Customer Webinar 5

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North American Classic Connectors ClampStar Presentation 1

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Yes, Problem Splices Exist Why Problem Splices Exist What is ANSI C119.4 Class A ClampStar as a PERMANENT Solution ClampStar Technical Attributes Installation Photos Labor Savings Typical ClampStar Uses Success Stories North American Classic Connectors Sales Training Program ClampStar ® Topics 2

Some ClampStar Users: 

Some ClampStar Users 3 3

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YES, Problem Splices Do Exist EVERYWHERE! 10 Million overhead splices on average sold in the U.S. each year 300 Million splices presently installed (conservative estimate) 80% of them were installed over 40 years ago. 60% + are approaching the end of their life 300,000 splices are repaired or replaced annually in the U.S. This number has increased by a factor of 10 over the last decade NOTE: The above figures only pertain to splices. Dead-ends, suspension clamps and up-rate projects are additional. 4

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Progression of Splice Failures 1940 1980 2000 2011 2030 2040 300,000 3,000,000 6,000,000 9,000,000 12,000,000 15,000,000 5 5

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Why Do Splices Fail? Improper installation a) Incorrect or insufficient amount of inhibitor b) Conductor not properly brushed/prepared c) Conductor not inserted all the way d) Improper tooling Mis -application (using wrong connector for the job) Old age – Originally designed for 30 years (Average useful life: automatics 20-40 years. Compression splices 40-70) 4. Highly corrosive environment 5. Excessive thermal excursions resulting from frequently operating the line above ampacity design limits of 70-75°C conductor temperatures. 6

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7 ANSI C119.4 American National Standard For Electric Connectors

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8 American National Standard ANSI C119.4-2010 For Electric Connectors — Connectors for Use Between Aluminum-to-Aluminum and Aluminum-to-Copper Conductors Designed for Normal Operation and Copper-to-Copper Conductors Designed for Normal Operation At or Below 100°C 1 Scope and Purpose 1.1 Scope This standard covers connectors used for making electrical connections between aluminum-to-aluminum or aluminum-to-copper or copper-to-copper conductors used on distribution and transmission lines for electric utilities. This standard establishes the electrical and mechanical test requirements for electrical connectors. This standard is not intended to recommend operating conditions or temperatures. 1.2 Purpose The purpose of this standard is to give reasonable assurance to the user that connectors meeting the requirements of this standard will perform in a satisfactory manner , provided they have been properly selected for the intended application and are installed in accordance with the manufacturer's recommendations. The service operating conditions and the selection of the connector class is the responsibility of the user. at or Below 93°C

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9 What Some Manufacturer’s Say

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10 Continuous Maximum for ACSR is 75 °C “ACSR is not a high-temperature conductor: it is rated for 75°C continuous operation and 100°C emergency operation for a total of 1,500 hours over the conductor life.” Mark Lancaster

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11 Development of ANSI C119.4 Class A includes an accelerated aging temperature for the purpose of assessing long term performance at “Operating Temperature” which is 75°C, in a short term period of only 500 cycles. The “accelerated aging” temperature is “100°C over ambient.” Typical ambient it 25°C (77°F) Aging temperature was determined by adding acceptable operating rise of 50°C (25°C ambient + 50°C rise = 75°C “Continuous Maximum Conductor Operating Temperature”) twice, i.e., 100°C Rise. Testing connectors to this temperature, per this standard DOES NOT qualify a connector for use at 120 °C. Any manufacturer stating their connector, tested to this standard, is suitable for applications at higher temperatures, is imprudent and irresponsible. How Some Mfgs. Misconstrue Data

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ANSI C119.4 Class AA requires heat cycle testing at 175 °C rise above ambient – only to qualify for applications on conductors “at or below 93°C” and not for any conductor operating above that temperature! Again, typical ambient being about 25 °C, a 175°C rise above ambient therefore yields a 200°C test temperature, which is 392°F! ClampStar is tested and qualified to ANSI C119.4 Class AA as a minimum, but we go far beyond that, testing ClampStar at 390 °C (734°F ) conductor test temperature, which is suitable to qualify for application on weathered conductor at 250°C operations, the maximum continuous rating for any conductor today! Class “A” vs. Class “AA” 12 ANSI C119.4 Does have a provision for qualification of connectors for application on used or weathered conductor operating “at or below 93°C”, and that is Class “AA”

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13 Why is ClampStar a Permanent Solution? Side Opening, Inline Deadend Shoe Long favored design Well proven to provide ample conductor tensile support Widely used by nearly every electric utility Clamped holding strength of 40-95% of conductor RBS Similar design to:

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14 Why is ClampStar Superior to deadends? More keepers, typically twice as many Greater holding strength In most applications ClampStar sees no tension load ClampStar restores aged connectors to their original mechanical performance ratings and exceeds the electrical ratings

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ClampStar Technical Attributes 15 Designed to restore full mechanical integrity to an aged splice. Restore mechanical integrity to Dead-Ends and Suspension Clamps with use of ClampStar Safety Tether. No restriction on current, continuous operation up to 250° C

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Mechanical & Electrical Testing EPRI Laboratory, Charlotte, NC 16 2000 Thermal Cycles with conductor at 35.6 kN (8,000 lbs) tension, and conductor temperature of 200° C (No connector in between – ClampStar serving full electrical and mechanical load). Test photos courtesy EPRI Test laboratory, Charlotte, NC.

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ClampStar Used to Restore Test at EPRI Laboratory-Charlotte, NC 17 Testing of Single Die Compression Connectors at 200° C. Upon Thermal failure of one splice, rather than terminate the test, EPRI technicians used a ClampStar CSF-1108 to continue testing! Failed Connector 220° C Test photos courtesy EPRI Test laboratory, Charlotte, NC.

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ClampStar Used to Restore Test at EPRI Laboratory-Charlotte, NC 18 Lower Temp. Test photos courtesy EPRI Test laboratory, Charlotte, NC.

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ClampStar Test - IR Image EPRI Laboratory-Charlotte, NC 19 Test photos courtesy EPRI Test laboratory, Charlotte, NC.

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Broken Strands Shown With X-Ray 20

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X-Ray of Improperly Crimped Splice Incomplete compression Improper crimping causes premature failure Lack of stranding compaction is evident Difficult to detect without infrared 21

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Failed Dead-End Examples 22

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Failed Connector Examples 23

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Conductor Fatigue & Corrosion under Rods & Helical Type Suspension 24

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Strand Fatigue in Bolted Dead-End 25

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Dead-End Repaired With CSF-0883-036 26

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Strand Fatigue in Trunnion Suspension Problem… Fixing… No Problem CSS-0883-036 27

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Trunnion Suspension Repaired with CSS-0883-036 28

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Failed Splice Problem… No Problem Fixing… CSR-0883-030 29

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30 Splice Corrected with CSR-0883-030

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Gun Shot Damage Problem… No Problem CSR-1108-030 Fixing… 31

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Gun Shot Damaged Conductor Repaired with a CSR-1108-030 32

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33 Labor Savings With ClampStar Why Do This…..? 45 minutes 5 minutes Vs. When You Can Do This

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Typical ClampStar Uses Failing or compromised splices Usually found thru IR or visual inspection Up-rating Lines For Higher Ampacity Connectors are the weak link in the ampacity/thermal ratings of the line Reliability Standard TPL-002-0, requirement for (N-1) contingency Critical splice/deadend protection Major highway, railroad and river crossings Heavily populated areas; school yards, shopping centers & sidewalks Lines that feed critical customers; hospitals, airports, transportation systems, stadiums and convention centers Close proximity to sub stations subject to extreme fault current 4. Conductor damage (gun shot, abrasion and arcing from contact with vegetation) 5. Damaged conductor and suspension systems due to vibration 34

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Success Stories EXAMPLE #1: National Grid was diligently conducting line assessments which identified lots of hot splices. Due to the difficulty of getting a line outage (6-8 weeks schedule time) and the public commission was pushing them to make some changes, ClampStar was an instant solution for them. They could now do their required work on energized lines in poor weather conditions. EXAMPLE#2: Soon after a critical line fell, a ClampStar sample and literature was dropped off at LADWP’s ‘trouble crew’ office. They had recently received orders to replace every automatic splice on that line with 2 compression splices. Once they learned about ClampStar, the plan was soon revised to repair the splices with ClampStar instead of cutting them out. EXAMPLE #3. While conducting routine IR inspections, linemen for Sacramento Municipal Utility District identified some hot splices on a transmission line in a very remote area, not accessible with a bucket truck. Correcting those splices with ClampStar and a helicopter saved SMUD thousands of dollars and many man-hours. 35

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Thank You For Your Time! Please vist www.ClassicConnectors.com for more information 36 Email: Info@ClassicConnectors.com Tel: 800-269-1462