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AS 3822-2002 Test methods for bare overhead conductors
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AS 38222002
Australian Standard

Test methods for bare overhead


conductors
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This Australian Standard was prepared by Committee EL-010, Overhead Lines. It
was approved on behalf of the Council of Standards Australia on 30 July 2002 and
published on 23 August 2002.
The following are represented on Committee EL-010:
Australasian Railway Association
Australian Chamber of Commerce and Industry
Australian Electrical and Electronic Manufacturers Association
Australian Porcelain Insulators Association
Electricity Supply Association of Australia
Keeping Standards up-to-date
Standards are living documents which reflect progress in science, technology and
systems. To maintain their currency, all Standards are periodically reviewed, and
new editions are published. Between editions, amendments may be issued.
Standards may also be withdrawn. It is important that readers assure themselves
they are using a current Standard, which should include any amendments which
may have been published since the Standard was purchased.
Detailed information about Standards can be found by visiting the Standards
Australia web site at www.standards.com.au and looking up the relevant Standard
in the on-line catalogue.
Alternatively, the printed Catalogue provides information current at 1 January each
year, and the monthly magazine, The Australian Standard, has a full listing of
revisions and amendments published each month.
We also welcome suggestions for improvement in our Standards, and especially
encourage readers to notify us immediately of any apparent inaccuracies or
ambiguities. Contact us via email at mail@standards.com.au, or write to the Chief
Executive, Standards Australia International Ltd, GPO Box 5420, Sydney, NSW
2001.
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AS 38222002
Australian Standard
Test methods for bare overhead
conductors
Originated as AS 3822(Int)1998.
Revised and designated AS 38222002.
COPYRIGHT
Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 4773 6
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AS 38222002 2
PREFACE
This Standard was prepared by the Australian members of the Joint Standards
Australia/Standards New Zealand Committee EL-010, Overhead Lines.
After consultation with stakeholders in both countries, Standards Australia and Standards
New Zealand decided to develop this Standard as an Australian Standard rather than an
Australian/New Zealand Standard.
The objective of this Standard is to provide procedures for purchasers wishing to specify
performance tests on complete conductors.
Conductor users and manufacturers have recognized that the variety of conductors and
conductor constructions available is unlimited and that it is becoming necessary to find the
characteristics of the complete conductor. In addition there is a need to critically examine
existing conductors that may have suffered degradation because of their service history.
Existing conductor Standards specify only the properties of the individual wires. Conductor
properties are calculated from the wire data.
During its 1983 meeting, CIGRE* Australian panel 22 Overhead Lines established a local
working group to review the matter and in particular to determine
(a) which complete conductor characteristics were needed to enable the user to compare
conductor types and to confidently predict the performance of conductors in service;
(b) how these characteristics were to be determined; and
(c) which procedures would optimize the handling of conductors during erection.
Items (a) and (b) were completed and this Standard sets out performance tests for complete
conductors.
With regard to Item (c), it was recognized that current methods used for the calculation of
sag data for conductor erection include somewhat arbitrary allowances for the effect of
run-out tensions, time spent in sheaves before sagging and for permanent elongation.
While these methods have proved adequate in most conditions there is a growing need for
more precise analysis especially when using unfamiliar conductors and when designing for
extreme temperatures.
The information from the tests can be used with the CIGRE temperature compensation
method (Ref. 1).
In addition, computer models are being developed (Ref. 2) and power line designers and
constructors are encouraged to make use of the techniques.
This Standard provides procedures for purchasers wishing to specify performance tests on
complete conductors. The tests have three main purposes, as follows:
(i) To provide a basis for comparison of the design of conductors in terms of their
mechanical properties.
(ii) To provide conductor data for the new sag tension computer programs which are
being developed to provide a more realistic model of conductor behaviour over its
service life (Ref. 2).
(iii) To provide acceptance criteria for conductor purchasers. It is envisaged that the tests
will be regarded as Type Tests for a particular conductor type and will not be
required for every production run.

* International Conference on Large High Tension Electric Systems.
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3 AS 38222002
An article, A practical method of conductor creep determination, published in 1972 in
ELECTRA No. 24 (Ref. 1) gave results of typical values of permanent elongation based on
measurements from lines in service. The method of determination of permanent elongation
specified in this Standard is based on principles laid down by CIGRE WG 05 in document
22-78(WG 05)02 (Ref. 3), which provides some guidance on the use of predictor equations
and evaluation methods.
Permanent elongation of conductors. Predictor equations and evaluation methods, from
ELECTRA no. 75 March 1981, (Ref. 4) contains the final version of the complete creep test
method. The methods specified in this Standard have taken advantage of experience gained
by previous laboratory evaluation of creep and current technology for improved accuracy in
measurement and temperature control.
REFERENCES
1 A practical method of conductor creep determination. CIGRE ELECTRA no. 24,
1972.
2 BARRETT, J.S., DUTTA, S. and NIGOL, O. A new computer model of A.C.S.R.
conductors. IEEE Trans. on Power Apparatus & Systems, vol. PAS-102, no. 3, March
1983.
3 CIGRE Document 22-78 (WG 05)02.
4 Permanent elongation of conductors. Predictor equations and evaluation methods.
CIGRE ELECTRA no. 75, March 1981.
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AS 38222002 4
CONTENTS
Page
1 SCOPE........................................................................................................................ 5
2 REFERENCED DOCUMENTS.................................................................................. 5
3 DEFINITIONS............................................................................................................ 5
4 PREPARATION OF A SAMPLE FOR TENSILE LOADING OF A WHOLE
CONDUCTOR............................................................................................................ 8
5 MEASUREMENT....................................................................................................... 8
6 TEST METHODS....................................................................................................... 9
7 TEST RESULTS....................................................................................................... 18
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5 AS 38222002
www.standards.com.au ! Standards Australia
STANDARDS AUSTRALIA
Australian Standard
Test methods for bare overhead conductors
1 SCOPE
This Standard specifies methods for determining the following properties and
characteristics of bare conductors for use in overhead lines:
(a) Geometric properties.
(b) Breaking load.
(c) Coefficient of thermal elongation.
(d) Stress-strain characteristics.
(e) Creep characteristics (permanent elongation).
(f) d.c. resistance of conductors.
(g) Fatigue characteristics.
(h) Thermal aging characteristics.
2 REFERENCED DOCUMENTS
The following documents are referred to in this Standard:
AS
1222 Steel conductors and staysBare overhead
1222.1 Part 1: Galvanized (SC/GZ)
1222.2 Part 2: Aluminium clad (SC/AC)
1391 Methods for tensile testing of metals
1531 ConductorsBare overheadAluminium and aluminium alloy
1746 ConductorsBare overheadHard-drawn copper
2193 Methods for the calibration and grading of force-measuring systems of testing
machines
3607 ConductorsBare overhead, aluminium and aluminium alloySteel
reinforced
IEC
60468 Method of measurement of resistivity of metallic materials
3 DEFINITIONS
For the purpose of this Standard, the definitions below apply.
3.1 Aeolian vibration
A resonant vibration induced in overhead conductors by steady cross winds.
3.2 Batch
A quantity of conductor from which a sample is to be drawn and inspected to determine
compliance with acceptability criteria. Each batch is assumed, as far as practicable, to
consist of materials of a single type (grade, class, size, and composition), and to have been
manufactured under essentially the same conditions at the same time.
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AS 38222002 6
! Standards Australia www.standards.com.au
3.3 Breaking load
The maximum load obtained on a tensile testing machine before failure of a conductor test
piece.
3.4 Calculated breaking load (CBL)
The breaking load determined in accordance with relevant Australian Standards for a bare
overhead conductor.
NOTE: AS 1222.1, AS 1222.2, AS 1531, AS 1746 and AS 3607 specify requirements for bare
overhead conductors.
3.5 Coefficient of thermal elongation
The relationship between the change in the temperature of a material and its resultant
change in dimensions.
NOTE: The coefficient of thermal elongation is often known as the coefficient of linear
expansion.
3.6 Composite conductor
A conductor consisting of two or more wires of different metals, such as aluminium and
steel or copper and steel, assembled and operated in parallel.
3.7 Conductor stress
The force per unit area where area is the nominal cross-sectional area of the individual
wires given in the relevant conductor Standard.
3.8 Creep
The permanent elongation of metals held for long periods of time at stresses lower than the
normal yield stress. Creep in conductors is dependent on the material, conductor
construction, applied stress, time and temperature.
3.9 Dynamic stress
A stress caused by the resonant vibration of overhead conductors by steady cross winds in
the velocity range of approximately 0.5 m.s
"1
to 7.0 m.s
"1
.
3.10 Elongation
The increase in gauge length of a tension test specimen, usually expressed as a percentage
of the original gauge length.
3.11 Fatigue
The failure of a metal under the repeated application of cyclic or fluctuating stress below
the yield point.
3.12 Fatigue life
The number of stress (or strain) cycles that a specimen sustains before failure under a given
test condition and criterion of failure.
3.13 Fatigue limit
The maximum cyclic stress that a metal will withstand without failure for an indefinitely
large number of cycles of stress.
NOTE: Aluminium does not exhibit a fatigue limit.
3.14 Fatigue strength at N cycles
The stress level at which a specimen would have a life of exactly N cycles.
3.15 Gauge length
The prescribed part of a test piece over which elongation is measured.
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3.16 Initial creep
The early part of the time-elongation curve for creep, in which extension increases at a
rapid rate.
3.17 Lay length
The axial length of one complete turn of the helix (pitch) formed by an individual wire in a
stranded conductor.
3.18 Lay ratio
The ratio of the lay length to the external diameter of the helix of the corresponding layer of
wires in the stranded conductor.
3.19 May
Indicates the existence of an option.
3.20 Modulus of elasticity
The slope of the elastic portion of the stress-strain curve in mechanical testing (ratio of
stress to strain within the elastic range). The tensile elastic modulus is called Youngs
Modulus.
3.21 Proof load
The load that is required to produce a defined, small, permanent elongation (usually 0.1%
strain) during a tensile test.
3.22 Secondary creep
The secondary portion of the creep curve following the initial creep stage and in which the
exponential rate of creep has reached a constant value, i.e. the linear portion of the creep
versus time curve plotted on a log-log scale.
3.23 Shall
Indicates that a statement is mandatory.
3.24 Should
Indicates a recommendation.
3.25 S-N Diagram
A plot of maximum stress amplitude against number of cycles to failure. For N, a
logarithmic scale is almost always used. For S, a linear scale is used most often but a
logarithmic scale is sometimes used.
3.26 Strain
The deformation expressed as a pure number or ratio. It is normally expressed as # (epsilon)
equivalent to the change in length divided by the original length.
3.27 Stress
The axial force per unit of nominal cross-sectional area. It is usually expressed as
$ (sigma).
3.28 Test piece
A prepared piece of a conductor for testing made from or comprising a test sample.
3.29 Test sample
A portion of conductor selected by a sampling procedure from a batch. P
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4 PREPARATION OF A SAMPLE FOR TENSILE LOADING OF A WHOLE
CONDUCTOR
Preparation of a conductor test piece is critical to the accuracy and validity of the test
results. Test pieces shall be prepared with due consideration to the prevention of conductor
rotation and loosening of wires and to the minimizing of damage to wires.
The selected test sample shall be free from scratches and other blemishes and shall have
been manufactured under normal production conditions. Test pieces shall be taken at least
20 m from the end of a test sample. The total length of the test piece shall allow for the
gauge length and terminations. Low elongation binding tape and hose or screw clips have
been found to be suitable for retaining the wires in position.
The minimum gauge length shall be 3.0 m. The terminations shall be at least 1.0 m from
each gauge point.
The terminations shall be designed so that the tensile load is distributed evenly to all wires.
Care must be taken to ensure that the original position of the stranded layers is maintained
during termination.
A type test to determine the termination suitability may be necessary to ensure that the
termination will sustain 95% of the calculated breaking load of the conductor for at least
four hours without any detectable movement.
5 MEASUREMENT
5.1 Temperature measurement
The temperature of test pieces shall be measured by devices attached to their surface. There
shall be at least three temperature measuring devices equally spaced along the gauge length.
The ambient temperature shall also be measured.
For test pieces tested in an enclosed, controlled temperature environment, temperature
measurement of the environment is permissible in lieu of contact measurement of the
conductor.
Unless otherwise stated, all temperature measurements shall be made with an accuracy of
%0.5C. When gauge bars are used in the measurement of extension, the accuracy of
temperature measurement shall be in accordance with the following criteria:
for &' ( 4)m/m/C, T* +
' &
#*
for &' ( 4)m/m/C, T* + 0.5C
where
T* = the temperature measurement error in degrees Celsius
#* = the maximum allowable strain measurement error in micrometres per
metre
' & = the difference between the coefficient of linear expansion of the gauge
bar and the conductor.
To avoid the need for extremely accurate temperature measuring devices, it is
recommended that, when used, gauge bars be made of materials with a coefficient of
thermal expansion similar to that of the test piece (i.e. within %4 )m/m/C).
5.2 Strain measurement
5.2.1 General
Care should be taken to avoid errors due to rotation of the test piece.
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5.2.2 Creep test
All creep measurements shall be made with an accuracy of 2 )m/m. The measuring device
may include a reference material for the purpose of making temperature corrections when
applicable. If gauge bars are used it is recommended that they have similar thermal mass to
the test piece.
5.2.3 Stress/strain and coefficient of thermal elongation tests
Strain measurement shall be made with an accuracy of 20 )m/m.
5.2.4 Conductor elongation during the breaking load test
The extensometer used in this test shall permit simultaneous measurement of conductor
elongation while the tensile load is continually increased. The accuracy of measurement
shall allow a 0.1% proof load to be determined.
NOTE: A C Grade extensometer complying with AS 1391 will satisfy the requirements of
Clause 5.2.4.
5.3 Load measurement
The load measuring device shall be calibrated to meet the requirements of AS 2193 for
Grade A.
6 TEST METHODS
6.1 Geometric properties
6.1.1 General
The lay length and diameter shall be measured for each layer of a conductor. The lay ratio
shall be calculated for each layer.
6.1.2 Test pieces
The measurement shall be done on a conductor as it is produced in a stranding machine.
The test pieces shall represent normal stranding operations.
6.1.3 Apparatus
Measurements shall be made with suitable equipment of appropriate discrimination.
Callipers are usually used for the measurement of diameter. A steel rule or tape is usually
used for the measurement of lay length.
6.1.4 Conductor layer diameter
Diameter shall be measured with a suitable device fitted with jaws broad enough to cover
not less than two adjacent wires along the test piece (see Figure 6.1) and shall be measured
on a straight portion of the test piece that is not under tension.
Measurement shall be taken at two locations spaced at least 1 m apart. At each location two
diameters at right angles shall be measured. The average of these four measurements shall
be recorded.
6.1.5 Lay length and lay ratio
Lay length shall be measured and lay ratio shall be calculated as follows:
(a) Ensure that each layer to be measured is well formed and representative of normal
stranding for that layer.
(b) Ensure that the test piece is at normal stranding machine tension.
(c) Place a sheet of good quality paper along the strand covering one or more lay lengths.
(d) Take an impression of the wires in the strand on the paper by rubbing a crayon or
similar rectilinearly on the paper along the longitudinal axis of the strand.
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(e) Mark a start point on the impression made by one wire and from this point
commencing with the next mark count the number of impressions equal to the number
of wires in the layer. Mark the impression of the last counted wire as the finish point.
Measure the distance between the two points to the nearest millimetre. This length is
the lay length.
NOTE: Greater accuracy may be obtained by counting a multiple of the number of wires in
the layer, taking the measurement and dividing by the multiplier.
(f) Measure the diameter of the layer to the nearest 0.05 mm in accordance with
Clause 6.1.4 except that the measurement may be made under normal stranding
machine tension.
(g) Divide the lay length measured at Step (e) by the diameter measured at Step (f) for
each layer. Each result is reported as the lay ratio of the corresponding layer.
FIGURE 6.1 METHOD OF MEASURING CONDUCTOR DIAMETER
6.1.6 Nominal cross-sectional area
The nominal cross-sectional area of a conductor may be determined by calculating the
cross-sectional area of each wire using the nominal diameter and then summing the cross-
sectional areas of all the wires in the conductor.
6.2 Breaking load
6.2.1 Principle
A test piece is subjected to a continuously increasing tensile force until failure occurs. The
maximum value of the load prior to failure is the conductor breaking load. The elongation
of the conductor may also be measured.
6.2.2 Apparatus
The apparatus shall include devices to retain the test piece terminations and shall have
means of applying the desired load. The test piece terminations shall be made in accordance
with Clause 4.
6.2.3 Procedure
The procedure shall be as follows:
(a) Mount and secure the test piece into the test frame and position the extensometer.
Conductor elongation shall be measured in accordance with Clause 5.2.4.
(b) Apply the load smoothly and evenly.
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(c) Increase the load progressively until either
(i) failure occurs (i.e. one or more wires fracture outside the terminations); or
(ii) the terminations fail by either fracture of a termination, or slippage or fracture
of the wires within a termination.
(d) Record the maximum load at which failure as defined in Step (c) occurs.
6.2.4 Test validity
The results are valid only for test pieces which fracture outside the terminations.
6.3 Coefficient of thermal elongation
6.3.1 Scope and general
This Clause (6.3) provides a method for determining the coefficient of thermal elongation
of bare overhead conductors. A change in conductor temperature will affect the length of
the conductor. The thermal behaviour of the conductor is characterized by its coefficient of
thermal elongation.
6.3.2 Principle
The temperature of a conductor test piece is incrementally and gradually raised from
ambient to 100C and lowered back to ambient. At regular temperature intervals the
conductor tension is briefly raised to 20% CBL and simultaneous measurements of
conductor tension, temperature and strain are taken.
6.3.3 Apparatus
The apparatus shall consist of the following:
(a) A machine capable of supplying the load smoothly and uniformly. The machine shall
include devices to maintain the specified load and secure the sample terminations.
The terminations shall be made in accordance with Clause 4.
(b) A temperature control system capable of controlling the mean conductor temperature
within %2.5C of the desired temperature so that the variation in temperature
distribution along the gauge length does not exceed %2.5C.
6.3.4 Procedure
The procedure shall be as follows:
(a) Install the test piece in the machine with due consideration given to minimizing the
loosening of strands.
(b) Apply tension briefly to the test piece to 20% of CBL. Set the extensometers to zero
and simultaneously measure the gauge length, tension and cable temperature.
(c) With the conductor slack, increase the mean conductor temperature by approximately
10C and briefly raise the conductor tension to 20% of CBL. Simultaneously measure
conductor tension, elongation and temperature. It may be necessary to allow time for
the conductor temperature to be uniformly distributed through its cross-section before
taking measurements.
(d) Repeat Step (c) to 100 %2.5C in increments of 10C, and back to ambient in
decrements of 10C.
6.3.5 Analysis of data
Determine a value of the linear coefficient of thermal elongation (in )m/m/C) by linear
regression analysis of the experimental data.
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6.4 Stress/strain
6.4.1 Scope and general
The stress/strain test measures the elongation of a complete conductor when it is subjected
to successive and progressively increasing tensile loads for short periods of time. The
stress/strain behaviour of a conductor is characterized by stress/strain curves. The stress
strain characteristics quantify
(a) the short-term loading behaviour;
(b) the initial and final modulus of elasticity; and
(c) for non-homogeneous conductors, the stress distribution and the aluminium zero
stress/strain point.
6.4.2 Principle
A test piece of the conductor is subjected to a tensile load. The load is applied smoothly and
uniformly to a value equivalent to 30% of the CBL. The load is held at this value for a
defined period of time and then released at approximately the same rate as the application.
Measurements of extension are made at frequent intervals during the load cycle. The cycle
is repeated for 50% and 70% of the CBL. Tests at the three levels of CBL may be done on
one test piece. From these data stress versus strain curves may be derived.
When composite conductors with reinforcing cores are tested, the tests are repeated on the
core alone. This is done to evaluate the tensile properties of the core and the outer layer.
NOTE: Composite conductors which have wires of different materials in the same layer require
special consideration and are not covered by this Standard.
6.4.3 Apparatus
The apparatus shall consist of the following:
(a) A machine capable of suppling the load smoothly and uniformly. The machine shall
include devices to maintain the specified load and secure the sample terminations.
The terminations shall be made in accordance with Clause 4.
The machine shall be able to maintain the specified load within %1% of its designated
value.
(b) A temperature control and measuring system capable of controlling the temperature
within %2.5C during a test so that the mean test temperature during the core test does
not vary by more than %2.5C from the mean temperature during the complete
conductor test.
6.4.4 Procedures
6.4.4.1 Conductors
The procedure for conductors shall be as follows:
(a) Install the test piece in the machine with due consideration to minimizing the
loosening of wires. Apply and maintain a load of between 1% and 2% of CBL and
maintain this while measuring the gauge length. Set the extensometer to zero.
(b) First cycle:
(i) Increase the load at a uniform rate up to 30% CBL over 2 to 3 min, taking at
least four simultaneous readings of load and extension over the load range.
(ii) Maintain the load of 30% CBL for 30 min. Take simultaneous readings of load
and extension at 5, 10, 15 and 30 min.
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(iii) Reduce the load at a uniform rate to almost zero over a period of 2 to 3 min,
taking at least four simultaneous readings of load and extension during the
unloading period.
(c) Second cycle:
(i) Apply load at a similar rate as in the first cycle but up to 50% CBL, taking at
least four simultaneous readings of the load and extension.
(ii) Maintain the load of 50% CBL for 60 min, taking simultaneous readings of load
and extension at 5, 10, 15, 30, 45 and 60 min.
(iii) Reduce the load at a uniform rate to almost zero using a similar rate of
reduction as in the first cycle, taking simultaneous reading of the load and
extension at the same intervals as in the first cycle.
(d) Third cycle:
(i) Apply load at a similar rate as in the first cycle but up to 70% CBL, taking at
least four simultaneous readings of the load and extension.
(ii) Maintain the load of 70% CBL for 60 min, taking simultaneous readings of load
and extension at 5, 10, 15, 30, 45 and 60 min.
(iii) Reduce the load at a uniform rate to almost zero using a similar rate of
reduction as in the first cycle, taking at least 10 simultaneous readings of the
load and extension.
6.4.4.2 Steel core (if applicable)
The procedure for steel cores shall be as follows:
(a) Set a new test piece of the conductor core in the apparatus. The test piece shall be
taken from the same test sample used in Clause 6.4.4.1.
(b) For the holding periods, the core shall be loaded until the elongation at the beginning
of each period corresponds to the final elongation obtained on the complete conductor
at 30, 50 and 70% CBL respectively.
6.4.5 Analysis of data
The data shall be analysed as follows:
(a) Plot the stress (MPa) versus strain ()m/m) for each of the test pieces. A typical plot is
shown in Figure 7.1.
(b) Correct the strain data to compensate for any initial slack in the wires in the test
piece. This can be done by extrapolating the linear portion of the increasing load
section of the first cycle down to the initial curve for the steel core. The resultant
strain offset must then be subtracted from every strain record. A large strain offset
may indicate incorrect sample preparation (see Clause 4).
(c) Determine a smooth composite stress-strain curve (curve 1 of Figure 7.2) by fitting an
appropriate polynomial or curve of best fit to the corrected origin and to the end point
of each holding period.
(d) Determine the final modulus of the steel core, if any, by regression analysis of the
data in the linear portion of the curve obtained on unloading from the equivalent of
the 70% CBL of the complete conductor.
(e) Determine the final modulus of the steel core, if any, by regression analysis of the
data in the linear portion of the curve obtained on unloading from 70% CBL.
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(f) Determine the initial modulus and the final modulus for the aluminium in a composite
conductor by numerical subtraction of the values of the steel core from those of the
complete conductor. Figure 7.2 shows a typical plot of moduli for a composite
conductor.
NOTE: AS 1391 provides relevant information on the slope of the elastic section of the stress-
strain curves.
6.5 Creep
6.5.1 Scope and general
The creep test measures the extension of a conductor with time when held at a constant load
and temperature.
Creep results in changing conductor sag with time. Compensation for creep is required to
account for this change.
When carrying out creep tests, it is essential that adherence to a strict routine be maintained
throughout, particularly during the initial stage, to ensure repeatability.
6.5.2 Principle
In a temperature controlled environment a test piece is loaded to a nominated percentage of
its CBL.
A gauge length equidistant from both ends of the test piece is fitted with an extensometer to
permit measurement of creep with time.
6.5.3 Apparatus
The apparatus shall include devices to maintain the specified load within %1%, and to
secure the test piece terminations. Terminations shall be made in accordance with Clause 4.
The test apparatus shall apply the load either
(a) within 30 s (fast-loading method); or
(b) between 4 min and 5 min (slow-loading method).
The load shall be applied smoothly and uniformly. The load shall be held within %1% of the
specified test load.
The test piece temperature shall be controlled at 20 %2.5C, unless a higher temperature is
specified.
If an immersion oil bath is used to control temperature, the test piece shall be jacketed in a
suitable tube to allow heat transfer from the oil to the test piece and to prevent oil
lubricating the wires during the long period of test.
6.5.4 Procedure
The procedure shall be as follows:
(a) Mount the test piece in the machine with due consideration being given to minimizing
the loosening of wires.
(b) Position the temperature measuring devices in accordance with Clause 5.1. The
temperature of the gauge bar shall be measured at positions adjacent to the devices
measuring the conductor temperature.
(c) Allow the thermal control system to stabilize for at least 24 h so that the test pieces
come to the same temperature.
(d) Apply and maintain the specified load. For testing at 20C, separate test pieces shall
be loaded to 20%, 30% and 40% of the CBL. For testing at elevated temperatures a
load of 20% of the CBL shall be used.
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(e) Measurements of strain and temperature shall be taken simultaneously at the
following elapsed times after full load has been reached: 1, 2, 3, 4, 5, 10, 15 and
30 min; then at 1, 2, 3, 4, 5, 6, 7, 24, 50, 80, 150, 300, 600, 1000 and 2000 h.
(f) The minimum test period shall be 1000 h or until sufficient data have been obtained
to predict the long-term behaviour of the conductor.
6.5.5 Analysis of data
6.5.5.1 Correction of thermal strain
Strain measurements shall be corrected for variations in temperature by assuming the
theoretical values of the coefficient of thermal elongation.
6.5.5.2 Load application rate
For the fast-loading method only, data of strain versus time for the first 10 minutes of the
test shall be plotted on linear scales. A curve of best fit shall be drawn through the strain
versus time data and the strain at six minutes shall be read from the curve. The strain at six
minutes is subtracted from subsequent readings to minimize the effects of initial varying
load application rates.
6.5.5.3 Strain variation
A graph of strain against time shall be plotted on log-log scales and the best straight line
fitted by analysis through the points. The time (t
s
) from the start of the test until the straight
line is established shall be determined. All points for time greater than t
s
and for which the
strain varies by more than 2% or by more than 20 )m/m from the value predicted by the
straight line shall be discarded.
6.5.5.4 Temperature
The test temperature shall be assumed to be the average of the temperature readings.
6.5.6 Test validity
A test shall be considered to be invalid if
(a) the time before the straight line is established is greater than 10% of the duration of
the test; or
(b) if the points rejected in accordance with Clause 6.5.5.3 exceed 10% of the points
taken after the straight line is established.
6.6 d.c. resistance
Measurements of the resistivity of wires shall be made in accordance with IEC 60468.
6.7 Fatigue
6.7.1 General
Fatigue is caused by repetitive dynamic stress in the wires resulting in crack initiation and
propagation. Crack propagation ultimately results in wire fracture. After one or more wires
fracture redistribution of stress occurs in the conductor which accelerates the crack
propagation in the remaining intact wires. This process of wire fractures may continue until
the entire conductor fails.
6.7.2 Principle
Fatigue is induced in the test piece at a constant axial tension by mechanically vibrating it
at a natural frequency. A series of tests must be performed to generate the complete fatigue
characteristics of a conductor.
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6.7.3 Apparatus
A suitable test span layout is shown in Figure 6.2. The free span length should be
approximately 30 m.
The test span shall have the capability of maintaining a constant test tension.
Rigid non-articulating clamps shall be used at each end to support and restrain the test
piece. These shall not be used to maintain tension on the span and should have a low-
friction sleeve to allow longitudinal movement. The inner part of the clamp assembly in
contact with the conductor shall be square edged to provide a fixed point for conductor
bending.
The inertia of the vibrating mechanism should be small relative to the conductor mass under
test.
The system shall have a frequency selection sensitivity within %0.1 Hz. A schematic
drawing of a typical conductor vibration system is shown in Figure 6.3. A schematic
drawing of a typical conductor fatigue test measurement system is shown in Figure 6.4. The
length of test conductor between a linear differential transducer and the nearest clamp
should be at least 90 mm.
FIGURE 6.2 A TYPICAL TEST SPAN LAYOUT
6.7.4 Procedure
The procedure shall be as follows:
(a) Install the test piece in the machine giving due consideration to minimizing the
loosening of wires and conductor twisting.
(b) Apply a nominated axial load to the test piece. The load shall be maintained within
2% of its specified value.
(c) Vibrate the test piece at one of its natural frequencies and at a peak-to-peak amplitude
which corresponds to the outer strand dynamic stress. The frequency should be in the
range of 10 to 50 Hz to avoid overheating.
(d) Terminate the test when either one or more wires fail or at a specified number of
cycles.
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FIGURE 6.3 SCHEMATIC DRAWING OF A TYPICAL
CONDUCTOR VIBRATION SYSTEM
FIGURE 6.4 SCHEMATIC DRAWING OF A TYPICAL
CONDUCTOR FATIGUE TEST MEASUREMENT
6.8 Thermal ageing
6.8.1 General
The effects of thermal ageing (annealing) on bare overhead conductors are a reduction in
conductor strength and a decrease in electrical resistance. The thermal ageing
characteristics of conductors are influenced by the alloy, the operating temperature, and the
diameter of the component wires in the strand. The loss of strength of a composite
conductor will be less than an equivalent AAC or AAAC conductor because typical
operating temperatures have a negligible effect on the steel core.
It is assumed that the loss of strength of the conductor due to thermal ageing is reflected by
the loss of strength of the component wires. The decrease in strength of the thermally aged
wires can be expressed as a fraction of the tensile strength of the wires before thermal
ageing.
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6.8.2 Apparatus
An oven, furnace or other thermal cabinet suitable for containing the required number of
test pieces at the specified temperature and for the specified time is required.
The temperature inside the thermal cabinet shall vary by no more than %2.5C from the
specified temperature.
6.8.3 Test piece
Sufficient test pieces shall be prepared from the same test sample for each time period
specified during the test. For example, for a test duration of 10 000 hours and time periods
of 0, 10, 20, 40, 70, 100, 200, 400, 700, 1000, 2000, 4000, 7000 and 10 000 hours, 14 test
pieces are required.
6.8.4 Procedure
The procedure shall be as follows:
(a) Raise the temperature in the thermal cabinet to the specified thermal ageing
temperature. The thermal ageing temperature shall be 75, 100, 125 or 150C.
(b) Place all but the zero-hour test piece in the thermal cabinet and allow the temperature
in the thermal cabinet to recover to the specified thermal ageing temperature. The
time to recover to the specified thermal aging temperature shall be no more than
10 min.
(c) Measure the test time, starting when the thermal cabinet recovers to the thermal
ageing temperature.
(d) At each specified time period, remove a test piece from the thermal cabinet and allow
the test piece to cool to room temperature.
(e) Determine the tensile strength of three wires from each test piece in accordance with
AS 1391. The test shall be performed with a strain rate not exceeding category S in
accordance with AS 1391.
6.8.5 Analysis of data
The average tensile strength of the three wires at each time period can be used to calculate
either the percentage of the original tensile strength (%S) or the percentage change in
tensile strength (%&S). These data can be plotted as a function of annealing time to produce
an isothermal annealing curve. A typical set of curves is shown in Figure 6.5.
7 TEST RESULTS
7.1 Geometric properties (see Clause 6.1)
The test results shall include:
(a) The four measurements of diameter and their average.
(b) The lay length and lay ratio.
(c) The cross-sectional area.
7.2 Breaking load (see Clause 6.2)
The test results shall include:
(a) The gauge length when applicable, the test length and lay ratios for each wire layer.
(b) The maximum tensile load achieved in the test.
(c) A load-strain curve, if applicable.
(d) The location of the wire breaks, the wire break mode and the longitudinal location
relative to the end of the conductor terminations.
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(e) Any termination failure or slippage.
7.3 Coefficient of thermal elongation (see Clause 6.3)
The test results shall include:
(a) Gauge length, lay length and diameter.
(b) A description of the procedure used to heat the test piece.
(c) Tabulated results of conductor strain, stress and temperature.
(d) Linear-linear graphical representation of conductor strain versus conductor
temperature showing increasing and decreasing temperature cycles.
(e) The coefficient of thermal elongation for the test piece.
(f) A correlation coefficient.
FIGURE 6.5 TYPICAL ISOTHERMAL ANNEALING CURVE
7.4 Stress/strain (see Clause 6.4)
The test results should include the following:
(a) Gauge length, lay length and diameter.
(b) Tabulated results of conductor elongation, conductor test temperature and conductor
tension for each of the three load cycles for the complete conductor and the core
component when applicable.
(c) Graphical representation of conductor stress versus conductor strain for each of the
three load cycles for the complete conductor and the core component when applicable
(see Figure 7.1).
(d) Zero correction of the complete conductor, and the core component when applicable.
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(e) Linear-linear graphical representation of the initial and final modulus curves for the
complete conductor and its constituent components as stress versus strain (see
Figure 7.2).
(f) If required, coefficients in an appropriate polynomial or curve of best fit describing
the initial loading curve of the complete conductor and the core component and, when
applicable, the determined loading curve of the aluminium component.
(g) Final modulus of elasticity for the complete conductor and, when applicable, for the
core components.
(h) The correlation coefficient for the data used for the linear regression to determine the
moduli of elasticity for the complete conductor and components as applicable.
7.5 Creep (see Clause 6.5)
The test results shall include the following:
(a) Gauge length, lay length and diameter.
(b) Tabulated results of conductor strain, time elapsed, conductor temperature and
conductor tension expressed as a percentage of the CBL.
(c) Logarithmic-logarithmic graphical representation of the tabulated conductor
permanent elongation versus time elapsed for given conductor tensions expressed as a
percentage of the CBL.
(d) A linear-logarithmic graphical representation of temperature versus time elapsed.
(e) A linear regression analysis of the conductor logarithmic strain curve from at least
one hour elapsed time to the final reading time, which shall take the following form:
1
n
1
t A E ,
where
E = the conductor strain in micrometres per metre
A
1
, n
1
= constants determined by the linear regression analysis
t = time in hours.
(f) A linear correlation coefficient for the data used for the linear regression
determination.
(g) A multiple regression analysis of the conductor logarithmic strain curves for varying
temperature and conductor tension from at least one hour elapsed time to the final
reading time which may take the following form:
E = - . 20
1
n n n
2
3 2 1
" $ T e t A
where
E = the conductor strain in micrometres per metre
A
2
, n
1
, n
2
, n
3
= constants determined by the multiple regression analysis
t = the elapsed time in hours
$ = the conductor stress in megapascals
T
1
= elevated conductor temperature in degrees Celsius.
(h) A statistical correlation coefficient for the data to be used for the multiple regression
determination.
NOTE: Alternative forms of predictor equations may be used, if deemed appropriate.
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FIGURE 7.1 TYPICAL FORM OF GRAPH FROM STRESS AND STRAIN CYCLE
(Composite conductor shown)
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FIGURE 7.2 TYPICAL TEST RESULTSACSR
7.6 Fatigue (see Clause 6.7)
The test results shall include the following:
(a) The vibration amplitude, vibration frequency and elapsed time.
(b) The total number of wire breaks, if any, and the layers in which they occurred.
(c) The location of the wire breaks and wire cracks, if any, within the cross-section of the
conductor and their longitudinal location relative to the vibration termination block.
(d) The position at which fatigue cracks were initiated.
(e) General qualitative comments on wire fretting, wire deformation and other
observations as applicable.
(f) The total elapsed time.
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7.7 Thermal ageing (see Clause 6.8)
The test results shall include the following:
(a) The breaking loads of each group of test pieces, their average, their thermal ageing
temperature, and their time at the thermal ageing temperature.
(b) The isothermal annealing curves plotted from the data in Item (a).
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AS 38222002 24
NOTES
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Standards Australia
Standards Australia is an independent company, limited by guarantee, which prepares and publishes
most of the voluntary technical and commercial standards used in Australia. These standards are
developed through an open process of consultation and consensus, in which all interested parties are
invited to participate. Through a Memorandum of Understanding with the Commonwealth government,
Standards Australia is recognized as Australias peak national standards body.
Australian Standards
Australian Standards are prepared by committees of experts from industry, governments, consumers
and other relevant sectors. The requirements or recommendations contained in published Standards are
a consensus of the views of representative interests and also take account of comments received from
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technology.
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visit us at
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GPO Box 5420 Sydney NSW 2001
Administration Phone (02) 8206 6000 Fax (02) 8206 6001 Email mail@standards.com.au
Customer Service Phone 1300 65 46 46 Fax 1300 65 49 49 Email sales@standards.com.au
Internet www.standards.com.au
ISBN 0 7337 4773 6 Printed in Australia
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