7 Standards and Testing

Clause 1:

Standards are nothing but the development and implementation of concepts,

guidelines, procedures and design to achieve and maintain the required
levels of compatibility, interchangeability or commonality in the operational,
procedural, material, technical and administrative field to attain required
performance, reliability, consistency, durability or aesthetics.

Standards provide technical specification and performance-based

requirements, which focus on functional capabilities of covered products/
Technologies.

The standards are essential for both manufacturers and consumers. They
help manufacturers to produce their products in the best possible
way/method which optimize their manufacturing costs as well as ensuring
the required quality of the product. Standards help customers in choosing the
appropriate product to suit their requirements.

It is the standard, which provides a common base for selection of materials,

method of production and testing.

Throughout the design procedure, the engineer who is responsible for

making the final material selection decision must be aware of relevant
performance and production specification and standards.

Conformity with standards generally signify product has been properly

designed, so that it will ensure the environmental, electrical and mechanical
stress which it is expected to encounter in service.

The design engineer must ensure that the standard complies to the product
being fabricated and must be certain that the standard ensure that the end
product will perform satisfactory.

We have many standards available such as NEEMA, DIN, ESI, AS/NZS,

IEC, ANSI, ASTM, IS, BSI etc for the design and testing of most of the
connectors. However, design and testing of certain type of connectors such
as Insulation Piercing connector and the Connector with Insulated cover may
require development of standards which apart from the requirements
contained in generic standards shall have additional requirements included in
it. Supreme after careful evaluation of materials and different types of tests
such as TGA, DSC analysis, Protection degree verification etc required to
ensure the suitable electrical and mechanical requirements of every
component of the connector and also the special requirements of different
customers and utilities such as ENEL, has developed such specially
developed standards keeping the product-specific features in mind for these
exceptional type of connectors.

Supreme has got a well equipped in-house testing laboratory with facilities
for performing various tests as per different international standards and
experienced Quality assurance personnel who do constant inspection at
every stage in the manufacture of product from raw materials to finished
product in order to ensure that standards of quality set by manufacturer, by
standards or by customer are being met.

We carry out New design testing, Pre-purchase qualification testing, On-

delivery conformance testing and Failure analysis. Our quality procedures
and practices comply with ISO 9001 requirements. We also provide test
reports from government accredited testing laboratories on request of the
customers.

Clause 2:

Tests Performed:

Routine tests:

1. Chemical analysis.
2. Galvanizing test.
3. Visual Inspection
4. Dimension check
5. Resistance test
6. Tensile test.
7. Hardness test

Type tests:
 1. Assembly & Removal test.
2. Thermal cycle test (refer clause 2.1).
3. Short time current test (refer clause 2.2)
4. Slip load test
5. Residual break load test

Special tests for EHV Connectors

1. Pull out Strength test

2. Cantilever strength test of bus supports (refer clause 2.3).
3. Torque strength test of bolted connectors.
4. Tensile/ Bending test on Aluminum weldment couplers.
5. Corona/ RIV test. (explained in clause 2.4)

Special tests for Insulated connectors:

1. Water Penetration test (explained in clause 2.5)

2. Protection degree Verification
3. Ageing test (explained in clause 2.6)

Clause 2.1:

Temperature cycle test:

A set of six/ four samples is connected in a loop with their appropriate main
and branch conductors. A current required to raise the temperature of the
connector to 100 degree Celsius with the temperature of reference conductor
not exceeding 140 degree Celsius is applied to the loop for a definite time.
The current is then interrupted once the connector reaches 100 degree
Celsius. The loop is allowed to cool to the atmospheric temperature. This
cycle is repeated several times as per the specification.

Clause 2.2:

Short time Current test*:

The sample is connected to short circuit generator and a short time current
pulse, which is required to increase the temperature of the reference
conductor to 250 degree Celsius, is applied for a duration of 1 second. Such
kind of particular number of shots is applied to the connector depending
upon the number of heat cycles performed.

Clause 2.3:

Cantilever strength test of bus supports:

The cantilever strength is determined by applying a load at the centerline of

the conductor, transverse to the conductor longitudinal axis.

Clause 2.4:

Corona/RIV test*:

The test is conducted in a darkened area to locate and observe the presence
or absence of Corona. The observation is made only for Positive corona as it
is the primary cause of radio interference. A voltage equal to 30 % over
voltage is gradually applied to identify the corona locations and the corona
inception voltage. The voltage shall then be reduced gradually to identify the
corona extinction voltage.

RIV can be made with High voltage testing apparatus as per NEEMA
standards or other international standards. RIV test shall be omitted if all the
sources of corona have been identified with the test set up of Visual
observation.

EHV connector testing is done with the conductors of smallest cross section
as smaller conductors are susceptible to corona at low voltages.

Clause 2.5:

Water Penetration test/ Dielectric test:

The test sample is kept immersed in water for a duration of one hour. Then a
voltage equal to 3/4/6 KV is applied to the sample through a High voltage
test apparatus and this voltage is reached in 1 minute. The sample is allowed
to withstand this tension for 15 minutes and the voltage is brought down

Clause 2.6:

Ageing test*:

The sample is kept under different simulated weather conditions such as salt-
water spray, fog, dust, high humidity, Ultra violet exposure and a
combination of any of these to observe the ageing properties of the material.

Clause 3:

Applicable Standards:

1. BS 3288
2. BS 1490
3. BS 729
4. IEC 1238
5. IEC 61284.
6. AS/ NZS 4396
7. ESI 43-14
8. ANSI C 119.4
9. ASTM D 570
10. ASTM A 153
11. IS 2004
12. NEMA CC1
13. NEMA CC3

* To be performed in NABL Accredited Laboratories.

Clause 4:

Reference Current ratings for Thermal cycle test (as per NEEMA CC1):
For Bare Copper conductors:

Current ratings, Amperes

1 2 3
Size of Conductors Indoor Outdoor
Solid Wire
0 AWG (54 sq mm) 160 250
00 AWG (67 sq mm) 190 290
0000 AWG (107 sq mm) 260 390
Stranded Wire
0 AWG (54 sq mm) 160 250
00 AWG (67 sq mm) 190 300
0000 AWG (107 sq mm) 270 400
250 MCM (127 sq mm) 290 430
400 MCM (203 sq mm) 410 580
500 MCM (253 sq mm) 480 670
600 MCM (304 sq mm) 540 750
750 MCM (380 sq mm) 630 860
1000 MCM (507 sq mm) 770 1030
1500 MCM (760 sq mm) 1000 1310
2000 MCM (1013 sq mm) 1190 1530

Current ratings, Amperes (Based upon

57-61 % conductivity)
1 2 3
Size of Conductors Indoor Outdoor
Solid Wire
0 AWG (54 sq mm) 120 190
00 AWG (67 sq mm) 140 220
0000 AWG (107 sq mm) 210 300
Stranded Wire
0 AWG (54 sq mm) 130 200
00 AWG (67 sq mm) 150 230
0000 AWG (107 sq mm) 200 320
250 MCM (127 sq mm) 240 350
400 MCM (203 sq mm) 340 480
500 MCM (253 sq mm) 400 550
600 MCM (304 sq mm) 450 620
750 MCM (380 sq mm) 530 720
1000 MCM (507 sq mm) 650 870
1500 MCM (760 sq mm) 850 1110
2000 MCM (1013 sq mm) 1030 1320
For Bare Aluminum conductors:

Current Ratings, Amperes

1 2 3
Standard
Pipe Size
(mm) Indoor Outdoor
Schedule Schedule Schedule Schedule
40 80 40 80
12.7 380 420 510 580
19 540 590 710 780
25.4 650 750 850 1010
31.8 870 975 1120 1250
38.1 1020 1150 1280 1450
50.8 1250 1500 1550 1850
63.5 1700 1975 2000 2400
76.2 2175 2475 2550 2950
88.9 2575 2875 3050 3400
101.6 2850 3100 3400 3800
127 3450 3850 4100 4600
152.4 4000 4500 4700 5200

Current Ratings, Amperes (Based upon 53

% conductivity
1 2 3
Standard
Pipe Size
(mm) Indoor Outdoor
Schedule Schedule Schedule Schedule
40 80 40 80
12.7 315 360 400 455
19 400 455 495 565
25.4 535 605 650 740
31.8 680 780 810 930
38.1 790 910 930 1070
50.8 1000 1175 1155 1355
63.5 1365 1570 1550 1780
76.2 1670 1935 1895 2195
88.9 1945 2265 2170 2530
101.6 2230 2605 2460 2880
114.3 2515 2955 2750 3230
127 2845 3355 3080 3635
152.4 3500 4205 3735 4490
 Initial test amperes for Hot line clamp:

Test Conductor Size Initial Test Amperes

Cu 70 sq mm 405

Cu 2/0 400

Cu 95 sq mm 505

Cu 4/0 550

Al 50 sq mm 220

Al 1/0 230
 1 Electrical Testing

Resistance Test

Thermal Cycle Test

Dielectric Test
 2 Chemical Testing

Chemical Analysis / Galvanising Test

3 Mechanical Testing

Hardness Test

Tensile Test
8 Glossary of Terms
 Definitions As per Standards
NEEMA CC-1-2002.

Bolted type Connector:

In a bolted type connector, the contact between the conductor and the
connector is made by pressure exerted by one or more clamping bolts.

Branch Connector:

A branch connector is an angle connector, which joins a branch conductor to

the main conductor at a specified angle.

Bus support:

A bus support is a metal member, usually mounted on an insulator, which

supports a bus conductor.

Combined “t” and straight connector (“t” coupler):

A combined “T” and straight connector joins two main conductors end to
end and also joins a branch conductor to the main conductors at an angle of
90 degrees.

Conductor:

A conductor is constructed from conducting material so that it may be used

as a carrier of electric current.

Connector:

A connector is a device, which joins two or more conductors for the purpose
of providing a continuous electrical path.

Cross connector:
A cross connector joins two branch conductors to the main conductor. The
branch conductors are opposite to each other and perpendicular to the main
conductor.

Design tests:

Design tests are made on the completion of the development of a new design
to establish representative performance data. They need to be repeated only
if the design is changed to modify its performance.

HV, EHV, UHV power connectors:

A HV, EHV or UHV power connector is a connector, bus support or other

device which, when installed on its conductor, does not generate corona or
noise at nominal voltage.

Expansion connector:

An expansion connector provides a flexible connection between rigid

conductors or between a rigid conductor and electrical apparatus.

Hot-line clamp:

A hot-line clamp is a connector, which shall be permitted to be installed

while the conductor is energized.

“ L” connector:

An “L” connector is an angle connector, which joins two conductors end to

end at an angle of 90 degrees.

Main Conductor:

A main conductor is a continuous conductor from which other conductors

branch.

Pad angle terminal connector:

A pad angle terminal connector joins a conductor to the terminal pad of

electrical apparatus at a specified angle.
Pad terminal connector:

A pad terminal connector joins a conductor to the terminal pad of electrical

apparatus.

Parallel connector:

A parallel connector joins to parallel conductors, which may overlap each

other.

Pressed-tubular terminal connector:

A pressed tubular terminal connector is fabricated or pressed from tubing.

Pressure type connector:

A pressure type connector is applied with integral screw, cone, or other

mechanical parts.

Range-taking connector:

A range taking connector accommodates more than one conductor size.

Routine test:

Routine test are made to verify the quality and uniformity of the
workmanship and materials used in the manufacture of electric power
connectors.

Service connector:

A service connector is a parallel connector in which the contact between the

conductor is obtained by mechanically applied pressure.

Shrink-fit type connector:

In a shrink-fit type connector the contact between the conductor and the
connector is made by a shrink-fit.
Single size connector:

A single size connector accommodates only one conductor size.

Solder type connector:

In a solder type connector the contact between the conductor and the
connector is made by a soldered joint.

Split-sleeve connector:

A split-sleeve connector is of split sleeve form and is tinned for soldering.

Straight adapter connector:

A straight adapter connector joins two conductors of different shapes end to

end in a straight line.

Straight connector:

A straight connector joins two lengths of conductor end to end in a straight

line.

Straight coupler connector:

A straight coupler connector joins two conductors of equal sizes end to end
in a straight line.

Straight reducer connector:

A straight reducer connector joins two conductors of unequal sizes end to

end in a straight line .

Stud angle terminal connector:

A stud angle terminal connector joins a conductor to the round terminal stud
of electrical apparatus at a specified angle.

Stud terminal connector:

A stud angle terminal connector joins a conductor to the round terminal stud
of electrical apparatus .

“T” connector:

A “T” connector is a branch connector, which joins a branch conductor to

the main conductor at an angle of 90 degrees.

Tang:

A tang is that portion of the connector, which is used to fasten a connector to

a terminal pad.

Tap conductor:

A tap conductor branches off from a main conductor.

Terminal connector:

A terminal connector joins a conductor to a lead, terminal pad or round

terminal stud of electrical apparatus.

Terminal pad:

A terminal pad is the flat conducting part of a device to which a terminal

connector is fastened.

Threaded type connector:

In a threaded type connector the contact between the conductor and the
connector is made by pressure exerted on a threaded part.

Twisted sleeve connector:

A twisted sleeve connector is a parallel connector in which the contact

between the conductors is obtained by a spiral twist in the connector and the
conductors after their assembly.

“V” Connector:
A “V” connector joins two branch conductors to a main conductor. The
branch conductors are perpendicular to the main conductor and have an
included angle between them of less than 180 degrees.

Wedge-type connector:

In a wedge-type connector the contact between the conductor and the

connector is made by pressure exerted by a wedge.

“Y” connector:

A “Y” connector joins two branch conductors to the main conductor at an

angle. The three conductors are in the same plane.

Weld-type connector:

In a weld-type connector the contact between the conductor and the

connector is made by welding.

According to IEC 1238,

Connector:
Device for connecting a conductor to an equipment terminal or for
connecting two or more conductors to each other.

Through connector:
Connector for connecting two consecutive length of conductor.

Branch connector:
Connector for connecting a branch conductor to a main conductor.

Terminal lug:

Connector comprising a palm and a connector barrel, for connecting a

conductor to an equipment terminal.

Palm:
Part of a terminal lug used to make the connection to the equipment
terminals.

Connector barrel:

Part of a connector, into which the conductor to be connected is introduced.

Joint:

Assembly comprising the connector barrel and that portion of the conductor
which has been brought into intimate contact with it during the joining
process.

Reference conductor:

Length of un joined bare conductor or conductor with the insulation

removed, which is included in the test loop and which enables the reference
temperature and reference resistance to be determined.

Equalizer:

Arrangement used in the test loop to ensure a point of equi-potential in a

stranded conductor.

Compression jointing:

Method of securing a connector to a conductor by using a special tool to

produce permanent deformation of the connector and the conductor.

Mechanical jointing:

Method of securing a connector to a conductor, for example by means of a

bolt or screw acting on the latter.
Bibliography:

1. Guide for Power Connectors By Dr. Milenko Braunovic, Montreal, QC

Canada.
2. NEEMA CC1, 2002 – Electric Power Connection for Substations.
3. BS 3288- Specification for Insulator and Conductor fittings for overhead
powerlines.
4. IEC 1238 – Compression and Mechanical connectors for Power cables with
copper or aluminum conductors.
5. IEC 61284 – Over head lines – Requirement and tests for fittings.
6. ANSI C 119.4 – Connectors for use between Aluminum to aluminum or
Aluminum to Copper bare overhead conductors.
7. High Voltage Engineering and Testing By H.M. Ryan.