Laboratory Testing of Aged Conductors and Groundwires

Craig J. Pon, Member, IEEE

1
Abstract – As overhead conductors and groundwires age
substantially beyond their respective design lives, there is
increasing pressure on owners of these assets to know
their present physical condition to help make decisions on
major capital expenditures. Physical assessment is the
only way of knowing the current condition of conductors
and groundwires with any degree of reliability and
accuracy. This discussion presents some laboratory tests
that have been used to assess the condition of conductors
and groundwires. It is beyond the scope of the discussion
to define end of life or remaining life.

I. INTRODUCTION

Many overhead transmission and distribution lines in North

America have far exceeded their design life. In fact, the Figure 1a: New, Unused 3/0 ACSR Conductor
oldest lines may be approaching twice their original design
life. Issues such as competition, reliability, availability,
system planning, public and worker safety among others, are
becoming increasingly important for owners of overhead
lines. Consequently, the desire to know the actual condition
of transmission and distribution line components is also
increasing. Conductors and groundwires are of primary
interest because their condition often drives the decision
whether to commit to, or possibly defer, multi-million dollar
capital refurbishment programs.

Figures 1a-b show two(2) 3/0 ACSR conductors. One is new

and has never been installed. The other was installed in 1939.
Although the surface condition of the 1939 conductor looks
as good as the new one, is it good enough to remain in-
service? Figure 1c shows a conductor installed in 1922. Figure 1b: 3/0 ACSR Conductor Installed in 1939
Although the surface condition has deteriorated, is it enough
reason to replace it?

There are some specialized devices that assess certain aspects

of conductors/groundwires in the field. Laboratory evaluation
can provide much more detailed information about the
condition of conductors/groundwires.

This discussion presents some laboratory test methods

available to assess the present condition of overhead
conductors and groundwires and to better understand their
aging processes. It is beyond the scope the discussion to
define end of life or remaining life.

Craig J. Pon is a Principal Engineer at Kinectrics, Inc, Figure 1c: 605 kcmil,54/7 ACSR Conductor Installed in 1922
Toronto, Ontario, M8Z 6C4, Canada. His email is
craig.pon@kinectrics.com.

0-7803-7519-X/02/$17.00 © 2002 IEEE

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 II. DETERIORATION OF STRENGTH
There are two(2) main mechanisms that will cause conductors
and groundwires to deteriorate due to natural aging processes.
1) Loss of Fatigue Strength due to wind-induced vibration
2) Loss of Tensile Strength due to corrosion
III. LABORATORY TESTS
Laboratory tests can provide detailed information on samples
of aged conductors/groundwires that cannot be obtained using
in-situ or analytical techniques. The information can be used
to:
i) requalify conductors/groundwires for a specified period
in the future
ii) help in the estimation of the remaining physical life of
conductors/groundwires
iii) help determine if opportunities to uprate lines exist
The tests provide information on different characteristics and
properties of the whole conductor/groundwire or of the
individual strands. The information from the tests contributes
directly or indirectly to an overall assessment relating to the
deterioration mechanisms or other end of life criteria.
Any given test may or may not provide information that leads
to definitive conclusions. However, when the data from
several tests are taken together, more reliable interpretations
of the present condition of the conductor/groundwire can be
made.
The following tests, analyses and examinations can be
performed in the laboratory. Other tests not listed may also
provide useful information.
i) Aeolian Vibration Endurance Test
ii) Galloping Endurance Test
iii) Sheave Passing Test
iv) Torsional Ductility Test
v) Tension and Elongation at Failure Test
vi) Creep Test
vii) Remaining Zinc Test
viii) Wrap Test
ix) Visual Analysis
x) Electrical Resistance Test
xi) Metallurgical Examination
xii) Chemical Analysis
xiii) Accelerated Corrosion Test
The results of some tests can be referenced to either new,
unused samples of similar construction or to industry
standards. If the assessment program has been in place for a
sufficient period of time, the results can also be compared to
the results of previous tests to estimate the rate of
deterioration.
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i) Aeolian Vibration Endurance Test
It is possible to estimate the history of aeolian vibration at
specific locations on a line by taking filed measurements
using line vibration recorders. If vibration levels are below
recognized safe levels, then loss of fatigue strength of the
aluminum strands is unlikely. If vibration is detected above
safe levels, then an estimate of remaining fatigue life can be
made. Vibration dampers are normally used to reduce
vibration activity to safe levels.
If a laboratory assessment of the remaining fatigue strength is
pursued, an Aeolian Vibration Endurance Test can be
performed to requalify aged conductor/groundwires. IEEE
Std 1138-1994 “IEEE Standard Construction of Composite
Fiber Optic Overhead Ground Wire (OPGW) for Use on
Electric Utility Power Lines” describes a test method. They
are subjected to aeolian vibrations for a specified number of
cycles at a specified severity that may be experienced in a
specified future period. If the conductor/groundwire survives
this test without fatigue damage, then it can be requalified for
that specified time.
The sample used for these tests should be performed with the
suspension clamp or other hardware still installed and
undisturbed on the cable from the time of removal. Fatigue
cycles imparted during the test will be added to the fatigue
cycles accumulated in the field.
ii) Galloping Endurance Test
Galloping can also cause damage to the aluminum strands
through low cycle, high amplitude fatigue. However, unlike
aeolian vibration, quantitative field measurements are much
more difficult to obtain because of the randomness of the
event.
A Galloping Endurance Test can be approached in a similar
manner as for aeolian vibration. IEEE Std 1138-1994 “IEEE
Standard Construction of Composite Fiber Optic Overhead
Ground Wire (OPGW) for Use on Electric Utility Power
Lines” describes a test method for galloping.
iii) Sheave Passing Test
A Sheave Passing Test can verify the ability of the aged
conductor/groundwire to withstand passing over a sheave a
number of times without undesirable damage to the
conductor. Some utilities use the existing conductor or
groundwire to pull in the new cable. It is important that the
outside strands of the existing conductor/groundwire pass
through the sheaves without breaking. Broken strands will
separate from the body of the conductor and get entwined in
the sheaves resulting in costly delays. Added confidence
about the good condition of the cable can be obtained by
performing this test after the vibration test. In either case, the
section of cable under the suspension clamp, other hardware
attachment points or where corrosion may be more advanced
should be passed over the sheave. IEEE Std 1138-1994
“IEEE Standard Construction of Composite Fiber Optic
Overhead Ground Wire (OPGW) for Use on Electric Utility
Power Lines” describes a test method for sheave passing.

iv) Torsional Ductility Test

The Torsional Ductility Test can either requalify the

conductor/groundwire for a specified period of time or
identify it as a candidate for replacement. The test method is
based on ASTM A938-1997 “Standard Test Method for
Torsion Testing of Wire” and was originally applied to
groundwires. It relates the number of turns to failure to a
subjective assessment of the degree of corrosion on steel
strands. Threshold numbers are used to make an assessment
about what future action should be taken. Use of the data
from this test is based largely on experience. The test has also
been used to assess the steel strands of ACSR conductors. Figure 2a: 5/16”, 7 Strand Galvanized Steel Groundwire
(Avg turns to Failure –31.2, Tensile Strength– 108.5% RTS)
Figures 2a-b show two(2), 5/16”, 7 strand galvanized steel
groundwires. The groundwire is shown intact at the bottom of
each photo and shown with the strands separated at the top of
the photo. The strands in Figure 2a look in much better
shape than those in Figure 2b. The centre strand, without
helix, is almost always in better shape than the six(6) outer
strands and usually fails at a higher value. For this reason, the
centre strand is tested but not included in the analysis. The
average number of turns to failure of the six(6) strands, not
including the centre strand, was 31.2 for the ground wire in
Figure 2a and 2.8 for the groundwire in Figure 2b.

v) Tension and Elongation at Failure Test

The Tension Test is used to assess the remaining tensile

strength of the whole conductor/groundwire or of the
individual strands. The test method is based on ASTM E8-01
“Standard Test Methods for Tension Testing of Metallic
Materials”. This test is quite useful because it is quite simple
yet provides the most information directly related to the
tensile strength in relation to design or actual field loads.
Knowledge of the elongation of the strand at failure can help
determine if the strand material has become more brittle or
ductile over time.
The tensile strength of the groundwire calculated by adding
the breaking strength of the individual strands including the
centre strand was 108.5% of the RTS for the groundwire in
Figure 2a and 94.8% for the groundwire in Figure 2b.
vi) Creep Test
Creep Tests can be used to determine how much creep can be
expected in future years. The test method is based on the
Aluminum Association-1971, “A Test Method for
Determining the Long Term Tensile Creep of Aluminum
Figure 2b: 5/16”, 7 Strand Galvanized Steel Groundwire
(Avg turns to Failure –2.8, Tensile Strength– 94.8% RTS)
Conductors in Overhead Lines” or IEC 61395-1998
“Overhead Electrical Conductors – Creep Test Procedures
for Stranded Conductors”. The test can be performed at room
temperature, at elevated temperatures and/or at varying
tensions. This test may provide useful information if the line
is being considered for uprating.
vii) Remaining Zinc Test
An estimate of the remaining zinc on steel wires of ACSR
conductors and groundwires is possible in-situ using a
specially designed device.
If more detailed information from laboratory testing is
required, the Remaining Zinc Galvanizing Test can be
performed using ASTM A90/A90M-01 “Standard Test
Method for Weight(Mass) of Coating on Iron and Steel
Articles with Zinc or Zinc-Alloy Coatings” on individual zinc
galvanized steel strands. The remaining zinc is removed from

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the strand and weighed. The average thickness of zinc that
remained on the strand can then be calculated. The quantity
of remaining zinc can be compared to the values specified by
ASTM B498/B498M-98 “Standard Specification for
Aluminum Steel Core Wire for Aluminum Conductors, Steel
Reinforced” or to previous measurements to estimate the rate
of deterioration.
viii) Wrap Test
The Wrap Test can be performed to verify the adherence of
the zinc coating on the steel strand. The test is performed to
ASTM A475-98 “Standard Specification for Zinc-Coated
Steel Wire Strand”. The zinc galvanized strand is wrapped at
least twice around a mandrel 3 times the nominal diameter of
the strand under test. Cracking or flaking of the zinc would
indicate loss of adhesion.
ix) Visual Examination
A Visual Examination of the surface condition of the whole
conductor/groundwire and the individual strands is a good
indicator of their general condition. Observations of how any
corrosion products accumulate within the conductor cross-
section and along its length can be instructive. They can also
serve as an indicator of what to expect for other tests.
x) Electrical Resistance Test
The Electrical Resistance Test can be performed to determine
and verify the current carrying capability of the conductor.
The resistance of the conductor of the conductor can be
compared to that of a new conductor and/or to ASTM
B232/B232M-01e1 “Standard Specification for Concentric
Lay Stranded Aluminum Conductors, Coated-Steel
Reinforced”.
An excessive increase in the resistance of the conductor may
indicate that its current carrying capacity may be reduced.
This may be useful information for corroded conductors.
xi) Metallurgical Examination
The objective of Metallurgical Examinations is to compare
the microstructure and microhardness of aged strands to new
strands.
xii) Chemical Analysis
Chemical Analysis can be performed to constituent elements
in aged strands to those specified in standard specifications.
The presence and concentrations of airborne pollutants can be
ascertained if they are part of the corrosion products.
xiii) Accelerated Corrosion Test
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Accelerated Corrosion Tests can be useful to help determine
the remaining life of conductors/groundwires. By subjecting
aged conductors/groundwires to a standard set of controlled
corrosion conditions, the aging or deterioration process can be
accelerated to a condition of the conductor/groundwire that is
defined as end of life. It is necessary to relate the standard
corrosion condition in the laboratory to actual corrosion
conditions in the field. If this can be done then it would be
possible to relate the time to the end of life in the laboratory to
the end of life in the field. Standard test conditions specified
by ASTM B117-97 “Standard Practice for Operating Salt
Spray (Fog) Testing Apparatus” and EIA/TIA Std 455-16A
“Salt Spray (Corrosion) Test for Fibre Optic Components”
have been used.
V. LABORATORY TESTS AND REMAINING LIFE
Laboratory testing provides information on the present
physical state of a conductor/groundwire. Input of this
information into suitable models can provide an estimate of
remaining physical life. However, this will probably not be
the final determining factor when it is actually replaced. An
asset management program that considers many issues such as
public and worker safety, competition, reliability, availability,
system planning, availability of capital among others will
ultimately decide when to replace a conductor.
VI. CONCLUDING COMMENTS
1. When appropriate, laboratory tests can provide much
more detailed, quantitative and reliable information on
the condition of conductors/groundwires than
conventional inspection techniques.
2. Interpretation of laboratory test results for determining
remaining physical life is still evolving.
3. Laboratory inspections of conductor/groundwire are
location specific. Prudent selection and sampling criteria,
can identify line sections with the highest probability of
conductor/groundwire deterioration.
4. As well as determining if a conductor/groundwire is in
bad condition, laboratory tests can also verify the good
condition of a conductor/groundwire. This can lead to
confidence that the conductor/groundwire can remain in-
service for longer than might be expected.
Craig J. Pon (M) received his B.A. Sc. and M. Eng. degrees in Mechanical
Engineering from the University of Toronto in 1979 and 1989, respectively.
He began his working career in 1979 with the Research Division of Ontario
Hydro. He is currently a Principal Engineer with Kinectrics, Inc., a successor
company of Ontario Hydro. He is involved with mechanical testing and
assessment of transmission and distribution line components. He also is
involved with testing fibre optic cables and accessories. He has been a
member or chairman of several IEEE WG’s including WG on Overhead
Conductors Dynamics and the WG on Fibre Optic Standards.