ctc global accc conductor overview august 2016

ACCC® ConductorImproving the Efficiency, Capacity and Reliability of the Grid

Deployed to over 425 project sites in 40 countries by over 150 utilitiesCTC Global ACCC Conductor

• Privately held Delaware Corporation • Headquartered in Irvine, California• R&D began in 2003• Trial Lines Installed in 2004• Commercially Deployed in 2005• ISO Certified Production in 2006• Stranding Partners Worldwide• 38,000 km at over 425 project sites

CTC Global Corporation

CTC Global ACCC Conductor

ACCC

Its hybrid carbon fiber core is 70% lighter and 50% stronger than steel. Its has a coefficient-of-thermal-expansion about 10 times less than steel. This allows the use of 28% more aluminum which helps increase capacity, improve efficiency & mitigate thermal sag.

High Performance Conductor for a Modern Grid


Greater Strength & Reduced Sag

Higher Ampacity Limits at Cooler Temperatures

Able to Tolerate N-1 Conditions

Increased Spans on Fewer / Shorter Structures

Proven Reliability with Reduced Line Losses

Selected as the Most Cost Effective Solution

High-Capacity, Low-Sag ACCC Offers:

The world’s most efficient conductor

10 years of Installation & Operating Experience


Carbon Fiber Widely Utilized

High Strength, Light Weight & Excellent Resistance to Cyclic Load Fatigue CTC Global ACCC Conductor

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Temperature (C)

ACCC

GAP

Invar

ACCR

ACSS

ACSR

How Does it Compare to Other Conductors?

Comparison testing performed by Hydro One on a 65 meter span, 1600 amps, Drake size

Cooler operating temperatures underscore improved efficiency and reduced losses


Example of sag differences in the field (UK)


1. Developed & Tested the Composite Core 2. Tested Electrical Properties of the Conductor3. Developed & Tested Ancillary Hardware4. Assessed Environmental Exposure and Longevity5. Evaluated Conventional Installation Procedures6. Commercially Deployed in 20057. ISO Certified in 2006

The Substantial Path to ACCC® DeploymentIn consultation with several International Utilities and laboratories, CTC Global:


Core Testing:

2.1.1 Tensile Testing2.1.2 Flexural, Bending & Shear Tests2.1.3 Sustained Load Tests2.1.4 Tg Tests2.1.5 CTE Measurements2.1.6 Shear Testing2.1.7 Impact and Crush Testing2.1.8 Torsion Testing2.1.9 Notched Degradation Testing2.1.10 Moisture Resistance Testing2.1.11 Long Term Thermal Testing2.1.12 Sustained Load Thermal Testing2.1.13 Cyclic Thermal Testing2.1.14 Specific Heat Capacity Testing2.1.15 High Temperature Short Duration 2.1.16 High Temperature Core Testing2.1.17 Thermal Oxidation Testing2.1.18 Brittle Fracture Testing2.1.19 UV Testing2.1.20 Salt Fog Exposure Tests2.1.21 Creep Tests2.1.22 Stress Strain Testing2.1.24 Micrographic Analysis2.1.25 Dye Penetrant Testing2.1.26 High Temperature Shear Testing2.1.27 Low Temperature Shear Testing

Mechanical Conductor Testing:

2.2.28 Stress Strain Testing2.2.29 Creep Testing2.2.30 Aeolian Vibration Testing2.2.31 Galloping Tests2.2.32 Self Damping Tests2.2.33 Radial Impact and Crush Tests2.2.34 Turning Angle Tests2.2.35 Torsion Tests2.2.36 High Temperature Sag Tests2.2.37 High Temperature Sustained Load 2.2.38 High Temperature Cyclic Load Tests2.2.39 Cyclic Ice Load Tests2.2.40 Sheave Wheel Tests2.2.41 Ultimate Strength Tests2.2.42 Cyclic Thermo-Mechanical Testing2.2.43 Combined Cyclic Load Testing2.2.44 Conductor Comparison Testing

Electrical Conductor Testing:

2.3.45 Resistivity Testing2.3.46 Power Loss Comparison Testing2.3.47 Ampacity2.3.48 EMF Measurements2.3.49 Impedance Comparison Testing2.3.50 Corona Testing2.3.51 Radio Noise Testing2.3.52 Short Circuit Testing2.3.53 Lightning Strike Testing2.3.54 Ultra High Voltage AC & DC Testing

Systems & Hardware Testing:

2.4.55 Current Cycle Testing2.4.56 Sustained Load Testing2.4.57 Ultimate Assembly Strength Testing2.4.58 Salt Fog Emersion Testing2.4.60 Static Heat Tests2.4.61 Suspension Clamp Testing2.4.62 Thermo-Mechanical Testing2.4.63 Cyclic Load Testing

Field Testing:

2.5.64 Ambient Temperature2.5.65 Tension, Sag, and Clearance2.5.66 Conductor Temperature2.5.67 Electric Current2.5.68 Wind Speed and Direction2.5.69 Solar Radiation2.5.70 Rainfall2.5.71 Ice Buildup2.5.72 Splice Resistance2.5.73 Infrared Measurements2.5.74 Corona Observations2.5.75 Electric and Magnetic Fields2.5.76 Wind and Ice Load Measurements2.5.77 Vibration Monitoring2.5.78 Typhoon Test

US / UK / France / Canada / Mexico / China / Brazil / Chile / Belgium / Indonesia / Germany

Testing & Validation


Torsion Testing

“After completing nearly one and a half revolutions per foot, my lab guys got tired of trying to break it so they gave up.” Craig Pon, Kinectrics

4 Revolutions

54 Revolutions


Bending Tests

Conductor bent 90 degrees 10 times around a 6 inch

radius. No visual damage to core was noted.

Dye penetrant did appear after 2 minutes in the outer

glass strands showing some degradation.


Thermal Oxidation Tests

Core sample cooked at 220OC for one year

Oxidation limited to ~60 microns in depth CTC Global ACCC Conductor

Longevity Assessment by Alpha StarPrimary Contractor to Boeing, Airbus and NASA

Substantial Empirical Test Data provided the basis for high-level & very accurate computer modeling


Substantial Experience 38,000 km at 425 project sites

Over 45,000 Dead-Ends & Splices in service

Countries:• USA• China• France• UK• Poland• Spain• Scotland • Portugal• Mexico• Chile• Qatar• Indonesia• Belgium• Brazil• Germany• South Africa• South Korea• Russia• Costa Rica

• India• Columbia• Congo• Ireland• Mozambique• Netherlands• Nigeria• Vietnam• Australia• Malaysia• Croatia• Kazakhstan• Panama• Estonia• Laos• Serbia• New Zealand• Paraguay• Bangladesh*


Utah, USA

Reconductor Project

Project Name: PacifiCorp 90 South to Oquirrh, UtahProject Goal: Increase Ampacity (use existing structures) Conductor Size: Drake Conductor Length: 30 kmVoltage: 138 kVEnergized: 2005Over 100 existing structures saved


Kansas, USA

New Line

Project Name: Kingman to Cunningham, KansasProject Goal: Install New Line Conductor Size: Hawk Conductor Length: 108 kmVoltage: 34.5 kVEnergized: 2006


Nevada, USA

Heavy Ice Application

Project Name: NV Energy Line 107 (Reno to Carson City)Project Goal: Increase Ampacity (existing structures) Conductor Size: Linnet Conductor Length: 90 kmVoltage: 120 kVEnergized: 2009


Mexico Bay

Corrosive Marine Environment

Project Name: CFE Carmen to NoresteGoal: Increase ampacity reduce line sag, avoid corrosionConductor Size: HawkConductor Length: 32 kmVoltage: 230 kVEnergized: 2009


Chile

Long Span Application

Project Name: Chilectra El Salto to Torre 8 LineProject Goal: Increase Ampacity – (existing structures)Conductor Size: LinnetConductor Length: 28 kmVoltage: 110 kVEnergized: 2009


Spain

Wind Farm Link

Project Name: NEO Energia 80 turbine upgradeProject Goal / Type: Increase Ampacity (existing structures)Conductor Size: AmsterdamConductor Length: 57 kmVoltage: 66 kVEnergized: 2008


Germany

Extra High Voltage Application

Project Name: Amprion GmbhProject Goal / Type: Trial LineConductor Size: Oslo (bundled)Length: 8.6 kmVoltage: 400 kVEnergized: 2009


Nevada, USA

Extreme Wind Survival

Project Name: NV Energy Line 107 (Reno to Carson City)Project Goal: Increase Ampacity (existing structures) Conductor Size: Linnet Conductor Length: 90 kmVoltage: 120 kVEnergized: 2009100+ mph Winds: 2010 Conductor Undamaged


Nevada, USA

Fire Storm Survival

Project Name: NV Energy Line 107 (Reno to Carson City)Project Goal: Increase Ampacity (existing structures) Conductor Size: Linnet Conductor Length: 90 kmVoltage: 120 kVEnergized: 2009Firestorm: 2012 – ACCC CONDUCTOR UNDAMAGED


Portugal

River Crossing

Project Name: River MondegoProject Goal: Increase Amps - Reduce Sag Conductor Size: AmsterdamSpan Length: 475 MetersVoltage: 60 kVEnergized: 2012


Fujian Provence, China

Typhoon Survival (2,600’ spans)ED


Tornado Toughness


UKFrance

California

Kansas

Ice & Wind Load Testing


Lessons Learned


1. Pulling sleeve “sock” swivels broke causing conductor to drop (US, Poland, Columbia) Inspect/test older equipment prior to use

2. Installation grips slipped causing birdcage (Vietnam, US, Russia) Use correct size grip

3. Conductor damaged at dead-end interface (US, China) Do not kick dead-end out of compression die, use soap to lubricate dies

4. Conductor damaged at installation grip (Indonesia) Control loose end while installing dead-end, don’t drop assembly which could cause excessive bending at Chicago grip

5. Core damaged while being bent around very small reel alignment pulleys (US, Poland) Use hydraulic reel brakes to control back tension Use mid-span sheave wheel to avoid sharp bending when necessary

Installation Events & Corrective Actions


Installation Methods


Installation Equipment


Hardware Components


Installation Training and Support

Check out our installation Training Videos on YouTube CTC Global ACCC Conductor

http://www.youtube.com/ctcaccc

A few of CTC’s International Customers:


http://www.amprion.net/en

http://www.elia.be/

http://en.wikipedia.org/wiki/File:Energias_de_Portugal.png

http://www.oxy.com/

http://www.weg.net/us

http://www.grupoice.com/wps/portal/!ut/p/c4/04_SB8K8xLLM9MSSzPy8xBz9CP0os3gjdz9Ho1BHX0cv32BDA09LAxMfZ19DAxNTA_2CbEdFADZeHsI!/

Why Did These Utilities Choose ACCC?

Because, after discovering its technical merits and evaluating its durability, it provided the most economical solution for their specific projects


The Value of Line Loss Reduction

Reduced line losses saves money… every year


The Value of Generation Capacity Savings

Reduced line losses reduces generation capacity investmentIt is much less expensive to save energy than it is to produce it


The Value of Emission Reduction

Reduced line losses reduces fuel consumption …and associated emissions

Average car in US = 4.7 mt CO2 / scenario 1 = 13,513 cars / scenario 2 = 53,313 cars


345 kV Line – Replace ACSR with ACCC

• Increased line capacity by 75% with 625 amp emergency reserve• Reduced line losses by 30%• Line loss reduction saves 141,580 MWh / year (=$7.1M @ $50/MWh)• Emission reductions saves 83,316 Metric Tons CO2 / year• This equates to removing over 17,500 cars from the road• Line loss reduction also frees up over 17 MW of generation ($17 M+)

Notes: Double bundled Drake conductor. Load factor Assumption = 34% Texas State Average CO2 = 1.297# / kWh. (1 car = 4.75 MT CO2 / year) Cost of wire ~ $15.4M Assuming installation cost of $18.6 M – total project cost $34 Million Equals ~$285,000 per circuit mile (WECC Estimate basis)

120 Circuit Mile AEP Project Example


• Over 60 standard conductor sizes• New ULS conductors for extreme spans• Design & Engineering Support• 24/7 Customer Service• Installation Training & Support• Extensive Engineering Database

GLOBAL Support


ACCC Engineering Manual:Helpful resource for understanding the unique attributes of ACCC Conductor


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ACCC® ConductorImproving the Efficiency, Capacity, Reliability & Resilience of the Grid

CTC Global2026 McGaw Avenue Irvine, California 92614 USA+1 (949) 428-8500 www.ctcglobal.com
