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Draka USA

Draka USA Comparative Testing of Longitudinally Corrugated vs. Helically Applied Shields for Transit Applications. Draka USA. DISCUSSION ITEMS. PURPOSE OF TESTS ALTERNATIVE CONSTRUCTIONS TEST SAMPLES MADE TESTS CONDUCTED TEST RESULTS CONCLUSIONS. Draka USA. PURPOSE OF TESTS.

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Draka USA

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  1. Draka USA Comparative Testing of Longitudinally Corrugated vs. Helically Applied Shields for Transit Applications

  2. Draka USA DISCUSSIONITEMS • PURPOSE OF TESTS • ALTERNATIVE CONSTRUCTIONS • TEST SAMPLES MADE • TESTS CONDUCTED • TEST RESULTS • CONCLUSIONS

  3. Draka USA PURPOSE OF TESTS DEMONSTRATE EQUIVALENT PERFORMANCE TO STANDARD CLASS 1 RAILROAD SIGNAL CABLE DESIGNS EMPLOYING HELICALLY APPLIED BRONZE TAPES.

  4. Draka USA PURPOSE OF TESTS • TEST PROGRAM • PURPOSE: EVALUATE ALTERNATIVES • NUMBER OF ALTERNATIVES: 3 • KEY PERFORMANCE ISSUES:      FLEXIBILITY • DURABILITY

  5. Draka USA CONSTRUCTIONS CURRENT ARMORED SIGNAL CABLE: EPR INSULATION TINNED COPPER CONDUCTORS SBR TAPE or BEDDING LAYER HELICAL BRONZE TAPE PE, NEOPRENE OR LSZH JACKET

  6. Draka USA CONSTRUCTIONS PROPOSED ARMORED SIGNAL CABLE: EPR INSULATION TINNED COPPER CONDUCTORS SBR TAPE or BEDDING LAYER LONGITUDINAL CORRUGATED BRONZE SHIELD PE, NEOPRENE OR LSZH JACKET

  7. Draka USA ALTERNATIVE CONSTRUCTIONS ALT. 1: MYLAR/LC BRONZE SHIELD MYLAR TAPE LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELD ALT. 2: SBR/LC BRONZE SHIELD SBR TAPE LONGITUDINALLY APPLIED, CORRUGATED, BRONZE SHIELD ALT. 3: SBR/LC STEEL SHIELD SBR TAPE LONGITUDINALLY APPLIED, CORRUGATED, STEEL SHIELD

  8. Draka USA TEST SAMPLES MANUFACTURED SAME CABLE CORE AND JACKET FOR ALL FOUR SAMPLES: 5 Conductors Tinned copper EPR Insulation 78 MIL PE Jacket

  9. Draka USA TEST SAMPLES MANUFACTURED STANDARD CONSTRUCTION: SBR TAPE 10 MIL HELICAL, BRONZE SHIELD ALT. 1: MYLAR/LC BRONZE SHIELD MYLAR INSTEAD OF SBR TAPE LC INSTEAD OF HELICAL SHIELD ALT. 2: SBR/LC BRONZE SHIELD LC INSTEAD OF HELICAL SHIELD ALT. 3: SBR/LC STEEL SHIELD 6 MIL COATED, LC STEEL SHIELD

  10. Draka USA TESTS CONDUCTED CRUSH TEST Measures compressive force needed to cause electrical failure CYCLIC FLEXING TEST Measures capability of cables to withstand multiple flexes FLEXIBILITY TEST Measures force required for a single bend CUT THROUGH TEST Measures the force on a 90o wedge required to cut through to the armor and to the conductors

  11. Draka USA CRUSH TEST APPARATUS

  12. Draka USA CRUSH TEST RESULTS CABLE FORCE (LB) AT FAILURE TYPE AVE. MIN. STD. 9,000 7,000 ALT. 1 > 10,000 > 10,000 ALT. 2 9,100 8,300 ALT. 3 9,500 8,600

  13. Draka USA CRUSH TEST RESULTS TEST CONDITIONS: ONE 4 FT. SAMPLE PER TYPE TEN APPLICATION POINTS PER SAMPLE LOAD RATE: 0.5 IN/MIN. MAX. APPLIED FORCE: 10,000 LB. FAILURE WHEN SHORT DETECTED

  14. Draka USA CYCLIC FLEXING TEST APPARATUS

  15. Draka USA CYCLIC FLEXING TEST RESULTS CABLE TYPE NO. OF CYCLES DESCRIPTION OF FAILURE____ STD 233 CONTINUITY LOST IN ONE COND. 426 JACKET SPLIT OPEN 538 JACKET & ARMOR SEVERELY SPLIT ALT. 1 230 CONTINUITY LOST IN ARMOR 282 CONTINUITY LOST IN ONE COND. ALT. 2 316 CONTINUITY LOST IN ONE COND. 482 CONTINUITY LOST IN ARMOR ALT. 3 260 JACKET SPLIT OPEN 288 CONTINUITY LOST IN ONE COND. 322 CONTINUITY LOST IN ARMOR

  16. Draka USA CYCLIC FLEXING TEST RESULTS TEST CONDITIONS: ONE 3 FT. SAMPLE PER TYPE ONE CYCLE: TWO 90O BENDS 15 CYCLES PER MIN.

  17. Draka USA FLEXIBILITY TEST APPARATUS

  18. Draka USA FLEXIBILITY TEST RESULTS NO. 1 -- STANDARD TYPE NO. 2 -- ALTERNATIVE TYPE 1 NO. 3 -- ALTERNATIVE TYPE 2 NO. 4 -- ALTERNATIVE TYPE 3

  19. Draka USA FLEXIBILITY TEST RESULTS TEST CONDITIONS ONE SAMPLE PER TYPE SINGLE BEND, 90O 2.8 INCH MANDREL RATE: 20 INCHES PER MIN.

  20. Draka USA CUT THROUGH TEST APPARATUS

  21. Draka USA CUT THROUGH TEST RESULTS CABLE AVE. FORCE (LB) TO REACH TYPEARMORCONDUCTOR STD. 2,800 5,000 ALT. 1 3,100 5,100 ALT. 2 3,100 5,000 ALT, 3 4,300 4,700

  22. Draka USA CUT THROUGH TEST RESULTS TEST CONDITIONS: ONE 4 FT. SAMPLE PER TYPE TEN APPLICATION POINTS PER SAMPLE LOAD RATE: 0.5 IN/MIN. MAX. APPLIED FORCE: 10,000 LB. SHORT TO WEDGE DETECTED

  23. Draka USA CONCLUSIONS CRUSH TEST MYLAR TAPE WITH LONGITUDINAL CORRUGATED BRONZE SHIELD SIGNIFICANTLY BETTER CYCLIC FLEXING TEST NO SIGNIFICANT DIFFERENCES FLEXIBILITY TEST THE LONGITUDINAL SHIELD IS AS FLEXIBLE AS THE HELICALSHIELD CUT THROUGH TEST HELICAL SHIELD SLIGHTLY LESS RESISTANT TO CUT THROUGH

  24. Draka USA RECOMMENDATION ALLOW THE USE OF MYLAR TAPE AND 10 MIL, LONGITUDINAL CORRUGATED BRONZE SHIELD IN UNDERGROUND SIGNAL CABLE

  25. Draka USA BENEFITS ANNUAL COST SAVINGS NO REDUCTION IN PERFORMANCE  SAFER HANDLING DURING TERMINATION

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