Post on 01-Apr-2015
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Draka USAComparative Testing of
Longitudinally Corrugated vs. Helically Applied Shields for
Transit Applications
• PURPOSE OF TESTSPURPOSE OF TESTS
• ALTERNATIVE CONSTRUCTIONSALTERNATIVE CONSTRUCTIONS
• TEST SAMPLES MADETEST SAMPLES MADE
• TESTS CONDUCTEDTESTS CONDUCTED
• TEST RESULTSTEST RESULTS
• CONCLUSIONSCONCLUSIONS
Draka USA
DISCUSSION ITEMS
PURPOSE OF TESTSPURPOSE OF TESTS
DEMONSTRATE EQUIVALENT PERFORMANCE TO DEMONSTRATE EQUIVALENT PERFORMANCE TO STANDARD CLASS 1 RAILROAD SIGNAL CABLE STANDARD CLASS 1 RAILROAD SIGNAL CABLE DESIGNS EMPLOYING HELICALLY APPLIED DESIGNS EMPLOYING HELICALLY APPLIED BRONZE TAPES.BRONZE TAPES.
Draka USA
PURPOSE OF TESTSPURPOSE OF TESTS
TEST PROGRAMTEST PROGRAM
PURPOSE: EVALUATE ALTERNATIVESPURPOSE: EVALUATE ALTERNATIVES
NUMBER OF ALTERNATIVES: 3NUMBER OF ALTERNATIVES: 3
KEY PERFORMANCE ISSUES:KEY PERFORMANCE ISSUES: FLEXIBILITYFLEXIBILITY
DURABILITYDURABILITY
Draka USA
CONSTRUCTIONSCONSTRUCTIONS
CURRENT ARMORED SIGNAL CABLE:CURRENT ARMORED SIGNAL CABLE:
EPR INSULATIONEPR INSULATION
TINNED COPPER CONDUCTORSTINNED COPPER CONDUCTORS
SBR TAPE or BEDDING LAYERSBR TAPE or BEDDING LAYER
HELICAL BRONZE TAPEHELICAL BRONZE TAPE
PE, NEOPRENE OR LSZH JACKETPE, NEOPRENE OR LSZH JACKET
Draka USA
CONSTRUCTIONSCONSTRUCTIONS
PROPOSED ARMORED SIGNAL CABLE:PROPOSED ARMORED SIGNAL CABLE:
EPR INSULATIONEPR INSULATION
TINNED COPPER CONDUCTORSTINNED COPPER CONDUCTORS
SBR TAPE or BEDDING LAYERSBR TAPE or BEDDING LAYER
LONGITUDINAL CORRUGATED BRONZE LONGITUDINAL CORRUGATED BRONZE SHIELDSHIELD
PE, NEOPRENE OR LSZH JACKETPE, NEOPRENE OR LSZH JACKET
Draka USA
ALTERNATIVE ALTERNATIVE CONSTRUCTIONSCONSTRUCTIONS
ALT. 1: MYLAR/LC BRONZE SHIELDALT. 1: MYLAR/LC BRONZE SHIELD
MYLAR TAPEMYLAR TAPE
LONGITUDINALLY APPLIED, CORRUGATED, LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELDBRONZE SHIELD
ALT. 2: SBR/LC BRONZE SHIELDALT. 2: SBR/LC BRONZE SHIELD
SBR TAPESBR TAPE
LONGITUDINALLY APPLIED, CORRUGATED, LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELDBRONZE SHIELD
ALT. 3: SBR/LC STEEL SHIELDALT. 3: SBR/LC STEEL SHIELD
SBR TAPESBR TAPE
LONGITUDINALLY APPLIED, CORRUGATED, STEEL SHIELDLONGITUDINALLY APPLIED, CORRUGATED, STEEL SHIELD
Draka USA
TEST SAMPLES TEST SAMPLES MANUFACTUREDMANUFACTURED
SAME CABLE CORE AND JACKET FOR ALL FOUR SAME CABLE CORE AND JACKET FOR ALL FOUR SAMPLES:SAMPLES:
5 Conductors5 Conductors
Tinned copperTinned copper
EPR InsulationEPR Insulation
78 MIL PE Jacket78 MIL PE Jacket
Draka USA
TEST SAMPLES TEST SAMPLES MANUFACTUREDMANUFACTURED
STANDARD CONSTRUCTION:STANDARD CONSTRUCTION:
SBR TAPESBR TAPE
10 MIL HELICAL, BRONZE SHIELD10 MIL HELICAL, BRONZE SHIELD
ALT. 1: MYLAR/LC BRONZE SHIELDALT. 1: MYLAR/LC BRONZE SHIELD
MYLAR INSTEAD OF SBR TAPEMYLAR INSTEAD OF SBR TAPE
LC INSTEAD OF HELICAL SHIELDLC INSTEAD OF HELICAL SHIELD
ALT. 2: SBR/LC BRONZE SHIELDALT. 2: SBR/LC BRONZE SHIELD
LC INSTEAD OF HELICAL SHIELDLC INSTEAD OF HELICAL SHIELD
ALT. 3: SBR/LC STEEL SHIELDALT. 3: SBR/LC STEEL SHIELD
6 MIL COATED, LC STEEL SHIELD6 MIL COATED, LC STEEL SHIELD
Draka USA
TESTS CONDUCTEDTESTS CONDUCTED
CRUSH TESTCRUSH TEST
Measures compressive force needed to cause electrical failureMeasures compressive force needed to cause electrical failure
CYCLIC FLEXING TESTCYCLIC FLEXING TEST
Measures capability of cables to withstand multiple flexesMeasures capability of cables to withstand multiple flexes
FLEXIBILITY TESTFLEXIBILITY TEST
Measures force required for a single bendMeasures force required for a single bend
CUT THROUGH TESTCUT THROUGH TEST
Measures the force on a 90Measures the force on a 90oo wedge required to cut through to wedge required to cut through to the armor and to the conductors the armor and to the conductors
Draka USA
CRUSH TEST APPARATUSCRUSH TEST APPARATUSDraka USA
Side view of area shown above enclosed within dotted lines.
Load Cell
Cable Under Test
Tensile Test Machine
Crosshead movement at0.50 inches per minute
Crosshead
3/4 inch Steel Mandrel
Continuity testers, monitoringfor shorts between cable
components and testapparatus.
3/4 inch Steel MandrelIndicates directionof movment and
compressive force
Cable Under Test
CRUSH TEST RESULTS
CABLECABLE FORCE (LB) AT FAILURE FORCE (LB) AT FAILURE
TYPETYPE AVE.AVE. MIN.MIN.
STD.STD. 9,0009,000 7,000 7,000
ALT. 1ALT. 1 > 10,000> 10,000 > 10,000> 10,000
ALT. 2ALT. 2 9,1009,100 8,3008,300
ALT. 3ALT. 3 9,5009,500 8,6008,600
Draka USA
CRUSH TEST RESULTS
TEST CONDITIONS:TEST CONDITIONS:
ONE 4 FT. SAMPLE PER TYPEONE 4 FT. SAMPLE PER TYPE
TEN APPLICATION POINTS PER SAMPLETEN APPLICATION POINTS PER SAMPLE
LOAD RATE: 0.5 IN/MIN.LOAD RATE: 0.5 IN/MIN.
MAX. APPLIED FORCE: 10,000 LB.MAX. APPLIED FORCE: 10,000 LB.
FAILURE WHEN SHORT DETECTEDFAILURE WHEN SHORT DETECTED
Draka USA
CYCLIC FLEXING TEST APPARATUS Draka USA
55 lbWeight
90° 90°
7 inch Rollers
8½in.
Cable under test, withconductors and armorconnected in series.
Continuity monitor,stops machine fromflexing cable when
open circuit isdetected
Lower Rollers, tostabilize cableduring flexing
CYCLIC FLEXING TEST RESULTS CABLE TYPE NO. OF CYCLES DESCRIPTION OF FAILURE____CABLE TYPE NO. OF CYCLES DESCRIPTION OF FAILURE____
STDSTD 233233 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.
426426 JACKET SPLIT OPEN JACKET SPLIT OPEN
538538 JACKET & ARMOR SEVERELY JACKET & ARMOR SEVERELY SPLITSPLIT
ALT. 1ALT. 1 230230 CONTINUITY LOST IN ARMOR CONTINUITY LOST IN ARMOR
282282 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.
ALT. 2ALT. 2 316316 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.
482482 CONTINUITY LOST IN ARMOR CONTINUITY LOST IN ARMOR
ALT. 3ALT. 3 260260 JACKET SPLIT OPEN JACKET SPLIT OPEN
288288 CONTINUITY LOST IN ONE CONTINUITY LOST IN ONE COND.COND.
322322 CONTINUITY LOST IN ARMOR CONTINUITY LOST IN ARMOR
Draka USA
CYCLIC FLEXING TEST RESULTS
TEST CONDITIONS:TEST CONDITIONS:
ONE 3 FT. SAMPLE PER TYPEONE 3 FT. SAMPLE PER TYPE
ONE CYCLE: TWO 90ONE CYCLE: TWO 90OO BENDS BENDS
15 CYCLES PER MIN.15 CYCLES PER MIN.
Draka USA
FLEXIBILITY TEST APPARATUS Draka USA
Side view of area shown above enclosed within dotted lines.
Steel Cable
Load Cell
Cable Under Test
Tensile Test Machine
Crosshead
Crosshead movement at20 inches per minute
Cable Clamp
Steel Cable
2.8 inch Mandrel
Cable clamps spaced 24" apart
Cable Under Test
Crosshead
FLEXIBILITY TEST RESULTS Draka USA
1
1
2
2
3
4
34
NO. 1 -- NO. 1 -- STANDARD TYPESTANDARD TYPE
NO. 2 -- NO. 2 -- ALTERNATIVE TYPE 1ALTERNATIVE TYPE 1
NO. 3 -- NO. 3 -- ALTERNATIVE TYPE 2ALTERNATIVE TYPE 2
NO. 4 -- NO. 4 -- ALTERNATIVE TYPE 3ALTERNATIVE TYPE 3
FLEXIBILITY TEST RESULTS
TEST CONDITIONSTEST CONDITIONS
ONE SAMPLE PER TYPEONE SAMPLE PER TYPE
SINGLE BEND, 90SINGLE BEND, 90OO
2.8 INCH MANDREL2.8 INCH MANDREL
RATE: 20 INCHES PER MIN.RATE: 20 INCHES PER MIN.
Draka USA
CUT THROUGH TEST APPARATUS
Draka USA
Side view of area shown above enclosed within dotted lines.
Load Cell
Cable Under Test
Tensile Test Machine
Crosshead movement at0.50 inches per minute
Crosshead
3/4 inch Steel Wedge
Continuity testers, monitoringfor shorts between cable
components and testapparatus.
3/4 inch Steel WedgeIndicates directionof movment and
compressive force
Cable Under Test
CUT THROUGH TEST RESULTS
CABLECABLE AVE. FORCE (LB) TO REACHAVE. FORCE (LB) TO REACH
TYPETYPE ARMORARMOR CONDUCTORCONDUCTOR
STD.STD. 2,8002,800 5,0005,000
ALT. 1ALT. 1 3,1003,100 5,1005,100
ALT. 2ALT. 2 3,1003,100 5,0005,000
ALT, 3ALT, 3 4,3004,300 4,7004,700
Draka USA
CUT THROUGH TEST RESULTS
TEST CONDITIONS:TEST CONDITIONS:
ONE 4 FT. SAMPLE PER TYPEONE 4 FT. SAMPLE PER TYPE
TEN APPLICATION POINTS PER SAMPLETEN APPLICATION POINTS PER SAMPLE
LOAD RATE: 0.5 IN/MIN.LOAD RATE: 0.5 IN/MIN.
MAX. APPLIED FORCE: 10,000 LB.MAX. APPLIED FORCE: 10,000 LB.
SHORT TO WEDGE DETECTEDSHORT TO WEDGE DETECTED
Draka USA
CONCLUSIONS CRUSH TESTCRUSH TEST
MYLAR TAPE WITH LONGITUDINAL CORRUGATED BRONZE MYLAR TAPE WITH LONGITUDINAL CORRUGATED BRONZE SHIELD SIGNIFICANTLY BETTERSHIELD SIGNIFICANTLY BETTER
CYCLIC FLEXING TESTCYCLIC FLEXING TEST
NO SIGNIFICANT DIFFERENCESNO SIGNIFICANT DIFFERENCES
FLEXIBILITY TESTFLEXIBILITY TEST
THE LONGITUDINAL SHIELD IS AS FLEXIBLE AS THE HELICALTHE LONGITUDINAL SHIELD IS AS FLEXIBLE AS THE HELICAL SHIELDSHIELD
CUT THROUGH TESTCUT THROUGH TEST
HELICAL SHIELD SLIGHTLY LESS RESISTANT TO CUT HELICAL SHIELD SLIGHTLY LESS RESISTANT TO CUT THROUGHTHROUGH
Draka USA
RECOMMENDATION
ALLOW THE USE OFALLOW THE USE OF
MYLAR TAPE ANDMYLAR TAPE AND
10 MIL, LONGITUDINAL10 MIL, LONGITUDINAL
CORRUGATED BRONZE SHIELDCORRUGATED BRONZE SHIELD
IN UNDERGROUND SIGNAL CABLEIN UNDERGROUND SIGNAL CABLE
Draka USA
BENEFITS
ANNUAL COST SAVINGSANNUAL COST SAVINGS
NO REDUCTION IN PERFORMANCE NO REDUCTION IN PERFORMANCE
SAFER HANDLING DURING TERMINATIONSAFER HANDLING DURING TERMINATION
Draka USA