To: Bill Arrington

Composite Technology Corporation

2026 McGaw Avenue
Irvine, CA 92614
USA

HIGH TEMPERATURE - SAG CHARACTERIZATION TEST

ON 1020 KCMIL ACCC/TW CONDUCTOR
FOR COMPOSITE TECHNOLOGY CORPORATION

Kinectrics North America Inc. Report No.: K-422024-RC-0003-R00

February 23, 2004

Craig Pon
Transmission and Distribution Technologies Business

1.0 INTRODUCTION

A High Temperature Test was performed on a sample of 1.108 inch, 1020 kcmil
Aluminum Conductor, Composite Core – Trapezoidal Wires (ACCC/TW) conductor
supplied by Composite Technology Corporation (CTC). The test was performed as part
of project commissioned by Hydro One to assess the high temperature sag and tension
behaviour of various High Temperature Low Sag (HTLS) conductors in an indoor
laboratory. The ACCC/TW conductor comprises a Composite Fiberglass/Carbon Fiber
Core and trapezoidal, fully annealed aluminum alloy wires. The conductor was stranded
for CTC by General Cable. The code name for the conductor is 1020 kcmil ACCC/TW
Custom Design (24 wire). The specification for the conductor is contained in Appendix
A.

The test was performed between November and December, 2003 by Kinectrics North
America Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4, Canada.
Although testing is complete, the processing and analysis of the data is continuing at the
time of this report. The purpose of this report is to document the initial results. The
reported data are considered accurate however the final interpretation and assessme nt
of the data should be made only after all test data are appropriately and thoroughly
processed and analyzed.

PRIVATE INFORMATION
Contents of this report shall not be disclosed without authority of the client.
Kinectrics Inc., 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4
2.0 PURPOSE OF TEST

The purpose of the test was:

i) to compare the measured behaviours of CTC’s ACCC/TW conductor and a

conventional ACSR conductor with same outside diameter. The 1.108 inch, 1020
kcmil ACCC/TW conductor was tested with the 1.108 inch, 795 kcmil ACSR
conductor with round wires.
ii) to compare the measured behaviour of the ACCC/TW high temperature conductor
against the behaviour predicted by CTC. CTC provided sag-tension information for
their conductor.

3.0 TEST SET-UP

The High Temperature Test was carried out in the Indoor Conductor Dynamics
Laboratory at Kinectrics. The schematic arrangement and span details are shown in
Figure 1.

Conductor Preparation

Each conductor was terminated using epoxy-resin deadends to ensure that all
constituent components of the conductor would be tensioned. The deadends comprised
a U-bolt and a housing with a cone shaped cavity. The individual wires of the conductor
were splayed out in the housing and then encapsulated in epoxy. This technique of
termination also minimized any slack being introduced into the span. The conductors
were reconstituted on the untensioned side of the epoxy-resin deadends and fitted with
compression terminals at each end. A 4-hole NEMA pad provided an electrical
connection.

Physical Set-Up

The test facility was designed to test the ACCC/TW and the ACSR conductors
simultaneously. The conductor length between deadend clamps was 215 feet. The
conductors were installed parallel to each other about 40 inches apart for the length of
the span. A load cell and a short insulator were installed at each end of the span. The
height of the attachment points at A-A were approximately 8 feet from the floor. The
conductor and associated hardware were attached to heavy concrete abutments. A
hydraulic cylinder was used to tension each conductor to the initial value.

Electrical Set-Up

The conductors were heated using four(4) AC current transformers connected in series
at the North end of the span. Approximately 1600 amps was supplied by the current
transformers. An electrical jumper cable was used to connect the ACCC/TW conductor
to the ACSR conductor at the South end of the span. The full available current was
cycled on to increase the temperature in the conductors.

2 K-422024-RC-0003-R00
Instrumentation

The following instruments made measurements on each conductor

i) Load Cells measured the conductor tension

ii) String Potentiometers measured the vertical conductor position at midspan (C-
C), at the north end (D-D) and at the south end (E-E). This permitted calculation
of conductor sag in the “effective” span length (B-B)
iii) Thermocouples measured the temperature of the ACCC/TW and ACSR
conductors at various locations
iv) Current transformer measured the AC current in the loop.

Data Acquisition

The signals from the instrumentation were monitored and recorded using Labview
software. The instruments were sampled once every minute.

4.0 TEST PROCEDURE

The conductors were tensioned to 25% of their respective rated tensile strengths (RTS).
Current was circulated through both conductors to increase the temperature to the target
temperature. The intent was to increase the temperature of both conductors to
approximately 240oC and measure their respective sags during the heat up and cool
down.

5.0 TEST RESULTS

The maximum temperature measured in each conductor is plotted against sag and
tension for the respective conductors in Figures 2 and 3, respectively.

The following observations are made from Figures 2 and 3.

1) The maximum temperature achieved in the 795 kcmil ACSR Drake conductor was
240oC. The maximum temperature achieved in the 1020 kcmil ACCC/TW conductor
was 183oC. Unfortunately, the temperature in the ACSR conductor could not be
increased further because of the limit on the available current.

2) The initial sags and tensions for the 795 kcmil ACSR and 1020 kcmil ACCC/TW
conductors at ambient temperature of 21.6oC are:

Sag Tension
795 kcmil ACSR 9.3 inches 7862 lbf
(236 mm) (3566 kgf)
1020 kcmil ACCC/TW 7.8 inches 8257 lbf
(198 mm) (3745 mm)

3 K-422024-RC-0003-R00
The sags and tensions for the 795 kcmil ACSR and 1020 kcmil ACCC/TW conductors at
183oC are:

Sag Tension
795 kcmil ACSR 56.0 inches 1372 lbf
(1422 mm) (622)
1020 kcmil ACCC/TW 12.3 inches 5447 lbf
312 mm) (2471 mm)

The change in sags and tensions for the 795 kcmil ACSR and 1020 kcmil ACCC/TW
conductors between 21.6oC and 183oC are:

Change in Sag Change in Tension

from 21.6oC to 183oC from 21.6oC to 183oC
795 kcmil ACSR +46.7 inches -6490 lbf
(+1186 mm) (-2944 kgf)
1020 kcmil ACCC/TW +4.5 inches - 2810 lbf
(+114 mm) (-1275 kgf)

The sag and tension for the 795 kcmil ACSR conductor at 240oC are:

Sag Tension
795 kcmil ACSR 69.6 inches 1103 lbf
(1768 mm) (500 kgf)

The change in sag and tension for the 795 kcmil ACSR conductor between 21.6oC and
240oC are:

Change in Sag Change in Tension

from 21.6oC to 240oC from 21.6oC to 240oC
795 kcmil ACSR +60.3 inches -6759 lbf
(+1532 mm) (-3066 kgf)

3) The “kneepoint” of the 795 kcmil ACSR conductor is about 85oC. The “kneepoint” of
the 1020 kcmil ACCC/TW conductor is difficult to distinguish but is reached soon
after heating begins at about 30oC-40oC.

4) When comparing the measured data to the calculated data, it should be noted that
the starting temperatures used in the CTC model are slightly below the actual
starting temperatures in the test. The analysis could be repeated using the actual
starting temperatures.

5) The predicted values overestimate the measured values for sag for both the ACSR
and ACCC/TW conductors.

4 K-422024-RC-0003-R00
6.0 DISCUSSION

It should be noted when analyzing the results that the intent of the test was to compare
the high temperature sag-tension behaviour of ACSR Drake conductor with the CTC
ACCC/TW conductor of the same outside diameter. The diameter of both conductors
was 1.108 inches. It is recognized that the tested ACCC/TW conductor had trapezoidal
wires while the ACSR conductor had round wires. The ACSR Drake conductor has a
circular cross-sectional area of 795 kcmil while the ACCC conductor has a cross-section
of 1020 kcmil. The ACCC/TW conductor has 28.3% more aluminum cross-sectional
area than the 795 kcmil ACSR Drake conductor.

Sources of Error

The simulation of sag behaviour in an indoor laboratory will be influenced to some

degree by the following end effects.

i) Weight of the attachment hardware such as the deadand fittings, insulators, links,
load cells, etc. will influence the
ii) Elongation of the attachment hardware
i) Deflection of end supports
ii) Change in angle of conductor at the attachment point during the heating/cooling
cycles

Prepared by:

C.J. Pon
Principal Engineer
Transmission and Distribution Technologies Business

Approved by:

Dr. J. Kuffel
General Manager
Transmission and Distribution Technologies Business

CJP:JC

DISCLAIMER

Kinectrics Inc., has prepared this report in accordance with, and subject to, the terms
and conditions of the contract between Kinectrics Inc. and Composite Technology
Corporation and Hydro One.

 Kinectrics North America Inc., 2004.

5 K-422024-RC-0003-R00
 English Metric Fig. 1 Ref.
ACSR & ACCC
Span Length over-all 225 ft 68.6 m A-A
Span between North -South String Pots 215 ft 65.5 m B-B

ACSR Conductor
Initial Sag Centre ACSR 259 mm C-C
Initial Sag 1.5m from North end ACSR 26 mm D-D
Initial Sag 1.5m from South end ACSR 20 mm E-E
ACSR weight 1.0934 lb/ft 1.6272 kg/m
RTS 31,500 lb 14,288 kg

ACCC Conductor
Initial Sag Centre ACCC 222 mm C-C
Initial Sag 1.5m from North end ACSR 28 mm D-D
Initial Sag 1.5m from South end ACSR 20 mm E-E
ACCC weight 0.957 lb/ft 1.4242 kg/m
RTS 32,998 lb 14,968 kg

Hardware at North end, in order from out to inboard of span:

length - mm weight - kg
Strain Plate 100 3.22 F
Load Cell 240 3.04 G
Short Insulator 350 1.18 H
U-Bolt & Housing ACSR 640 5.17 (length as installed) J
6

U-Bolt & Housing ACCC 510 5.17 (length as installed) J

Hardware at South end, in order from out to inboard of span:

length - mm weight - kg
Load Cell 240 3.04 K
Long Insulator 450 1.32 L
U-Bolt & Housing ACSR 660 5.17 (length as installed) M
U-Bolt & Housing ACCC 580 5.17 (length as installed) M
K422024-RC-0003-R00

Figure 1: Schematic of Set-Up for the High Temperature Test

 ACSR (Measured) ACSR (CTC Model) ACCC/TW (CTC Model) ACCC/TW (Measured)

2000

1800 70

cooling
1600
60
1400

Conductor Sag (inches)

heating
Conductor Sag (mm)

50
1200
7

1000 40

800
30
heating
600
20
K422024-RC-0003-R00

cooling
400
heating
10
200 cooling

0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260
Maximum Conductor Temperature (deg C)

Figure 2: CTC 1020 kcmil ACCC/TW and 795 kcmil Drake ACSR Sag vs. Temperature
 ACSR (Measured) ACCC/TW (CTC Model) ACCC/TW (Measured)

4000

8000
3500

cooling 7000
3000

heating 6000
Conductor Tension (kgf)

Conductor Tension (lbf)

2500
5000
8

2000
heating
4000
cooling

1500
3000

1000
2000
K422024-RC-0003-R00

500 1000

0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260
Maximum Conductor Temperature (deg C)

Figure 3: CTC 1020 kcmil ACCC/TW and 795 kcmil Drake ACSR Tension vs. Temperature
 APPENDIX A

DATA SHEET FOR CTC 1020 KCMIL ACCC/TW CONDUCTOR

A-1
 Cable Design for Trapezoidally Shaped Conductor
Code Name: 1020 kcmil ACCC/TW Custom Design (24 wire) Type: 14

Governing Standard ASTM or CSA ASTM Total Cross Sectional Area of cndr 0.9116 in² ( 588.1 mm²)
AAC, ACSR, or ACSS ACSS Annular Alum area 1087.4 kcmil
Aluminum Cross-Sectional Area 1020. kcmil ( 516.7 mm²) Fill factor 93.8 %
Calculated Cable OD 1.108 in ( 28.15 mm ) Design Area Alum. 1020.0 kcmil
Diameter of a strand wire in Core Strand 0.3750 in ( 9.53 mm ) Actual Alum. area 1020.1 kcmil
No. Strand(s) in Core 1 No. Al. strands 24
No. of Alum. Wire Layers 2
No. Strands in 1st Layer 9 Al. in 1st layer 37.64 %
No. Strands in 2nd Layer 15 Al. in 2nd layer 62.36 %
No. Strands in 3rd Layer 0 Al. in 3rd layer 0.00 %
No. Strands in 4th Layer 0 Al. in 4th layer 0.00 %

Steel - GA, MA, HS, MS or S1A or S3A or AW CTC Core

Conductivity of outer aluminum (%IACS) 63.0 % ASTM B857 for overall conductor
Conductivity of inner core (%IACS) .0 % ASTM B609 for 1350 O temper aluminum
Frequency of Operation 60 Hz CTC Composite Fiberglass/ Carbon Fiber Core

Conductor Design:

Diameter of Steel Core .3750 in ( 9.53 mm )

1st Layer - number of wires = 9
Equiv. Round Wire Dia. .2066 in ( 5.25 mm ) Area per strand 42.66 kcmil
Diameter Over Layer .7416 in ( 18.84 mm ) Height "t" 0.1833 in
2nd Layer - number of wires = 15
Equiv. Round Wire Dia. .2059 in ( 5.23 mm ) Area per strand 42.41 kcmil
Diameter Over Layer 1.1082 in ( 28.15 mm ) Height "t" 0.1833 in
3rd Layer - number of wires = 0
Equiv. Round Wire Dia. .0000 in ( .00 mm ) Area per strand . kcmil
Diameter Over Layer .0000 in ( .00 mm ) Height "t" 0.0000 in
4th Layer - number of wires = 0
Equiv. Round Wire Dia. .0000 in ( .00 mm ) Area per strand . kcmil
Diameter Over Layer .0000 in ( .00 mm ) Height "t" 0.0000 in

Mechanical Properties:
Aluminum (1350) CTC Core Total
Conductor Mass 957 lb/kft 1425 kg/km 86 lb/kft 128 kg/km 1043 lb/kft 1553 kg/km
Conductor Area .8012 sq.in. 516.9 sq.mm .1104 sq.in. 71.3 sq.mm .9116 sq.in. 588.1 sq.mm
Rated Strength 6540 lb 29.1 kN 33130 lb 147.4 kN 39700 lb * 176.5 kN
Tensile Strength Basis 8500 psi 300000 psi * value rounded to nearest 100lb unit
Strength Derating Factor 0.96 1

Thermal Heat Capacity 230.4 W.s/ft per F 414.7 ... per C tbd

Electrical Properties: @ 60 Hz
Temperature dc Resistance ac Resistance ac Resistance ac Resistance
20 C 0.016486 ohm/kft 0.01687 ohm/kft 0.0891 ohm/mile 0.0553 ohm/km
( 0.054091 ohm/km)
25 C 0.016829 ohm/kft 0.01720 ohm/kft 0.0908 ohm/mile 0.0564 ohm/km
50 C 0.018544 ohm/kft 0.01888 ohm/kft 0.0997 ohm/mile 0.0620 ohm/km
75 C 0.020258 ohm/kft 0.02057 ohm/kft 0.1086 ohm/mile 0.0675 ohm/km
100 C 0.021973 ohm/kft 0.02226 ohm/kft 0.1175 ohm/mile 0.0730 ohm/km
125 C 0.023687 ohm/kft 0.02395 ohm/kft 0.1265 ohm/mile 0.0786 ohm/km
150 C 0.025402 ohm/kft 0.02565 ohm/kft 0.1354 ohm/mile 0.0842 ohm/km
175 C 0.027116 ohm/kft 0.02735 ohm/kft 0.1444 ohm/mile 0.0897 ohm/km
200 C 0.028831 ohm/kft 0.02905 ohm/kft 0.1534 ohm/mile 0.0953 ohm/km

A-2
DISTRIBUTION

Mr. C.W. Arrington Composite Technology Corporation

2026 McGaw Avenue
Irvine, CA 92614
USA

Mr. C.J. Pon Transmission and Distribution – KB104