0 evaluări0% au considerat acest document util (0 voturi)
20 vizualizări4 pagini
Time-load (static fatigue) testing of fiberglass rods used in non-ceramic insulators has been underway for over 20 years. Results indicate a very flat time-load curve under nominal conditions. Residual strength tests were unable to quantify any significant loss in strength as a result of long-term overload conditions.
Time-load (static fatigue) testing of fiberglass rods used in non-ceramic insulators has been underway for over 20 years. Results indicate a very flat time-load curve under nominal conditions. Residual strength tests were unable to quantify any significant loss in strength as a result of long-term overload conditions.
Time-load (static fatigue) testing of fiberglass rods used in non-ceramic insulators has been underway for over 20 years. Results indicate a very flat time-load curve under nominal conditions. Residual strength tests were unable to quantify any significant loss in strength as a result of long-term overload conditions.
R. A. Bernstorf Hubbell Power Systems - Ohio Brass Co. Abstract: Time-Load (static fatigue) testing of fiberglass rods used in non-ceramic insulators (NCIs) has been underway for over 20 years. Data collected over that time frame is reported in this paper for NCIs manufactured with 16 mm ( 5 / 8 ' ) diameter and 22 mm (7/8") diameter epoxy fiberglass rods. All of the samples tested utilized crimped steel end fittings for transference of the applied tensile load to the fiberglass rod and from the rod to the support structure. Samples with and without a polymer housing covering the core rod are included. The data includes time-load test results under constant load to failure and residual strength evaluations after the removal of a long- term time-load. The results indicate a very flat time-load curve under nominal conditions. The residual strength tests were unable to quantify any significant loss in strength as a result of long-term overload conditions. Over the course of 20 years, the investigation looked into looked into the characteristics of 16" and 22 mm rod insulators. In 1998, the test program was terminated, with this paper reporting the final test results. 11. TIME-LOAD TESTING Time-Load testing involves applying a constant load to an insulator for an extended period of time (typically until it fails). Unless otherwise noted, that is the means of testing employed for the included data. Keywords: Non-ceramic Insulators, Time-load. I. INTRODUCTION With the introduction of non-ceramic insulators in the late 60s and early 70s came a growing concern for the long term strength characteristics of the fiberglass rods used as strength members, as well as the integrity of the end fitting attachment methods to that rod. These concerns were a product of the aerospace industry which had been testing composite materials and their long-term creep characteristics. Fig. 1 - Typical outdoor load racks - 16 mm samples. In an effort to address those concerns, a series of long-term loading tests (time-load) were undertaken. The goal of the testing program was the development of an understanding of the long-term load bearing characteristics of the non-ceramic insulators. The non-ceramic insulators evaluated in this test program utilized either a 15.9 mm (nominal 518 inch) Or 22.3" (nominal 718 inch) diameter fiberglass rod. For the Purposes of this paper, the two types will be referenced as 16 mm and 22 mm, respectively. The fiberglass rods were an epoxy resin system with a E-type unidirectional glass fibers. Fiberglass rod lengths were at least 20X the diameter in order to minimize end effects. End fittings were composed of forged steel. These fittings were crimped to the fiberglass rod using a rolling crimp, which proceeded from the innermost point of the end fitting toward the end. The crimp lengths were 63.5 mm(2.5 in) and 101.6 mm(4 in) for the 16 mmand 22 mm diameter rod insulators, respectively. 0-7803-5515-6/99/$10.00 0 1999 IEEE 823 The minimum ultimate tensile strength load ratings for the insulators were 89 kN for the 16 mm rod and 222 kN for the 22 mm rod. The recommended maximum loadings for these insulators were 44 kN and 11 1 kN for the 16 mm and 22 mm rod insulators, respectively. Samples were tested in load frames located both indoors Samples without weathersheds were only and outdoors. tested indoors (see fig. 1) The load frames used lever arms to apply a load to the insulator. All loads were established by inserting a load cell (originally hydraulic, later electronic) and measuring the load during three applications. The error listed for the data represents the range. Pivot points within the load frames were lubricated with a high pressure lubricant. The date and time of loading was recorded exactly. For newly loaded samples, conditions were checked daily. As time went by, the samples were checked less frequently. Sample failure was indicated by mechanical failure and noted by the load bucket at the free end of the moment arm resting on the floor. Time to failure was established as an average time (between checks) and a range. The data displayed large variations in time to failure as a function of load. To make sense of the data, it was plotted as a log-log graph (see fig. 2). The 16 mm rod diameter data was also analyzed using Chi-Squared analysis. The analysis was performed in the statistical mode using a logarithmic equation as shown on the face of the graph. Assumed errors were 3% for all data. 16" ROD - TIME LOAD DATA course of the test for the 5/ 8 samples. All of these tests were performed with the insulator in a vertical position. The solid line represents the equation derived using the Chi-squared analysis. Since the samples which did not fail are included, the curve will be somewhat pessimistic. Had those units been permitted to remain on test until failure, the curve would have demonstrated less slope. With the data for the samples which did not fail removed, the graph shown in Fig. 3 results. 16" TIME-LOAD FAILURES o m 1 Owool o w 0 1 owl 001 0 1 I IO I W ,,ME, YE, , , , s Ln(Y)=-O OOor88'Ln(X)+4 414 ChiA2=0 000416 Fig. 3 - Time-load data including only failures. It should be noted that more than 95% of the samples which failed during the test sustained a rod failure. The remainder sustained crimp slips (the crimped fitting slides from the rod) or hardware failures (the metallic coupling zone fails). 100 3 2 s 9 U1 Y 0 2 - 4 10 0000001 000001 00001 0001 001 0 1 1 10 100 EUPSED TIME. YEARS WO=- 000839*Ln(X)+4 3948 Ch1"2=00213 Fig. 4 - Outdoor load racks for 22 mm rod samples. Fig. 2 - Time-load data including samples which did not fail. This graph includes all of the data obtained, including the time to removal for samples which did not fail during the The test program for the 22 mm insulators was performed in a similar manner. In this instance, all of the insulators 824 were tested in frames which placed the insulators in a horizontal position (see fig. 4). All of the tests were performed outdoors, requiring the use of full insulators. The data for the 22 mm samples was not run through the Chi-squared analysis. However, the data is plotted in fig. 5. 22 mm Rod Time-Load Data 10 OOWOl o w 0 1 ow1 001 0 1 1 10 Elapsed Ti m. Yean Fig. 5 - Time-load data including samples which did not fail. 111. ULTIMATE AND RESIDUAL STRENGTH The time-load results indicate the ability of the insulator to sustain a fixed load for a period of time. But that load is typically well above the loads which would be expected in the field. The primary concern of most users involves the residual strength in the design resulting from the insulator's service history. Before the time-load tests were begun, control samples were prepared. These insulators were tested in tension to determine the ultimate tensile strength. When the test program was established, every third insulator manufactured was tested to ascertain the characteristic tensile strength of the batch. Since no test protocol existed, the load was applied at a relatively uniform rate until failure occurred. A typical example of the loading profile (see fig. 6) and the initial data collected for all of the samples is shown in Fig. 7. After the termination of the time-load tests, the unfailed samples which were removed from the loading racks were subjected to the same ultimate tensile strength test. Those results are shown in Fig. 8 for the 16 mm test samples. 1m i m 80 4 60 I ; 40 20 0 1998 - UTS - Time-Load Sample 0 5 4 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 El.pr.d Thu. Fig. 6 -Typical Ultimate Tensile Strength load profile. 16mm -CONTROL SAMPLES - UTS 1E-07 O.OOWO1 O.OOW1 0.0001 0.001 0.01 0.1 1 EIAPSED TIME. YEARS Fig. 7 - Control Samples UTS data. The data was analyzed using a student's t-test [l]. For the analysis, a two-tailed distribution was assumed. Details follow: 1977: Average(l9) =124.25 1998: Average(l1) =120.95 P(T,n) =0.837 o =9.63 o =7.48 2( 1 -P) =.326 The analysis indicates a 32.6% probability that the two groups of data are from the same general population. That probability is substantial enough to make doubtful any supposition that the insulators sustained a measurable loss in strength as a result of the time under load. 825 16mm RODS - UTS SAMPLES - BEFORE AND AFTER I V. CONCLUSIONS The data collected over 20 years indicates that non-ceramic insulators exhibit very stable time-load characteristics. p ; ~ Extrapolations based upon the existing data indicate that the 2-to-1 safety factor applied to this type of insulator, if properly followed, provides sufficient margin to assure appropriate long term service. .S"Z A comparison of ultimate strength data collected at the start of the test program with that collected after 20 years of ODOOOOOI ooowo, Oo wo l oow1 ow1 001 0 1 ELIPSEDIIHE,IEIR~ . 1977 DATi. CONTROLS testing indicates no significant reduction in strength. SERIES 2 - 1998 DATA - POST LOAD Fig. 8 - Control samples and post test UTS data VI. REFERENCES IV. DISCUSSION The data collected over 20 years of testing indicates that the time-load strength reduction for non-ceramic insulators is minimal. The 2-to-I safety margin normally used for these insulators is sufficient to permit the insulator to be operated without fear of failure for any reasonable service life. The ultimate strength data collected before and after the time-load test indicates no substantial loss of strength resulting from the loading. However, since insulators do fail during time-load testing, there must be strength loss. The strength loss may be so gradual that it cannot be precisely determined or it may be non-linear. In either case, the data implies that evaluations of tensile strength for insulators removed from service may not be an indicator of their condition. [l ] S . L. Meyer, Data Analysis for Scientists and Engineers, J ohn Wiley and Sons, 1975, pp. 279- 282. VII. BIOGRAPHIES R. Allen Bernstorf graduated with a B.A. from Gettysburg College and an M.S. in physics from the University of Akron. In his current position as principal engineer, insulators, he is responsible for the testing and application of insulator products. He is a member of the IEEE and is active in the IEEEPES, the ANSI C-29 Committee, the CSA C411 Committee and NEMA HVITC. 826