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Abstract - This paper describes field and laboratory tests of ACSR province wide field sampling and testing in both the laboratory and
conductors and related line items from many of Ontario Hydro's the field, has been completed1. The findings, conclusions and
older transmission lines. A non-destructive corrosion detector was recommendations of this program have been used to develop Ontario
modified for live line measurement of the loss of galvanizing from Hydro's tactical plan2 for refurbishment of old transmission lines and
the steel cores of the ACSR conductors. Samples of conductors are described here and in the companion paper'. Figure 1 shows the
tested in the field have also undergone laboratory metallurgical scope of the definition phase program. ·
investigation, and tests of fatigue, tensile strength, torsional ductility
and electrical performance. Extensive environmental studies
identified corrosion products of ACSR conductors, the atmospheric I DEANITION PHASE REFURBISHMENT PROGRAM
~
.
CORROSION
the torsional ductility tests serve as a more precise condition SURVEY VISUAL EXAMINATION· 1 u:aLTS 7
indicator and can provide a guide for scheduling conductor I I ~I I
I 11 CONDUCTOR
CORROSION
ENVIRONMENTAL
STUDIES PRODUCTS JC!NTS
replacement. Test results and details of their interpretation are given
~
I AND PROCESSES
I
in the companion paper "Aged ACSR Conductors, Part II - ,I
~l J
FATIGUE IIN SUL.ATORS
AIR
POLLUTANTS TEST
Prediction of Remaining Life". T STEEL
ENVIRONMENTAll
CORROSION
TORSIONAL
DUCTILITY
I SCANNING
STRUCTURES
operating at 115 kV, have exceeded their forecasted mean useful life. I ONT ARIO HYDRO TACTICAL PLAN
The major consequences of decreased reliability of aged lines are
reductions in: system operability and maintainability; supply Fig. 1. Scope of the definition phase of the pverhead line
reliability; and public safety. refurbishment program.
The principal supply reliability consequence of the poor
performance of older lines is the increased potential for more ACSR CONDUCTOR TESTING
frequent and longer duration customer supply interruptions. Early
studies showed that non weather related outages on 115 kV lines In-situ Detection of Steel Core Galvanizing Loss
increased from less than 1 per year per 100 cct km for 10-30 year
old lines, to between 3 and 5 on 70-80 year old lines 1• The primary For ACSR conductors, the degradation begins as a loss of
safety risks to the public are from the increased probability of falling zinc from the galvanized steel core wires. This loss can be detected,
conductors, increased exposure to step and touch potentials as a non destructively, using the overhead line conductor corrosion
result of more frequent ground faults, and increased incidences of detector4, as shown in Figure 2. Loss of galvanizing is detected and
inadequate electrical clearances due to outmoded design practices, quantified by an eddy current sensor built into a radio-controlled.
encroachment and increased. sags, due to ice loads and possibly motorized electronic package that can travel along the conductor
conductor creep. Recognizing the importance and the scale of the
work involved. and the need to improve our knowledge on the aging
of transmission lines, a comprehensive three year program, including
836
Fatigue Tests on Old Conductors
ALUMINUM WIRES
OUTER LAYER INNER LAYER To evaluate the remaining fatigue life of conductors, seven
samples from the Guelph, Smiths Falls, Oakville and Otiawa areas,
BREAKING TENSILE BREAKING TENSILE
along with one new conductor were tested under fatigue loading9.
LOAD STRENGTH LOAD STRENGTH
The typical arrangement for the fatigue tests is shown in Figure 3.
N kPa N kPa The fatigue test conditions, the vibration amplitude, frequency and
lb ksi lb ksi the total number of loading cycles, were chosen to provide vibration
LOW 796 140 756 133
exposure equivalent to that of 50 years in service life. The test
179 20.3 170 19.3 frequency averaged about 60 Hz and up to about 108 cycles at strain
levels up to 425 x 10·• were applied. At the end of each test, the
HIGH 979 172 854 150 conductor was visually checked for any damage and fracture.
220 25.0 192 21.8
Except for one conductor sample from the Guelph area, which failed
at about 15.6 million cycles at an average strain level of 413 x ur•,
AVE. 863 152 814 143 all samples withstood the fatigue loading without any apparent
194 22.0 183 20.8 physical damage. Both of the samples from Guelph had been
significantly damaged due to corrosion prior to the test. It was
TOTAL 15532 9772 concluded that the life of a conductor will be significantly reduced
3492 2197 only if it is damaged by atmospheric corrosion due to some kind of
pollution source. A detailed analysis of the fatigue process is given
Aggregate Breaking Load (at 1% elong'n): 53.46 kN (12019 lb) in the companion paper.
Rated Brea.king Strength: 76.03 kN (17050 lb)
Metallurgical Analysis
Notes: Examination of the conductor sample showed that the outer
and inner aluminum wires are covered by a heavy contaminate. Microstructural evaluations were performed on transverse
However, these wires are in good condition. The outer steel sections from hot dip galvanized CSA 040.21 grade 330 above
reinforcing wires contain moderate to severe rust and pitting. The ground structural steel L-sections, ASTM B498 class A zinc coated
galvanizing on the core wire has partially oxidized. The aggregate steel conductor core wires and from ASTM B230 aluminum
breaking strength of the conductor is 30 per cent below the rated conductor wires'°. Samples of each were obtained following 61 to
breaking strength. The torsional ductility of the steel reinforcing 69 years of in-service exposure to rural, semi-rural and
wires is poor. Due to the degree of corrosion present on the outer urban-industrial Ontario environments. Corrosive action on the
steel reinforcing wires and the poor ductility characteristics the structural steel zinc coatings produced a predictable pattern in which
conductor is not considered to be mechanically reliable. total loss occurred only in areas of relatively high surface-to-mass
ratio, i.e external corners. Elsewhere remaining zinc coverage in the
The results of the tests show that the conductor age is only three zones of exposure averaged 0. 30 mm, 0.125 mm and 0.005 mm
one of several factors which determine their condition.. Manufactur- respectively. In no case was there significant damage to underlying
ing irregularities and local conditions are also important in steel. However, in zones of more severe exposure the structural
determining service life. Because these factors can interact, final members had been painted at some time. Corresponding residual
assessment of a conductor remaining life often requires careful visual zinc coverage values for conductor core wires are 0.051 mm, 0.033
examination, as well as careful analysis of the strength and the mm and zero mm respectively. Aluminum conductor wires suffered
torsional ductility tests. As described in detail in the companion corrosion pitting damage. The rural, semi-rural and urban-industrial
paper, these torsional ductility tests provided the most sensitive exposures produced maximum pit depths of zero, 0.060 mm and
indicator of conductor refining life. The data from a sample 0.115 mm respectively. Figures 4 and 5 illustrate median surface
conductor test report are presented in Table 1. conditions for steel core and aluminum conductor wires.
CONDUCTOR
rDEADENO ASSEMBLY
I
SHAKER
ELECTROMAGNET!~
i-----17.7m (58ft)
-1- - 17.7m (58fl)---
LffiEl:ill.
TC = THERMOCOJPLE
SG = STRAIN GAUGE i----------- 35.4m (116ft) - - - - - - - - -
A =ACCELEROMETER
837
Fig. 4. Residual zinc coating on a conductor steel core following Fig. 5. Surface corrosion pitting of an aluminum conductor wire
semi-rural exposure (x HlO). following semi-rural exposure (x 100).
A variety of analytical methods were employed to identify the Electrical Tests on 115 kV Conductor Joints
corrosion products of the conductor samples collected from three
sites: Port Colborne, Guelph and Smith Fallsu. X-ray fluorescent Seven compression-sleeve joints and two samples of
analysis supported presence of amorphous products on the surfaces conductor were removed for electrical testing from 115 kV circuits
of the aluminum and galvanized steel wires of each sample. X-ray that were built in the Guelph area around 191013 • It is uncertain how
diffraction analysis of the surface layers scraped from the inner and many joints are originals since the sleeve design and method of
outer aluminum and galvanized steel wires identified the crystalline crimping vary. ·Joints collected from the field included a 2 metre
structures. The presence of fluoride, chloride, nitrate and sulphate length of conductor at each end to facilitate electrical testing.
in the loose deposit on the outer aluminum wires from Port Colborne Several metres of additional, but physically detached, conductor were
was . determined by ion chromatography. Scanning electron also collected from the field at the same time for use as the
microscopy indicated thicker corrosion product layers on the surfaces reference conductor. While the initial objective was 10 measure only
facing the ambient atmosphere. The presence of FeO(OH) on the the DC resistance of each joint/conductor combination, a heat-run
galvanized steel wires from Guelph confirmed failure of the zinc test at rated current and zero tension was also made. Testing under
coating. In contrast, hydroxide and carbonate products on galvanized full tension is preferred but the cost is prohibitive. Each test
steel wires located in Port Colborne and Smith Falls, respectively, assembly was fitted with four thermocouples; one attached to the
are stable at near-neutral pH and are known to be passivating. These centre of the joint, one at each joint-end, and the fourth to the
passivating layers have offered significant protection against conductor. A thermocouple was also attached to the reference
corrosion since the respective ages of the Guelph, Port Colborne and conductor to provide a true reference temperature beyond the
Smith Falls conductors are 46.9, 64 and 60.8 years and yet negligible influence of the joint.
corrosion was observed for the Smith Falls sample. Studies on the
atmospheric corrosion of ACSR conductors indicate that more Tests were conducted at three different current levels
complete environmental data are necessary to determine atmospheric corresponding to various daily load conditions for the transmission
corrosivities of locations across Ontario. A brief field study 12 was line. The test currents were kept constant until the reference
conducted to determine the air quality, including: suspended particle conductor temperature stabilized, at which point the final joint
chemistry, SO2 concentration in air, precipitation, fog chemistry, and temperature was measured and the current turned off. After this
meteorological conditions such as: temperature, relative humidity, period joint temperatures had not always reached equilibrium but
and wind speed and direction, at sites in Etobicoke, Port Colborne, were close enough to determine if thennal runaway was imminent.
Guelph and Smith Falls. The key environmental parameters· are One to three hours was usually adequate since the thermal time
shown in Table 2. The results of this study were used to develop an constant of the joints averaged about 1.3 hours, at 130 amperes in
environmental corrosion index described in the companion paper. still air. The results of the DC resistance measurements correlate
reasonable well with the results of the heat-run tests. A joint resist-
ance higher than the conductor resistance generally results in a
higher joint temperature rise under load, although the relative
Table 2. Key Environmental Parameters
temperature rise is not always predictable from resistance
measurements. This is probably because a resistance measurement
Location is an average of the whole joint resistance while the temperature rise
can be localized at one spot due to a local high resistance.
Corrosive Etob- Pon Guelph Smiths Threshold
Agent icoke Colbome Falls Value
Suspension Clamps
sot** 9.35 8.34 3.3 2.45 4.1
Three designs of suspension clamp were evaluated from five
c1· ** 0.57 0.66 0.34 0.41 0.33
old line sections14. The clamps, and other hardware, removed from
NH,.** 1.28 0.63 0.61 0.47 0.59 these line sections were examined for physical and electrical damage,
defects, wear, corrosion and annealing. The suspension clamps were
SO2 (ppb) 3.95 8.15 3.61 0.87 4.9
mechanically loaded to simulate service loading. For this test a rigid
Ca2• * 3.05 1.01 7.63 0.3 0.74 rod replaced the conductor in the suspension clamp. The breaking
strength tests were performed on a 53.4 kN (12000 lb) capacity
Corrosion 5 5 3 I universal testing machine. Visual examination of the suspension
Index clamps showed that they are partially or fully rust covered but do
:suspenoeu arucles [µgtm'J. n Prec1p11auon (mg/LJ not contain any significant wear. Tests results show that the average
breaking strength of suspension clamps of all three designs is at least
as high as the rated strength of the suspension insulators. The
838
clamps show no significant wear and could remain in service for an leg integrity monitor to determine the extent of corrosion present;
indefinite length of time. visual inspection of grillage steel just below ground level; and
occasional detailed inspection by excavation down to the grillage
pad.
General surveys of towers on lines to be reconductored in This paper is based on studies carried out by a large number of
Southern Ontario were made to assess extent of steel corrosion and Ontario Hydro staff from Design and Development - Transmission,
to determine the work required to extend their life by 40-60 years15• Power System Operations, Research, System Planning, and
Considering their age, the structures surveyed were in good condition Transmission Operation Divisions, and the Regions Branch. The
with only superficial evidence of corrosion. Some towers that had authors would particularly like to recognize the contributions of:
been painted still had an intact red oxide primer coat even though D.E. Amm, M.K. Bissada, C.G.Fajardo, D.E. Horrocks, A. Kalvins,
the finish coat had weathered away almost completely. Overall J.R. Meale, F.X. Macedo, O.T. Melo, J.L. Phillips, D.J. Ryan,
rusting was evident on one line. However the oxide layer appeared G.A. Subject, M. Tabatabai, J.P. Toneguzzo, B.W. Warkentin, and
dense and tightly adherent and pitting or other metal loss was not R.W. Wolfendale,
apparent. Above ground tower angles were generally in excellent
condition on a line· in Eastern Ontario. A predictable pattern of zinc References
loss was discerned but the towers would have survived for at least
a further 25 years. 1) D.E. Amm, D.G. Havard, D.E. Horrocks, D.J. Horrocks, F.X.
Macedo, 'Development of a high voltage transmission line
Several towers, built in 1911 and 1928, were field tested to refurbishment program at Ontario Hydro", CIGRE paper No.
destruction under simulated design loads. That testing program has 22-201, 1990.
been documented in an earlier paper15• In general it was found that
these older towers had not deteriorated significantly in the Ontario 2) "Ontario Hydro transmission line refurbishment plan", Task
environment and could be reused and upgraded for future system Group Report - Part I. Summary and Recommendations, July
requirements. 1990.
Foundation Corrosion Survey 3) D.G. Havard, M.K. Bissada, C.G. Fajardo, D.J. Horrocks,
J.R. Meale, J. Motlis, M. Tabatabai, and K.S. Yoshiki-
The condition of pre-1950 vintage structure foundations was Gravelsins, "Aged ACSR conductors part Il - prediction of
assessed by examining a total of 500 tower sites during a survey of remaining life", mEE Transmission and Distribution
115 kV separate transmission lines2. 16• Most of the lines were 60 to Conference and Exposition, Dallas, 1991.
80 years old. The survey included: assessment and use of a tower
839
4) J. Sutton and K.G. Lewis, "The detection of internal 11) Ontario Hydro Research Report No. 90-113-K, May 18,
corrosion in steel-reinforced aluminium overhead power line · 1990, '1dentification of corrosion products and corrosion
conductors", UK Corrosion '86, Birrningham, UK, 1986, Vol processes of. ACSR conductors"
1, pp 345-359.
12) Ontario Hydro Research Report No. 90-199-K, August 14,
5) Ontario Hydro Research Report No. 90-15-H, April 11, 1990, 1988, "Atmospheric corrosion of transmission line
"Modification of the Corrnon overhead line corrosion detector conductors: environmental field studies"
to operate live-line".
13) Ontario Hydro Research Report No. 89-23-H, March 3, 1988,
6) CSA Standard CAN/CSA-C 49.l-M87 "Round wire, "Electrical tests on aged 115 kV conductor joints"
concentric lay, overhead electrical conductors", 1987.
14) Ontario Hydro Research Report No. B89K-8-K, March 28,
7) CSA Standard CAN/CSA-C 22.2 No.0.3 -M 1985 "Test 1989, "Evaluation of line items from the transmission line
methods for electrical wires and cables", 1985. refurbishment program"
8) ASTM Standard E558-83, "Standard test method for torsion 15) Krishnasamy, S.G., Senkiw, S.G., Havard, D.G., Pon, C.J.,
testing of wire", 1989. Tabatabai, M., Hathout, I., Radhakrishna, H.B., and Tsang,
R.H.K., "Testing of Lattice Towers for Ontario Hydro
9) Ontario Hydro Research Report No. B89-38K, July 26, 1989, Transmission Line Refurbishment Program", IEEE Trans
"Fatigue tests on old conductors". Power Delivery, Vol 5, No 3, July 1990.
10) Ontario Hydro Research Report No. M88-53-K, July 19, 16) Ontario Hydro Research Report No. 90-102-K, April 17,
1988, "Condition monitoring and life assessment on hardware 1989, "Assessment of tower corrosion for the transmission
from 115 kV lines SlK and D90" line refurbishment program"
840
David J. Horrocks (M'84) received the B.Eng. degree from the J. (Yakov) Motlis (M'84, SM'90) received
University of Liverpool and the M.Phil. degree from the University his M.Sc degree in Power Systems
of Southampton, both in electrical engineering. He has 25 years of Electrical Engineering in the Electrical
experience in transmission line design and development. Since lfJ74 Power Systems Department of the
he has been employed by Ontario Hydro where he is now a Technical University of Lvov, USSR, in
Supervising Design Engineer with responsibility for electrical design 1963. He has over 27 years experience in
of transmission lines. Mr. Horrocks has coauthored a number of various areas of construction and design of
papers on vario1JS aspects of line design. He is a registered transmission and distribution overhead and
Professional Engineer in the Province of Ontario. underground lines up to 500 kV. He is
currently a Design Engineer • Specialist in
the Ontario Hydro Transmission Lines
S.G. (Samy) Krishnasamy received his Design Department. He has coauthored
Bachelor's and Master's degrees from India. several papers on overhead and· underground lines design aspects.
He later received his Ph.D. from the Mr. Motlis is a registered Professional Engineer in the Province of
University of Waterloo, Canada. From Ontario.
1967 to 1971, Dr. Krishnasamy was an
Assistant Research Professor with the Karen S. Yoshiki-Gravelsins received her
University of Waterloo, Ontario. Dr. S. Honours BSc in Chemistry from the
Krishnasamy is c\llTCntly the Unit Head of University of Toronto in 1977, MASc in
the Transmission, Distribution & Structures 1984 from the Department of Chemical
Unit of the Applied Mechanics Section, Engineering and Applied Chemistry, and a
Ontario Hydro Research Division. He is PhD degree in 1989 from the Department
responsible for carrying out R&D work on of Metallurgy and Materials Science. She
probability methods applied to overhead transmission structures, joined the Research Division of Ontario
weather related loads on overhead power lines, studies of overhead Hydro as a postdoctoral fellow in January,
conductors, studies of transmission and distribution wood poles and 1990 where she participated in studies of
testing of civil nuclear structures. Dr. Krishnasamy is a registered the environmental factors involved in
Professional Engineer in the Province of Ontario. conductor corrosion. She is currently in
Japan on a postdoctoral fellowship carrying out studies of the
diffusion of Cr in the aqueous CrSO4-~SO4 system.
841