ACCC® Aluminium Conductor Composite Core

CEZ ROMANIA 16.07.2018

High-Capacity, Low-Sag ACCC Offers:

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

14 years of Installation & Operating Experience

ACCC has been installed by over 175 utilities at over 560 project sites.
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CTC Global Corporation & Manufacturing Partners
• Headquarters in Irvine, California
• 3 Core Production Facilities
• R&D began in 2003
• Trial Lines Installed in 2004
• Commercially Deployed in 2005
• ISO Certified Production since 2006
• 22 Conductor Manufacturing Partners
• 8 Hardware Suppliers
• Over 560 ACCC Projects Completed

CTC Global Factory tour video:

https://www.youtube.com/watch?v=Rum2uTyG_ms
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CTC Global Resume
• 175+ Utilities Served
Countries
• 300+ Installation Crews Trained
• 38,000 miles (63.000 km) of ACCC in Service USA India Montenegro
China Columbia Germany
• 560 Projects Completed South Africa
France Congo
• 11 kV to 533 kV Lines (AC and DC) England Ireland South Korea
Poland Mozambique Russia
• 48 Countries Served – in all climates and terrains Costa Rica
Spain Netherlands
• 22 Certified Master Installers Scotland Nigeria Argentina
Portugal Vietnam Romania
• 24 x 7 Technical Support
Mexico Australia Pakistan
Chile Malaysia Serbia
Qatar Croatia New Zealand
Indonesia Kazakhstan Paraguay
Belgium Panama Bangladesh
Brazil Estonia Iraq
Kosovo Laos Turkey
Slovenia Egypt

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ACCC Conductor

High Performance Conductor for a Modern Grid

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.
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Trade Trend: Carbon replacing steel & aluminum

ACSR ACCC ACCC vs Traditional

Carbon Fiber vs. Steel
Annealed aluminum is
70% lighter more efficient
50+% stronger Trapezoidal shape + core
90% lower CTE strength enable 28% more
aluminum
More aluminum that is
more efficient = 2X
capacity, up to 40% lower
losses
Conventional Steel Core Composite Carbon Core
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The Substantial Path to Deployment
In collaboration with several International
Utilities and laboratories, CTC Global:
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

Ongoing Research in Conjunction with:

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Testing and Validation
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
US / UK / France / Canada / Mexico / China / Brazil / Chile / Belgium / Indonesia / Germany
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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
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
2.4.64 EPRI Longevity Assessment (1,500 cycles)
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
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
Manufacturing Process

Fiberglass +
Carbon Fiber
“Tows”

Pulling Units
Curing Die Take-up Reel

Air Cooling

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Evolution of conductor performance

Evolution of Conductor Performance

ACCC conductors combine annealed aluminium with high temperature
composite technology and an increased aluminium cross sectional area

ACCC –TW Drake

ACSS -TW Drake

ACSR Drake

Carbon Fiber Core

Corrects Weight Gain
While Improving Strength
Use of Trapezoidal Wire
Increases Conductor Area
But Adds Weight 1,558 kg/km
Basic Conductor Design
Round Wire and Steel Core 1,960 kg/km

1,627 kg/km

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How ACCC Compares
Cooler operating temperatures underscore improved efficiency and reduced losses

Temperature (C)
0 20 40 60 80 100 120 140 160 180 200 220 240 260
0

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20
Cable Sag (Inches)

30
Sag may limit rated capacity
40
ACCC
50
GAP
Invar
60
ACCR

70 ACSS
ACSR
80

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

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ACCC Offers a Very Cost-Effective Solution

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The unit cost $ of ACCC (by length) is approximately 2.5 to 3.0 X ACSR
ACCC is Resistant to Cyclic Load Fatigue

Testing performed by American

Electric Power (AEP) proved the
ACCC conductor’s superior resistance
to vibration and cyclic load fatigue.

ACSS ACCC

After Sheave Test, 100 Million Cycles of Vibration, 100 Thousand Cycles of Galloping, and Tensile Test
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ACCC is Resistant to Thermal Aging

Core sample cooked at 220OC for one year

14 Oxidation limited to ~60 microns in depth

ACCC Can Handle N-1 Conditions (215°C testing)

ACCC & Hardware subjected to High Temperature Cyclic Tests

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ACCC Passed EPRI 1,500 Cycle Aging Test

Burndy and AFL splices (in the foreground)

after 1500 cycles

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ACCC Core Can Handle Extreme Torsional Loads

4 Revolutions

54 Revolutions

“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

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Robust and Resilient

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ACCC Project Examples

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AEP Energized Reconductor Project Example

Description: 240 circuit miles, 345 kV line, double bundle

Project: replace 1,440 miles of ACSR conductor with ACCC
Objectives
• Improve reliability (less sag and corrosion)
• Increased capacity to serve growth
• Retain existing structures – to reduce costs
• Eliminate down time with Live Line Reconductoring

Additional benefits received by AEP

• Project completed eight months ahead of schedule
• Reduced line losses by 30%
 Saving $15 million/yr. (300,000 MWh at $50)
 Reducing CO2 emissions by ~200,000 metric
tons per year (= 34,000 cars off the road)
 Freeing up ~34 MW of generation
This project won EEI Transmission Project of the Year - 2016
Video: https://www.youtube.com/watch?v=aPaNHawIdFA&feature=youtu.be
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Thank You

We would be pleased to
answer any questions
you may have!

CTC Global Corporation

2026 McGaw Avenue
Irvine, CA 92614 USA
+1(949)428-8500
www.ctcglobal.com
New 50 km 275 kV triple bundle
ACCC conductor generation tie line
21 energized in Malaysia July, 2017