Overview of the high-capacity, low-sag ACCC conductor used to improve the efficiency, capacity, reliability and resiliency of the electric power transmission grid

1. ACCC Conductor
Improving the Efficiency,
Capacity and Reliability of the Grid
Deployed to over 300 project sites in 30 countries by over 100 utilities

2. 1900 2000
Lets take a quick look back… What has changed?
Generation, Transmission and Demand-Side Appliances saw improvements,
but the fundamentals remained basically the same

3. Until Now…
2010 +++
Why…
Because Efficiency, Capacity and
Reliability Offer Substantial Social &
Economic Benefits
Globally, we have invested billions of dollars improving the efficiency of generation
and demand-side appliances. Now we are investing billions more gathering data
about generation capacity & consumer habits. Some call this “Smart Grid.” What
about the grid itself?

4. A true “Smart Grid” needs to be
Efficient, Reliable & Robust
In August 2003, the US/Canada blackout was caused by a number of factors:
• This included incorrect telemetry data, a “race condition” computer bug in an
Energy Management System and three 345kV transmission line trips due to
excessive conductor sag. This led to cascading sag-trip outages on the 138kV
distribution system.
• These events and lack of effective communication between utilities ultimately
shut down 508 generation units at 265 power plants.
• The use of a high-capacity, low-sag conductor such as ACCC® could have
prevented the cascading outages, in spite of the computer & telemetry glitches
It takes more than computers & telemetry to build a “Smart Grid”
ACCC®
ACSR

5. Why is this so important? Because,
without Reliable & Affordable Electricity…
• We can’t pump water to grow crops
• We can’t develop the infrastructure to attract new business
• We can’t improve the quality of life for millions of people
…and build stable, peaceful, and productive economies

6. ACCC (Aluminum Conductor Composite Core)
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

7. 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:
ACCC has been installed by over 100 utilities at over 300 project sites.
10 years of Installation & Operating Experience

8. Carbon Fiber Widely Utilized
High Strength, Light Weight & Excellent Resistance to Cyclic Load Fatigue

9. ACSS ACCC
After Sheave Test, 100 Million Cycles of Vibration, 100 Thousand Cycles of Galloping, and Tensile Test
Testing performed by American
Electric Power (AEP) proved the
ACCC conductor’s superior resistance
to vibration and cyclic load fatigue.
ACCC is Resistant to Cyclic Load Fatigue

10. 0
10
20
30
40
50
60
70
80
0 20 40 60 80 100 120 140 160 180 200 220 240 260
CableSag(Inches)
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

11. 1. Developed & Tested the Composite Core
2. Tested Electrical Properties of the Conductor
3. Developed & Tested Ancillary Hardware
4. Assessed Environmental Exposure and Longevity
5. Evaluated Conventional Installation Procedures
6. Commercially Deployed in 2005
7. ISO Certified in 2006
The Substantial Path to ACCC® Deployment
In consultation with several International
Utilities and laboratories, CTC Global:

12. Core Testing:
2.1.1 Tensile Testing
2.1.2 Flexural, Bending & Shear Tests
2.1.3 Sustained Load Tests
2.1.4 Tg Tests
2.1.5 CTE Measurements
2.1.6 Shear Testing
2.1.7 Impact and Crush Testing
2.1.8 Torsion Testing
2.1.9 Notched Degradation Testing
2.1.10 Moisture Resistance Testing
2.1.11 Long Term Thermal Testing
2.1.12 Sustained Load Thermal Testing
2.1.13 Cyclic Thermal Testing
2.1.14 Specific Heat Capacity Testing
2.1.15 High Temperature Short Duration
2.1.16 High Temperature Core Testing
2.1.17 Thermal Oxidation Testing
2.1.18 Brittle Fracture Testing
2.1.19 UV Testing
2.1.20 Salt Fog Exposure Tests
2.1.21 Creep Tests
2.1.22 Stress Strain Testing
2.1.24 Micrographic Analysis
2.1.25 Dye Penetrant Testing
2.1.26 High Temperature Shear Testing
2.1.27 Low Temperature Shear Testing
Mechanical Conductor Testing:
2.2.28 Stress Strain Testing
2.2.29 Creep Testing
2.2.30 Aeolian Vibration Testing
2.2.31 Galloping Tests
2.2.32 Self Damping Tests
2.2.33 Radial Impact and Crush Tests
2.2.34 Turning Angle Tests
2.2.35 Torsion Tests
2.2.36 High Temperature Sag Tests
2.2.37 High Temperature Sustained Load
2.2.38 High Temperature Cyclic Load Tests
2.2.39 Cyclic Ice Load Tests
2.2.40 Sheave Wheel Tests
2.2.41 Ultimate Strength Tests
2.2.42 Cyclic Thermo-Mechanical Testing
2.2.43 Combined Cyclic Load Testing
2.2.44 Conductor Comparison Testing
Electrical Conductor Testing:
2.3.45 Resistivity Testing
2.3.46 Power Loss Comparison Testing
2.3.47 Ampacity
2.3.48 EMF Measurements
2.3.49 Impedance Comparison Testing
2.3.50 Corona Testing
2.3.51 Radio Noise Testing
2.3.52 Short Circuit Testing
2.3.53 Lightning Strike Testing
2.3.54 Ultra High Voltage AC & DC Testing
Systems & Hardware Testing:
2.4.55 Current Cycle Testing
2.4.56 Sustained Load Testing
2.4.57 Ultimate Assembly Strength Testing
2.4.58 Salt Fog Emersion Testing
2.4.60 Static Heat Tests
2.4.61 Suspension Clamp Testing
2.4.62 Thermo-Mechanical Testing
2.4.63 Cyclic Load Testing
Field Testing:
2.5.64 Ambient Temperature
2.5.65 Tension, Sag, and Clearance
2.5.66 Conductor Temperature
2.5.67 Electric Current
2.5.68 Wind Speed and Direction
2.5.69 Solar Radiation
2.5.70 Rainfall
2.5.71 Ice Buildup
2.5.72 Splice Resistance
2.5.73 Infrared Measurements
2.5.74 Corona Observations
2.5.75 Electric and Magnetic Fields
2.5.76 Wind and Ice Load Measurements
2.5.77 Vibration Monitoring
2.5.78 Typhoon Test
US / UK / France / Canada / Mexico / China / Brazil / Chile / Belgium / Indonesia / Germany
Testing & Validation

13. 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

14. 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.

15. Thermal Oxidation Tests
Core sample cooked at 220OC for one year
Oxidation limited to ~60 microns in depth

16. Longevity Assessment by Alpha Star
Primary Contractor to Boeing, Airbus and NASA
Substantial Empirical Test Data
provided the basis for
high-level & very accurate
computer modeling

17. Substantial Experience 25,000 km at ~300 project sites
Over 35,000 Dead-Ends & Splices in service
Countries:
• USA
• China
• France
• UK
• Poland
• Spain
• Portugal
• Mexico
• Chile
• Qatar
• Indonesia
• Belgium
• Brazil
• Germany
• South Africa
• South Korea
• Russia
• India
• Costa Rica
• Columbia
• Congo
• Mozambique
• Netherlands
• Nigeria
• Vietnam
US Utilities:
• AEP
• APS
• PacifiCorp
• NV Energy
• Austin Energy
• Xcel Energy
• MI PUD
• KS PUD
• KAMO
• OG&E
• Ozark Electric
• WAPA
• STEC
• Entergy
• Riverside PUD
• Florida Power & Light
• Keys Energy
• Progress Energy
• Mohave Electric
• SCANA
• National Grid
• Alexandria (LA) PUD
• Duke Energy
• Oncor
• CIPCO
• Black Hills Power
• Com Ed
• TECO

18. Utah, USA
Reconductor Project
Project Name: PacifiCorp 90 South to Oquirrh, Utah
Project Goal: Increase Ampacity (use existing structures)
Conductor Size: Drake
Conductor Length: 30 km
Voltage: 138 kV
Energized: 2005
Over 100 existing structures saved

19. Kansas, USA
New Line
Project Name: Kingman to Cunningham, Kansas
Project Goal: Install New Line
Conductor Size: Hawk
Conductor Length: 108 km
Voltage: 34.5 kV
Energized: 2006

20. 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 km
Voltage: 120 kV
Energized: 2009

21. Mexico Bay
Corrosive Marine Environment
Project Name: CFE Carmen to Noreste
Goal: Increase ampacity reduce line sag, avoid corrosion
Conductor Size: Hawk
Conductor Length: 32 km
Voltage: 230 kV
Energized: 2009

22. Chile
Long Span Application
Project Name: Chilectra El Salto to Torre 8 Line
Project Goal: Increase Ampacity – (existing structures)
Conductor Size: Linnet
Conductor Length: 28 km
Voltage: 110 kV
Energized: 2009

23. Spain
Wind Farm Link
Project Name: NEO Energia 80 turbine upgrade
Project Goal / Type: Increase Ampacity (existing structures)
Conductor Size: Amsterdam
Conductor Length: 57 km
Voltage: 66 kV
Energized: 2008

24. Germany
Extra High Voltage Application
Project Name: Amprion Gmbh
Project Goal / Type: Trial Line
Conductor Size: Oslo (bundled)
Length: 8.6 km
Voltage: 400 kV
Energized: 2009

25. 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 km
Voltage: 120 kV
Energized: 2009
100+ mph Winds: 2010 Conductor Undamaged

26. 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 km
Voltage: 120 kV
Energized: 2009
Firestorm: 2012 – ACCC CONDUCTOR UNDAMAGED

27. Portugal
River Crossing
Project Name: River Mondego
Project Goal: Increase Amps - Reduce Sag
Conductor Size: Amsterdam
Span Length: 475 Meters
Voltage: 60 kV
Energized: 2012

28. Fujian Provence, China
Typhoon Survival (2,600’ spans)ED

29. Tornado Toughness

30. UK
France
California
Kansas
Ice & Wind Load Testing

31. Lessons Learned

32. 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

33. Installation Methods

34. Installation Equipment

35. Hardware Components

36. Installation Training and Support
Check out our installation Training Videos on YouTube

37. A few of CTC’s International Customers:

38. 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

39. The Value of Line Loss Reduction
Reduced line losses saves money… every year

40. The Value of Generation Capacity Savings
Reduced line losses reduces generation capacity investment
It is much less expensive to save energy than it is to produce it

41. The Value of Emission Reduction
Reduced line losses reduces fuel consumption
…and associated emissions

42. • Over 40 standard conductor sizes
• New ULS conductors for extreme spans
• Design & Engineering Support
• 24/7 Customer Service
• Installation Training & Support
• Extensive Engineering Database
GLOBAL Support

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

44. CCP Software Program:

45. Stay Informed with our Monthly Newsletters:

46. • 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
• Over 25,000 km at over 300 project sites
CTC Global Corporation

47. ISO Certified
Production

48. Low Thermal Sag and High Strength Allow:
 Increased capacity, increased revenue & reduced congestion
 Fewer short-circuit events & improved reliability
 Increased spans between fewer and/or shorter structures
Added Aluminum Content (without any weight penalty) Allow:
 A 25 to 40% reduction in line losses (depending upon load)
 Reduced fuel consumption & reduced emissions
 Reduces generation capacity requirements
Additional Advantages:
 Higher strength core reduces risk of mechanical failure
 Composite core is impervious to corrosion
 Composite core resists cyclic load fatigue
Summary of Technical Advantages:

49. ACCC® Conductor
Improving the Efficiency, Capacity,
Reliability & Resilience of the Grid
CTC Global
2026 McGaw Avenue
Irvine, California 92614 USA
+1 (949) 428-8500 www.ctcglobal.com