General Cable. The specifications for the conductor are shown in Appendix A. The test was performed September 2-9, 2005 by Kinectrics North America Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4, Canada under CTC Purchase Order No TEST OBJECTIVE AND STANDARD The objective of the test was to verify the room temperature sustained load carrying capability of the full tension compression deadend clamps for the 1572 kcmil ACCC/TW conductor. The outer aluminium sleeves were supplied by FCI/Burndy. The FCI/Burndy catalogue number for the complete deadend is YTW52REACCC. This is a special design for CTC s Composite Conductor. The internal steel components were supplied by Composite Technology Corporation. The CTC catalogue numbers for the internal components for the Bittern conductor are Eyebolts , Housings and Collets The test was carried out according to ANSI C , Paragraph 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

2 3.0 TEST SET-UP A compression deadend clamp was installed on each end an ACCC conductor sample. Mr. Peter Chan of FCI/Burndy supervised the installation of the deadend clamps at Kinectrics. The test set-up is shown in Figures 1 and 2. The sample was installed in a hydraulicallyactivated horizontal test machine. The distance between the pulling eyes of the compression clamp was about 46.2 ft (14.08 m). The length of exposed conductor between the clamps was 42.4 ft (13.23 m). Instrumentation The MTS equipment associated with the load cell # that monitors the load and controls the load rate was last calibrated on March It is due for calibration May TEST PROCEDURE A test machine having a load accuracy of ± 2% was used for this test. The tension in the sample was increased at a rate of 2,15 lbf/min (955 kgf/min) to 31,570 lbf (14,320 kgf) or 77% of the rated tensile strength (41,000 lbf, 18,597 kgf) of the 1572 kcmil conductor. The tension was maintained at this load for 168 hours. The temperature of the sample was approximately 20 o C±2 o C during the test. On completion of the sustained load test the sample was unloaded and then the tension was increased at a rate of 8,200 lbf/min (3,719 kgf/min) until failure occurred. 5.0 TEST RESULTS The conductor/deadend system failed at 44,315 lbf (20,101 kgf) or 108.1% of the rated tensile strength (RTS) of the conductor. The conductor core failed about 11 inches inside the south deadend clamp. The failure is shown in Figure ACCEPTANCE CRITERIA To qualify under the ANSI standard, a connector must hold 77% of the conductor s rated breaking strength (RBS) for seven days (168 hours) without failure. At the end of the sustained load period, the residual tensile strength must exceed 95% of the conductor RTS. 2

3 7.0 CONCLUSION The 1572 kcmil ACCC/TW deadend clamp met the requirements for the room temperature sustained load test as specified by ANSI C Prepared by: M. Kastelein Technical Specialist M. Colbert Technical Specialist C.J. Pon Principal Engineer Approved by: Dr. J. Kuffel General Manager MJK:MC:CJP:JC DISCLAIMER KNAI has taken reasonable steps to ensure that all work performed meets industry standards as set out in KNAI 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.,

4 Compression Deadend Hydraulic Cylinder Load Cell ACCC/TW Conductor Gauge length Displacement Transducer Cylinder Mount Fixed to Strong Floor Stationary End Fixed to Strong Floor Data Aquisition System Figure 1 Set-Up for the Room Temperature Sustained Load Test Figure 2 Test Sample Installed in Horizontal Test Facility 4

5 Figure 3 Conductor and Compression Deadend Clamp after Tensile Failure at South End 5

6 APPENDIX A DATA SHEET FOR COMPOSITE TECHNOLOGY CORPORATION BITTERN 1572 KCMIL ACCC/TW CONDUCTOR A-1

7 A-2