A subsidiary of Composite Technology Corporation Irvine, California INNOVATIVE CONDUCTOR SOLUTIONS FOR POWER TRANSMISSION AND DISTRIBUTION SYSTEMS

A subsidiary of Composite Technology CorporationIrvine, California

INNOVATIVE CONDUCTOR SOLUTIONS FOR POWER TRANSMISSION

AND DISTRIBUTION SYSTEMS

Copyright 2005 Composite Technology Corporation. All rights reserved.

Introducing the CTC Cable Solution - ACCC

A novel cable design using proven advanced materials

Increases capacity

Improves reliability of a grid system

Improves the safety of any power grid

Core incorporates high-strength carbon and glass fibers with special polymers to create a cable that:

Virtually eliminates thermal sag

ACCC (Aluminum Conductor Composite Core) Conductor


Provides up to 100% increase in ampacity

Has higher conductivity

Significantly reduces elevated temperature sag

Exhibits excellent self-dampening characteristics

Reduced sag and high-strength core allows greater spans (reduces number of structures or reducing height requirements)

Non-metallic core eliminates bi-metallic corrosion

Can replace ACSR without modifying structures due to it’s similar weight and tension properties

The CTC Cable Solution - ACCC


ACCC Cable Solutions for the Transmission Grid

Increased power demand

Aging transmission grid

Increasing number of constrained lines

Increased blackout potential

Difficulties in obtaining new pathway approvals

Limited incentives for investment in the grid

Increasing environmental concerns

Regulatory constraints

The ACCC Cable Provides Solutions for the Following:


concentric round conventional TW ACCC/TW eg 795 kcmil eg 959.6 kcmil eg 1020 kcmil

Compared to conventional conductors of the same diameter:

CTC’s ACCC core is lighter and stronger than steel

The ACCC cable has 28% more aluminum for increased conductivity

The ACCC cable uses trapezoidal-shaped aluminum wires and smaller diameter core to increase the kcmil rating

ACCC Design Features

ACCC’s Design is Stronger, Lighter and More Efficient


ACCC – Superior High-Temp Performance

ACCC operated 57° cooler than ACSR with identical current

ACCC cable: 4.5 inches at 183°C

ACSR cable: 60.3 inches at 240°C

Demonstrating Sag AdvantageKinetrics facility, Toronto, Nov. 2003

ACCC Has Very Low Thermal Expansion Coefficient

Testing at temperatures approaching 200 degrees C, shows the cable exhibiting very little sag


Comparison Conductors

High Temperature Sag Comparison

ACCC’s Exceptional High Temperature, Low Sag Capability

ACCC Conductor

1500 AMP - Sag Profile (@ enhanced amp rating)

------------------ 1000 ft Ruling Span* ------------------

(Drake ACSR)

Drake ACSS MS

Drake ACSS MS TW

Suwannee MS

Drake ACCC TW

32 ft sag limit


ACCC’s greater aluminum content enables higher conductivity and lower resistance properties, lowering I2R power losses.

Comparison Conductors

Lower I2R Power Losses

ACCC Has Lowest I2R Power Losses

I2R Conductor Power Loss (kW/mile)

0

100

200

300

400

500

Operation at 1500 Amps

Kilo

Wa

tt/m

ile (

pe

r c

on

du

cto

r)

DRAKE ACSR

DRAKE ACSS

DRAKE ACSS/TW

SUWANNEE ACSS/TW

DRAKE ACCC/TW


ACCC-ACCR-ACSS-ACSR Comparison

DRAKE KCMIL Overall Rated Core Core Core Core Core Core

COMPARISON Rating Diameter Strength Diameter Rated Tensile Thermal Stiffness Flexural

(TYPE) (area) (inches) (pounds) (inches) Strength Strength (psi) Expansion (modulus) Strength

ACCC (CTC) 1020 1.108 41,000 0.374 38,000 348,000 1.5 x 10 ̂-6 16 Msi 623 Mpa

ACCR (3M) 795 1.108 31,134 0.410 18,556 142,000 3.3 x 10 ̂ -6 32 Msi n/a

ACSS 795 1.108 25,900 0.408 20,596 158,000 12 x 10 ̂ -6 29 Msi n/a

ACSR 795 1.108 31,500 0.408 16,836 129,000 12 x 10 ̂ -6 29 Msi n/a

DRAKE RESISTANCE VALUES AMP ACITY RATINGS SAG AT 1,000 FOOT SP AN ***

COMPARISON DC 20 DEG C AC 75 DEG C AC 200 DEG C 75 C 100 C 200 C 75 C 100 C 200 C

(TYPE) (ohms/kft) (ohms/kft) (ohms/kft) (degrees) (degrees) (degrees) (degrees) (degrees) (degrees)

ACCC (CTC) 0.0165 0.0206 0.0291 1025 1265 1863 24.45 24.58 24.76

ACCR (3M) 0.0208 0.0255 0.0360 992 1221 1798 27.22 28.15 30.45

ACSS 0.0209 0.0257 0.0363 896 1103 1662 32.08 33.4 38.43

ACSR 0.0214 0.0263 0.0369 908 1123 --- 32.07 33.37 ---

*** Governing sag condition is equal tension set to 5670 pounds at 60 deg F


ACCC Installation Overview

A unique wedge assembly crimped inside the aluminum housing, assures long-term reliable performance.

EPRI SolutionsHaslet, TX, 8/04

Holland BOPWHolland, MI, 8/04

Niagara MohawkBuffalo, NY, 11/04

City of KingmanKingman, KS, 12/04

Austin EnergyAustin, TX, 12/04

Arizona Public Svc.Phoenix, AZ, 3/05

Xcel EnergyDenver, CO, 5/05

Installations to date, include:

ACCC Installations Use Conventional Methods and Tools


On-going testing and analysis will continue to ensure ACCC performance leadership.

• Stress / Strain• Creep• Thermal elongation and sag• Self dampening• Connector interface• Axial impact• Torsional ductility • Flexural strength• Environmental degradation

• Electrical resistivity• Conductivity • Power loss• Impedance• EMF/Corona• Sheave• Thermal expansion• Fatigue• Notched impact

ACCC Comprehensive Testing

ACCC Establishes Performance Leadership Through Testing


Team Designs and Manufactures Hardware for ACCC

CTC and FCI Burndy Team for Accessories

CTC produces core

FCI/Burndy produces splices, deadends and accessories

Accessories marketed world-wide

All CTC accessories are designed for full tension use, achieving a minimum of 95% of the ASTM rated strength of the ACCC conductor.


After extensive analysis and empirical testing, ACCC’s electrical and mechanical characteristics have been included in the PLS CADD design tool

ACCC in PLS CADD Design Tool

DRAKE ACSRTension = 5600 lbs.Sag @ 50°C (122°F)

Ampacity = 590 amps

DRAKE ACCCTension = 3600 lbs.

Sag @ 125°C (257°F)Ampacity = 1450amps

Power Line Designers Can Now Use ACCC in PLS-CADD


PLAT - New Power Line Analysis Tool by CTC

Showcases CTC’s innovative technology vs. conventional commodity products

Designed for utility executives and planning engineers to understand the increased financial, mechanical and electrical advantages of ACCC

The most comprehensive comparative line analysis tool in the industry

Illustrates that ACCC is the most cost-effective and reliable solution for increased power delivery

P.L.A.T. is available at: http://65.104.111.5/PowerLineAnalysisTool/


ACCC Conductor Economic Benefit Summary

Reduction in congestion cost

Revenue potential while reducing rates to consumers

Growth long after traditional solutions have reached maximum output

Increased daily power throughput

Confirm Economic and Performance Benefits for Each Line with CTC’s PLAT


CTC began ACCC conductor development in 2001

CTC composite conductor core testing initiated 2003

General Cable begins wrapping aluminum wire around CTC’s core to produce ACCC/TW conductor in 2003

FCI/Burndy strategic relationship formed in 2004

CTC Cable Corporation subsidiary begins commercial production in 2004

History of the ACCC Conductor

Documents

A subsidiary of Composite Technology Corporation Irvine, California INNOVATIVE CONDUCTOR SOLUTIONS FOR POWER TRANSMISSION AND DISTRIBUTION SYSTEMS