ACCC Conductor News  CTC Global  September 2012



How Aerospace Technology is Improving the Efficiency, Capacity and Reliability of the Electric Grid


For over one-hundred years, electricity has been delivered to consumers using bare overhead conductors that were made up of conductive aluminum strands commonly wrapped around a core that consisted of steel wires. As demand for electricity grew and new sources of generation were brought on line, many transmission and distribution lines became thermally constrained. The relatively high coefficient of thermal expansion ("CTE") of the steel core and aluminum strands, cause the conductor to sag as temperatures rise.


Recognizing the enormous challenge of increasing transmission line capacity, mitigating thermal sag, and improving conductor efficiency, CTC Global, of Irvine, California, USA, began developing the patented ACCC conductor in 2002. As the project evolved, CTC developed a hybrid carbon and glass fiber core that resisted degradation from UV, chemical, thermal, and cyclic load fatigue.


The ACCCconductor, which offers approximately twice the capacity of conventional conductors, is now being used to increase the capacity of existing transmission corridors without the requirement for structural modifications. The ACCC conductor's greater strength and improved thermal stability can also enable longer spans between fewer and/or shorter structures on new transmission lines which serves to reduce upfront capital costs.


The ACCC conductor's increased aluminum content compared to any other conductor of the same diameter and weight also helps reduce line losses by 30 to 40% under equal load conditions.


A reduction in line losses offers the utilities and society in general huge advantages. Not only can more electricity be delivered from existing sources of generation as demand increases - under normal load conditions - fuel consumption can be reduced. While reduced fuel consumption reduces costs, it can also reduce associated emissions.


Considering that the reduction of emissions represents such a significant challenge for the utilities today, reconductoring an existing line with ACCC conductor is by far the cheapest and fastest way to achieve that objective. It's often been said that it's much cheaper to save a "NegaWatt" than it is to produce a MegaWatt.


In 2007, American Electric Power (AEP) reported that by simply reconductoring an existing 20 km line with ACCC conductor, they reduced losses by 0.9 MW and also reduced overall system losses by an additional 0.2 MW, for a total improvement of 1.1 MW. To date, American Electric Power has completed eight ACCC conductor installations. In the next few months, with the help of Quanta Energized Services, they will begin the largest energized reconductoring project in history by upgrading 240 circuit miles of double bundled 345 kV conductor using ACCC.  CTC Global will be providing more than 1,665 miles of ACCC to support this project. 

Proven Reliability at over 220 Project Sites

The ACCC conductor's outstanding performance has allowed utilities worldwide to exploit its unique advantages while saving millions of dollars delivering more power, more efficiently, with reduced line losses, decreased fuel consumption and reduced generation emissions.  To learn more about how the ACCC conductor can work for you, please visit our website at




CSN Brazil Completes Second ACCC Conductor Installation

Second Installation Further Increases Power Delivery to Major Steel Factory

Companhia Siderúrgica Nacional (CSN), the largest vertically integrated steel producer in Brazil, completed its second ACCC conductor installation to further increase power delivery to their main factory in the city of Volta Redonda, Rio de Janeiro.


CSN delivers its steel products to customers in Brazil and 71 other countries in South America, North America, Europe and Asia. It is considered one of the most productive steel-makers in the world, producing more than six million tons annually. With the engineering and installation support of WEG, ACCC conductor was selected and installed due to its high capacity, proven reliability, high efficiency and low sag.


The existing ACSR (steel reinforced) Dove conductor was replaced with the composite core (carbon and glass fiber) ACCC Dove conductor to double the line's capacity without having to modify the existing steel lattice towers. According to Marcelo Munoz, WEG project manager, they were pleased with their choice of ACCC Dove. The alternative they considered was a larger, heavier ACSR Blue Jay size conductor, about twice the weight of the ACCC Dove conductor.  This alternative would have required major tower modifications and still caused clearance, capacity and sag issues.


Dave Ayers, Director Field Applications for CTC Global, said: "We completed the installation without any difficulties. Considering substantial under-build, it wasn't easy, but the WEG staff and the local linemen support were great."


How to Select a Conductor 


To help make conductor selection easier, CTC Global developed a conductor comparison program known as CCP.  The program is designed to help system planners and engineers compare the ampacity, line losses, thermal and ice load sag, and economic aspects of nearly any conductor type and size, so the numerous advantages of the ACCC conductor can be fully realized. The user simply selects the conductor types and sizes from drop down menus and enters the appropriate values & assumptions highlighted in the yellow boxes. The program is fully functional and uses standard industry formulas (such as IEEE 738-2006). Outputs are readily comparable to Sag10®, PLS CADD™ and other similar programs. (Note the screen shot below) The steps are simple:


1. Select Conductors to be compared from drop down menus

2. Input Ambient Conditions

3. Compare Ampacity & Temp

4. Input Electric Load Parameters

5. Assess Line Loss Reductions

6. Evaluate Line Loss Savings

7. Realize Emission Reductions

8. Note Peak Load Revenue

9. Assess Conductor Tension

10. Compare Conductor Sag


To Request a Free Copy CLICK HERE

In This Issue
How Aerospace Technology is Improving the Efficiency, Capacity and Reliability of the Electric Grid
220+ ACCC Projects Completed
CSN Brazil Completes 2nd ACCC Installation
How to Select a Conductor
New Engineering Software
New Engineering Manual
CTC at Your Service
CTC Global Wins Materialica Design + Technology Award
ACCC Field Experience
Please Join CTC at the
Cigre Grid of the Future Symposium 
October 28th - 30th 2012
Kansas City, Missouri USA


For More Information


New CCP Software

Makes ACCC Conductor
Selection Easy


Responding to an ever-increasing demand to help select the most appropriate size of the highest performing ACCC conductor available, CTC Global has developed a new software program, CCP.


The program is available at no charge to utility planners, transmission engineers and others involved in conductor selection, project engineering and project economics. Using the design parameters associated with your specific project, CCP can calculate and compare ampacity, sag / tension, line losses, and the economics associated with the reduction in thermal sag and line losses the ACCC conductor offers compared to any other conductor of the same diameter and weight.


To receive a free copy of CCP, or to request help with your project, please visit CTC Global's website for more information.





ACCC Engineering Manual 



To help T&D planners, engineers, and technicians take full advantage of the ACCC conductor's attributes, CTC Global has published a 250 page Engineering Manual. Contact CTC Global today to request a copy.




 CTC Global at Your Service


CTC Global's staff consists of dozens of individuals whose varied skill sets help us deliver the highest quality products and services, worldwide. 

In this issue, we'd like to acknowledge Dan Walsh, Master Machinist at CTC Global. 



Advanced Technology wouldn't be possible if it wasn't for good old fashioned experience and expertise.  Dan is a no nonsense head's down worker who has helped CTC build virtually every high-tech tool, fixture, part and component on every one of our high-capacity pultrusion machines and test fixtures.  The quality of Dan's work is evident in every meter of composite core we've produced since 2005.  Dan is one of those guys that's so busy, you hardly ever see him.  Nevertheless, when the lunch truck shows up, Dan pulls the cord on the train whistle he built himself.  If you've never heard it before you'd probably jump for cover.  At CTC we all smile and know its time to take a well deserved break.  All of us at CTC own Dan a huge debt of gratitude for helping us built a great product.  If you ever get a chance to visit CTC Global in Irvine, California, you've got to ask Dan to pull the cord for you.  (Remember to cover your ears)

 CTC Global named Winner

of Materialica Design + Technology Award
in product catagory



ACCC Field Experience
Hear first hand from one utility about their experience using ACCC Conductor

Please join us at Cigre Grid of the Future Symposium Oct 28-30, 2012 CLICK HERE 
*ACCC is a registered trademark of CTC Global Corporation
CTC Global - 2026 McGaw Ave. Irvine, CA 92614 USA +1 (949) 428-8500