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Copper Provides Value in a Wave Energy Converter High power electrical devices such as generators, inverters and submarine cable, along with low voltage electronic control systems used in an ocean system are subject to salt water corrosion. Because of its natural resistance to salt water corrosion and its superior reliability in electrical connections, copper is the ideal material for use in all electrical devices and wiring. A test comparing the performance of copper and aluminum connectors and conductors clearly shows the superiority of all-copper electrical systems. A paper, “Corrosion and Current Burst Testing of Copper and Aluminum Electrical Power Connectors”, was presented at the IEEE Industry Applications Society (IAS) Meeting in late 2005 in Hong Kong, as well as at the 2005/2006 IEEE Power Engineering Society (PES) Transmission & Distribution Conference & Exposition in Dallas in May, 2006. The test subjected 30 conductor/connector combinations to 2000 hours of salt fog combined with high current bursts. Of the 30 contacts, 10 were aluminum alloy conductor with aluminum connectors, 10 were copper conductors with aluminum connectors and 10 were copper conductor with copper connectors. In the end of the 10 all aluminum contacts, 2 had a moderate (1% to 5%) rise in resistance, 1 had a significant (5% to 10%) rise, and 4 were considered to have failed with greater than 10% rise in resistance. Of the copper conductor to aluminum connector contacts, 3 had a moderate rise in resistance, and 4 had a significant rise, while none failed. Of the copper conductor to copper connector, no resistance rose above 1% after the test. The results of this work show the value of choosing all copper cabling and all copper connectors, particularly in a salt water environment. In addition to the ravages of salt water, the coastal climate, especially during northern winters, is not a friendly place for performing maintenance or making repairs. Outage repairs on an offshore Wave Energy Convertor would likely have to be postponed till a calmer time in summer, or the WEC would have to be disconnected and towed to shore for repair. Either way the cost of the repair and the cost of the lost revenue could be substantial.  A failure in a submarine cable is also a costly event particularly in an offshore WEC array or farm. Depending on the connection scheme one cable section may connect the power from multiple WECs to shore, meaning extensive losses in the event of a cable failure. A cable repair requires a special ship or barge must be employed to drag for the cable and raise it to the surface for splicing. The equipment is specialized and costly, and the work can only be done in relatively calm waters. Again this could mean an expensive repair and a long and costly outage of multiple WECs. For improved reliability, It pays to use all copper. |
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