ACCC Conductor Improving the Efficiency, Capacity and Reliability of the Grid

Deployed to over 300 project sites in 30 countries by over 100 utilities

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

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?

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

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

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

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

Carbon Fiber Widely Utilized

High Strength, Light Weight & Excellent Resistance to Cyclic Load Fatigue

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

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0 20 40 60 80 100 120 140 160 180 200 220 240 260

Cab

le S

ag

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es)

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

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:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Fujian Provence, China

Typhoon Survival (2,600’ spans)ED

Tornado Toughness

UK France

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

A few of CTC’s International Customers:

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 investment

It 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

• 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

ACCC Engineering Manual:

Helpful resource for understanding the unique attributes of ACCC Conductor

CCP Software Program:

Stay Informed with our Monthly Newsletters:

• 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

ISO Certified Production

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:

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