t33_posterslides_iab_may08_gorur
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t33_posterslides_iab_may08_gorur

Course Number: MAY 14, Fall 2009

College/University: Wisconsin

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PSERC Characterization of Composite Cores for High Temperature-Low Sag (HTLS) Conductors (T-33) PSERC IAB Meeting May 2008 Academic Team Members: Ravi Gorur (EE) & Barzin Mobasher (CE), Arizona State Univ. R. Olsen (EE), Washington State Univ. Industrial Team Members: M. Dyer & J. Hunt, Salt River Project J. Gutierrez, Arizona Public Service J. Gurney, British Columbia Transmission Corp T-33 1...

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of PSERC Characterization Composite Cores for High Temperature-Low Sag (HTLS) Conductors (T-33) PSERC IAB Meeting May 2008 Academic Team Members: Ravi Gorur (EE) & Barzin Mobasher (CE), Arizona State Univ. R. Olsen (EE), Washington State Univ. Industrial Team Members: M. Dyer & J. Hunt, Salt River Project J. Gutierrez, Arizona Public Service J. Gurney, British Columbia Transmission Corp T-33 1 Composite cores evaluated Aluminum Conductor Composite Reinforced Aluminum Conductor Composite Core T-33 2 Cracks in resin at 200 deg C (Carbon composite Core) T-33 3 Metal Matrix Core after tensile strength test at 210 deg C Normal failure mode. High temperature has not changed failure mode T-33 4 Couplings: Mild steel T-33 5 Tensile strength testing of Carbon Composite Cores T-33 6 Stress Analysis of Carbon Composite core 1000 900 800 700 Stress (MPa) 600 500 400 300 200 100 0 0.00E+00 1.00E-03 2.00E-03 3.00E-03 4.00E-03 5.00E-03 6.00E-03 7.00E-03 8.00E-03 y = 131928x - 3.119 R2 = 1 Strain D = 0.00492 m Time = 9.296 sec Strain rate = 0.001 T-33 Max Force = 175.34 kN Max Stress = 922 MPa 7 FTIR Spectroscopy Analysis of Carbon Composite core FTIR spectrum 120 25 days at 200 C 20 days at 200 C 100 80 %Transmittance 10 days at 200 C New sample 60 New sample 10 days 20 days 25 days 40 20 3650 3150 2650 2150 1650 1150 0 650 Wavenumber(1/cm) T-33 FTIR spectrum comparing all the spectrums 8 Carbon Composite Core Tensile test results Sample A1 A2 B1 B2 C1 C2 D1 D2 Failure Load(lb) 1897 1783 3750 3213 1464 1259 2044 3189 Failure Mode Glue Failed Glue Failed Rod Failed Rod Failed Rod Failed Rod Failed Glue Failed Rod Failed 9 T-33 How protected is the core? T-33 10 Mechanical Stress+Chemical Exposure of fiber glass composite Nitric Acid High purity water T-33 11 HTLS: Pros and Cons More power through existing corridors, no new right-of-way needs Mitigate EMF concerns (no additional lines) Lower (than steel) coefficient of thermal expansion enables more current for same sag Expensive, new technology,manufacturer driven, life and performance concerns Users need independent research to maximize benefits T-33 12 What we have achieved so far? Identified differences in Carbon Composite conductor Developed preliminary thermal models for evaluating core temperature Developed test fixtures for tensile strength testing Performed failure analysis of samples failed at elevated temperatures T-33 13 Research Questions?? Two very different types of HTLS conductors using composite cores presently available. How do they compare? Supposed to operate at 180-240 oC (> 2 times presently used values). How does this affect performance (mainly mechanical)? Performance is strongly related to formulation and processing (manufacturers domain). What measures can users employ to validate manufacturers claims? Mixed experience with (polymeric) composite materials for insulators, can we avoid doing the same mistakes? T-33 14 Microscopic Details Metal Matrix Carbon Composite Submicron size Al2O3 fibers in aluminum metal matrix T-33 glass fibers + carbon fibers in epoxy resin matrix 15 Differences in thermal stability ACCC 200 C 0 1 200 0 ACCR Initial Weight: 32 mg Temperarure (C) 400 600 800 1000 1200 1 200 C 140 C, start of degradation -1 Mass Loss (mg) -2 M a s s L o s s (m Degradation starts at 140oC 0 0 100 200 3 00 400 500 600 -1 -2 -3 Slight weight gain after 200 oC -3 -4 -4 -5 -6 -5 T e m p e ra tu re (C ) T-33 16 Change due to thermal stress (ACCC) Virgin 120 hours at 200 oC T-33 17 Differences in chemical stability Stress corrosion cracking when exposed to nitric acid Corona from broken strands can generate nitric acid T-33 18 Proposed Tasks (Task 1,2) Explore different methods of fingerprinting Spectroscopic: Infrared, Energy Dispersive X-ray, Optical microscopy Assess fiber volume and distribution Electrical: partial discharge, tan (fiberglass) Mechanical: Failure under tension, bending and fatigue loads Are their differences before and after laboratory aging? T-33 19 Task 3 Accelerated aging tests: elevated temperatures (150, 200, 250 oC) for 500 hours Combined mechanical (bending) and Chemical exposure (water, nitric acid) tests Characterize samples Spectroscopic analysis Mechanical (tensile) tests T-33 20 Thermal Profile of Core (Task 4) Core is expected to be hotter than the conductor Can the core temperature exceed the glass transition temperature (transition from elastic to plastic phase)? IEEE 738 used for ACSR, new materials and construction methods have yield heat transfer properties....

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