D R A F T

This is an unapproved Kinectrics International Draft Report, subject to change
To: HES Hacilar Electrik San. Ve Tic.
Erciyes Mah. HES Cad.
No: 22 38210 Hacilar, Kayseri
Turkey
1.0 INTRODUCTION
D R A F T
KINECTRICS INTERNATIONAL INC. TEST REPORT
FOR HES HACILAR ELEKTRIK SAN. VE TIC.
(Ref. Stress-Strain Test on PHEASANT ACSR Conductor)
Kinectrics International Inc. Report No.: K-419148-RC-0002-R00
December 22, 2009
C. Dimnik
Transmission and Distribution Technologies Business
A Stress-Strain Test was performed on a conductor manufactured by HES Hacilar Elektrik San.
Ve Tic. of Turkey. The outside diameter of the conductor is 35.11 mm and is designated
1272 MCM PHEASANT ACSR. The data sheet for this conductor is included in Appendix A.
The cable was received in good condition. The test was performed on December 3 and 4, 2009
by Kinectrics North America Inc. personnel at 800 Kipling Avenue, Toronto, Ontario, M8Z 6C4,
Canada according to Kinectrics Quotation DIM-419-0910-068-R02 dated October 1, 2009.
DRAFT
The testing was videotaped and reviewed by Mr. Asim Mercan of HES.
A copy of Kinectrics ISO 9001 Certificate is included in Appendix C.
PRIVATE INFORMATION
Contents of this report shall not be disclosed without authority of the client.
Kinectrics North America Inc., 800 Kipling Avenue, Toronto, Ontario M8Z 6C4.
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This is an unapproved Kinectrics International Draft Report, subject to change
2.0 TEST OBJECTIVE AND STANDARD
The objective of the test is to provide the stress-strain characteristics of the conductor to be
used in the calculation of sags and tensions during the design of overhead transmission lines.
The test was performed in general compliance to IEC 61089 Round wire concentric lay
overhead electrical stranded conductors, Annex B; and BS EN 50182:2001 Conductors for
overhead lines – Round wire concentric lay stranded conductors, Annex C.
3.0 TEST SET-UP – for Whole Conductor and Steel Core
The set-up for the Stress-Strain Tests is shown schematically in Figure 1. A whole conductor
sample 13.95 m in length was terminated using epoxy-resin dead-ends. A steel core sample
14.97 m in length was also terminated using epoxy-resin dead-ends. The prepared sample was
installed in a hydraulically-activated horizontal tension test facility. During the initial set-up and
pre-loading steps, the sample was supported along its length to keep the sample as straight as
possible and to minimize the axial stress and sag. A pull-wire potentiometer was fixed to the
sample to measure elongation over a gauge length of about 10 m, centered midway between
the dead-ends. The actual gauge length for the test was measured at the first pre-load step. A
load cell located at the hydraulic end of the sample measured the tension. A photo of a typical
test sample installed in the test facility is shown in Figure 2.
A thermocouple was installed on the conductor and core samples during the test, outside the
gauge length.
The test was carried out in a temperature-controlled laboratory at 20ºC ± 2ºC.
Instrumentation and Data Acquisition
The conductor elongation and tension, as measured by the pull wire potentiometer and load cell
respectively, were monitored continuously using a digital data logging system. The data logging
rate during loading was every one (1) second and during holds every ten (10) seconds.
DRAFT
Temperature measurements were manually recorded at the end of each hold period.
The measuring instruments and equipment used in this test are listed in Appendix B.
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This is an unapproved Kinectrics International Draft Report, subject to change
4.0 TEST PROCEDURE
The conductor was subjected to the loading schedule outlined in IEC 61089 Annex B.
Step 1 – Whole Conductor
The conductor was tensioned according to the loading schedule on the following table. The
loads were applied at a rate of 3,054 kg/minute (6,732 lb/minute). This is based on achieving
30% of RTS in two (2) minutes.
Whole Conductor RTS= 20,357 kgf
Step % RTS kgf lbf
Hold
(minutes)
preload 2% 407 898
1 30% 6,107 13,464 30
2 2% 407898 1
3 50% 10,179 22,440 60
4 2% 407 898 1
5 70% 14,250 31,415 60
6 2% 407898 1
7 85% 17,303 38,147 60
8 2% 407 898 1
The completion of Step 8 of the above loading schedule marked the completion of the Stress-
Strain Test. The pull wire potentiometer was removed from the conductor, and the load
reapplied at a rate of 4,071 kg/minute (8,976 lb/minute) until the conductor failed. The breaking
load of the conductor was recorded.
Step 2 – Steel Core
The stress-strain test on the steel core was also performed according to IEC 61089 Annex B.
The procedure was similar as for the whole conductor except the tension levels for Steps 1, 3
and 5 for the steel core were determined by the elongation at the beginning of each hold period
obtained on the whole conductor at 30%, 50%, 70% and 85% RTS, respectively. That is, for
each load step, the tension was increased in the steel core until the % elongation was the same
as the whole conductor for the corresponding load step. This meant that the stress-strain test
must be performed on the whole conductor before the steel core. The steel core was tensioned
according to the loading schedule on the following table. The loads were applied at a rate of
3,054 kg/minute (6,732 lb/minute).
DRAFT
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This is an unapproved Kinectrics International Draft Report, subject to change
Step
Whole Conductor RTS=
20,357 kgf
Whole Conductor
Elongation, mm kgf lbs
Hold
(minutes)
preload 0 407 898
1 11.79 - - 30
2 - 407 898 1
3 21.78 - - 60
4 - 407 898 1
5 35.95 - - 60
6 - 407 898 1
7 51.49 - - 60
8 - 407 898 1
The completion of Step 8 of the above loading schedule constituted the completion of the
Stress-Strain Test.
5.0 TEST RESULTS
The strain data for the conductor and core have been corrected because the elongation
measurement was taken to be zero at the preload. Using a straight-line regression of the stressstrain
data while loading up to 30% RTS it was calculated that the corrected strain at preload was
+0.0032% for the conductor and +0.0291% for the steel core. After accounting for these
corrections, the data was extrapolated to the Y-axis to zero. The corrected data was the actual
conductor’s behaviour because the conductor will have zero elongation only when it is under zero
tension.
Figures 3a and 3b show load (i.e. tension) plotted against all strain data for the whole conductor
and steel core, respectively.
Figures 4a and 4b show stress plotted against strain (%) for only those points that contribute to the
stress-strain curve for the whole conductor and steel core, respectively.
DRAFT
Figure 5 shows the stress-strain curve for the PHEASANT ACSR conductor showing the plots for
the whole conductor, the aluminium layers, and the steel core.
The area of the conductor was 726.79 mm 2 according to the cable data sheet, included in
Appendix A.
The stress-strain curve for the aluminium layers is calculated by subtracting corresponding data
points of the steel core from the whole conductor.
The Modulus of Elasticity (MOE) of the conductor can be determined from the Stress-Strain
curve. The MOE is the slope of the unloading segment of the 85% RTS curve. The MOE for
the conductor is approximately 72,973 MPa.
Similarly, the MOE of the steel core can also be determined from the unloading curve on the
core only Stress-Strain curve. The MOE for the steel core (based on the area of the steel core
only) is approximately 187,471 MPa. The MOE for the steel core (based on the area of the
whole conductor) is approximately 21,077 MPa.
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This is an unapproved Kinectrics International Draft Report, subject to change
The MOE of the aluminum layers is calculated from the difference between the whole conductor
and steel core, from the unloading at 85% to their intersection (knee-point). The MOE for the
aluminum layers (based on the area of the aluminum only) is approximately 60,779 MPa. The
MOE for the aluminum layers (based on the area of the whole conductor) is approximately
53,946 MPa.
The whole conductor failed at 22,286 kgf or 109.5% of the Rated Tensile Strength of the
conductor.
The key results for the Stress-Strain Tests are shown in Tables 1, 2, and 3.
The general form of the equation of the loading curve for each of the whole conductor, steel
core and outer aluminum layers is:
y = AX3 +BX2 +CX+D
This equation is generated from a 3 rd order polynomial least-squares curve-fit based on the data
points at the end of each hold period. This is the formula used by the Alcoa Sag10 program.
Table 1 Summary of Stress-Strain Test Results for PHEASANT ACSR
Whole Conductor
Whole Conductor
Polynomial Coefficients
(MPa)
A= +4.0623 E+08
B= -8.3710 E+06
C= +7.5030 E+04
D= -1.0032 E-01
Final Modulus of
Elasticity
MPa
(before Knee-point)
** The knee-point is extracted from the 85% unloading curve.
The R-squared value for this curve-fit was R 2 = 1.0000.
Estimated
Knee-point Load
kN **
Breaking Load
kgf
72,973 46.5 22,286
Table 2 Summary of Stress-Strain Test Results for PHEASANT ACSR
Steel Core
Steel Core
Polynomial Coefficients
(MPa)
A= -2.3788 E+07
B= -4.3890 E+05
C= +2.2588 E+04
D= +6.8298 E-03
Final Modulus
of Elasticity
(based on area of
Steel Only)
MPa
The R-squared value for this curve-fit was R 2 = 1.0000.
DRAFT
Final Modulus
of Elasticity
(area corrected for
Consolidated Conductor)
MPa
187,471 21,077
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This is an unapproved Kinectrics International Draft Report, subject to change
Table 3 Summary of Stress-Strain Test Results for PHEASANT ACSR
Aluminum Layers
Aluminum
Polynomial Coefficients
(MPa)
A= +4.2684 E+08
B= -7.8971 E+06
C= +5.2329 E+04
D= -2.3784 E-03
Final Modulus
of Elasticity
(based on Area of
Alum Only)
MPa
The R-squared value for this curve-fit was R 2 = 1.0000.
6.0 ACCEPTANCE CRITERIA
Final Modulus
of Elasticity
(area corrected for
Consolidated Conductor)
MPa
60,779 53,946
As stated in IEC 61089 and BS EN 50182:2001, there are no acceptance criteria for the Stress-
Strain test.
As stated in IEC 61089 and BS EN 50182:2001, the breaking strength of the conductor shall
withstand, without fracture of any wire, not less than 95% of the rated tensile strength.
7.0 CONCLUSION
The primary purpose of the Stress-Strain Test is to provide stress-strain characteristics of the
conductor to be used in sag-tension calculations.
The conductor, as tested, met the requirements for the Tensile Test as specified in IEC 61089
and BS EN 50182:2001.
DRAFT
Page 6 of 20 K-419148-RC-0002-R00

Prepared by:
Reviewed by:
Approved by:
CD:CJP:RL
This is an unapproved Kinectrics International Draft Report, subject to change
C. Dimnik
Engineer
Transmission and Distribution Technologies Business
C.J. Pon
Principal Engineer
Transmission and Distribution Technologies Business
R. Lings
General Manager
Transmission and Distribution Technologies Business
DRAFT
DISCLAIMER
Kinectrics International Inc. (KII) has taken reasonable steps to ensure that all work performed meets
industry standards as set out in KII Quality Manual, and that, for the intended purpose of this report, is
reasonably free of errors, inaccuracies or omissions. KII DOES NOT MAKE ANY WARRANTY OR
REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THE
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OF ANY INFORMATION
CONTAINED IN THIS REPORT OR THE RESPECTIVE WORKS OR SERVICES SUPPLIED OR
PERFORMED BY KNAI. KII does not accept any liability for any damages, either directly, consequentially
or otherwise resulting from the use of this report.
�
� Kinectrics International Inc., 2009
Page 7 of 20 K-419148-RC-0002-R00

Page 8 of 20 K-419148-RC-0002-R00
Cylinder Mount
Fixed to Strong Floor
This is an unapproved Kinectrics International Draft Report, subject to change
Hydraulic Cylinder
Load Cell
Epoxy Deadend
ACSR ACS Conductor
Displacement
Transducer
Gauge length
DRAFT
Data Aquisition System
Figure 1 Set-up for Stress-Strain Test
Stationary End
Fixed to Strong Floor

DRAFT
Figure 2 Photo of Typical Test Sample Installed in Stress-Strain Test Facility.
Page 9 of 20 K-419148-RC-0002-R00

Page 10 of 20 K-419148-RC-0002-R00
Conductor Tension, kN
180
160
140
120
100
80
60
40
20
Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor)
DRAFT
0
0.00% 0.05% 0.10% 0.15% 0.20% 0.25% 0.30% 0.35% 0.40% 0.45% 0.50% 0.55% 0.60%
Conductor Strain, %
Figure 3a Load (tension) vs. Conductor Strain
46.5 kN Knee Point

Page 11 of 20 K-419148-RC-0002-R00
Core Tension, kN
80
70
60
50
40
30
20
10
Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor)
DRAFT
0
0.00% 0.05% 0.10% 0.15% 0.20% 0.25% 0.30% 0.35% 0.40% 0.45% 0.50% 0.55% 0.60%
Core Strain, %
Figure 3b Load (tension) vs. Steel Core Strain

Page 12 of 20 K-419148-RC-0002-R00
Conductor Stress, MPa
250
200
150
100
50
Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor)
Conductor area = 726.79 mm²
0.1276%, 82.45 MPa
0.2390%, 137.41 MPa
0.4018%, 192.35 MPa
DRAFT
0.5842%, 233.58 MPa
0
0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60%
Conductor Strain, %
Figure 4a Stress vs. Conductor Strain for Only Those Points That Contribute to the Stress-Strain Curve

Page 13 of 20 K-419148-RC-0002-R00
Core Stress, MPa
120
100
80
60
40
20
Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor)
Conductor area = 726.79 mm²
0.1472%, 32.26 MPa
0.2487%, 53.06 MPa
0.3950%, 80.94 MPa
DRAFT
0.5567%, 108.04 MPa
0
0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60%
Core Strain, %
Figure 4b Stress vs. Steel Core Strain for Only Those Points That Contribute to the Stress-Strain Curve

Page 14 of 20 K-419148-RC-0002-R00
Stress, MPa
250
200
150
100
50
Stress-Strain Test for HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor)
Conductor area = 726.79 mm²
Core Area = 81.71 mm²
Final Steel
0
0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60%
Unit Strain, %
Initial Steel
Initial Composite
DRAFT
Figure 5 Composite Stress-Strain Curve
Final Composite
Initial Aluminum
Final Aluminum

APPENDIX A
DESCRIPTION OF HES HACILAR ELEKTRIK SAN. VE TIC. CONDUCTOR
(Ref. 1272 mcm, 726.79 mm 2 , PHEASANT ACSR Conductor)
DRAFT
Page 15 of 20 K-419148-RC-0002-R00

PHEASANT
CONDUCTOR 1272 MCM
Stranding Direction Right
Conductor OD mm 35.11
Total Cross Section mm² 726.79
Construction 1(St)+6(St)+12(St)+12(Al)+18(Al)+24(Al)
Conductor Weight kg/km 1783.8
Conductor Tensile Strength kgf 20,357
Aluminum Cross Section mm² 645.08
Aluminum Weight kg/km 1783.8
Steel Core Diameter mm 11.7
Steel Core Cross Section mm² 81.71
Steel Core Weight kg/km 639.7
A.C. Resistance at 25 ° C, 50 Hz ohm/km 0.00475
Xa at 50 Hz ohm/km 0.231
X'a at 50 Hz Megaohm.km 0.1363
GMR 14.2
Conductor E-modulus (First) kg/mm² 5000
Conductor E-modulus (Final) kg/mm² 6000
Linear Thermal Coefficient / °C 19,3*10 -6
Current Carrying Capacity A 1160
Drum Length m 1600
Aluminum Wires
Nominal OD mm 3.9
Nominal Cross Section mm² 11.93
Tensile Strength(min) kg/mm² 16.5
DC Resistivity at 20 ° C (Max) n.ohm.m 28.264
Linear Thermal Coefficient / °C 23*10 -6
Steel Wires
CONDUCTOR PROPERTIES
DRAFT
Nominal OD mm 2.34
Nominal Cross Section mm² 4.29
Tensile Strength After Stranding kg/mm² 138
Tensile Strength at 1% Elongation (Min.) kg/mm² 128
Zinc Coating Weight g/m² 230
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Page 17 of 20 K-419148-RC-0002-R00
ISO-9001
Form: QF11-1
Rev 0, 97-10
APPENDIX B
INSTRUMENT SHEET
HES Hacilar Elektrik San. Ve Tic. (Ref. PHEASANT ACSR Conductor)
Test Description: Stress-Strain Test Test Start Date: December 3, 2009
Project Number: K-419148 Test Finish Date: December 4, 2009
TEST
DESCRIPTION
Stress-Strain
Test
EQUIPMENT
DESCRIPTION
Datalogger
Load Cell (MTS)
Load Cell
Conditioner
Displacement
Transducer
Conditioner
MAKE MODEL
ASSET # or
SERIAL #
National
Instruments PCI-6036E - B
Lebow
3156
17356-0
MTS
Ametek
Trans-tek
493.01DC
PT-10AT-HT
1002-000F
10000686-0
KIN-00658
PWP #2
Measuring Tape Stanley FatMax (34-813) KIN-00723
Digital Meter
Thermocouple
Fluke
Fluke
51
TC-K
ACCURACY
CLAIMED
CALIBRATION
DATE
CALIBRATION
DUE DATE
TEST
USE
±0.1% of
Reading June 25, 2009 June 25, 2010 Data Acquisition
±1.0% of
reading May 29, 2009 May 29, 2010
Stress Strain,
Breaking Load
19698-0 ±0.1 mm October 7, 2009 October 7, 2010 Cable Strain
DRAFT
17616-0
KIN-00613
< 0.05% of
Reading October 2, 2008 October 2, 2010
±0.9 degree C
±0.5 degree C
March 18, 2009
March 19, 2009
March 18, 2010
March 19, 2010
Cable and
Gauge Length
Cable
Temperature

APPENDIX C
KINECTRICS ISO 9001 QUALITY MANAGEMENT SYSTEM REGISTRATION
CERTICATE
DRAFT
Page 18 of 20 K-419148-RC-0002-R00

DRAFT
Page 19 of 20 K-419148-RC-0002-R00

DISTRIBUTION
Mr. Asim Mercan (2) HES Hacilar Elektrik San. Ve Tic.
Erciyes Mah. HES Cad.
No: 22 38210 Hacilar, Kayseri
Turkey
Telephone: 90 352 207 45 00
Email: amercan@hes.com.tr
C. Dimnik (1) Transmission and Distribution Technologies – KB223
DRAFT
Page 20 of 20 K-419148-RC-0002-R00