Connectors - The Weak Link

When considering increased conductor temperatures, numerous issues are of concern, particularly with the dynamic effects on electrical connectors when suspended overhead aluminum conductors are operated at high temperatures, specifically above 93°C (200°F). Click here to read the complete article.


Alabama Power Repairs Hot Splice In 8 Minutes and 23 seconds!

Following annual line surveys at Alabama Power, with the discovery of some hot (aged) splices found with IR Thermography, a decision was made to utilize the advantage of a helicopter to quickly and efficiently install ClampStar units over the hot splices to restore their electrical and mechanical integrity.  An EHV Live-Line crew from Haverfield Aviation was brought in for the installations, along with some additional work installing some marker balls.  A couple of the splices were located in areas where it would have required significant time and funding to access with a bucket truck.

Installing ClampStar CSF-1302-048
Installing ClampStar CSF-1302-048

The conductor was 1033.5 ACSR, and being energized at 230kV, corona shields were installed on the CSF-1302-048 ClampStar units.  These were the first ClampStar units this particular crew had seen, and personnel from Classic Connectors, Inc., were on site to answer any questions the crew might have.  The additional photos which follow show how easily the ClampStar units were installed.  Complete with a very thorough conductor cleaning, Haverfield installed the CSF-1302-048, complete with corona shields, in 8 minutes and 23 seconds!  A number of Alabama Power personnel on hand all had the same statement - "We should have been doing this for years!"


SMUD Uses Helicopter to Install ClampStar Unit After IR Inspection Identifies Hot Splice

Jim Wilhelm, Tower Patrol T&D Assets, Distribution Services Lineman for Sacramento Municipal Utility District said “Installation was difficult due to the movement of the helicopter, but allowed us to do this over a deep gorge, not accessible from a bucket truck. Had we not had ClampStar, this would have required a minimum of an 8 hour outage on the line, purchasing wheel (backup) power, letting the line down to the ground and changing out the splice and adding about 150’ of conductor in the “old” conventional manner of repair.

It would have been even easier if we could have worked it with the skid board on the chopper, but because it was the middle phase, it required the work be done suspended 60 feet below the aircraft. It is significantly more difficult to hover steady in this position, as the pilot has no close reference point on which to fix his position.”

Installing ClampStar from 60' below the chopper
Installing ClampStar from 60' below the chopper

“With ClampStar, not only did we save many thousands of dollars and many man-hours but got the extra benefit of having a superior connection, much better than we would have if we had put yet another connector up in place of the one that had already failed!” Click to see photos.


New "CSS" Style ClampStar

Due to popular demand, CCI has developed the New “CSS” style ClampStar units for use on Deadends and Suspension Clamp applications!  Made with a single conductor leg, the new unit installs in minutes, the same as the traditional ClampStar units that are installed over splices.

ClampStar CSS Unit
ClampStar CSS Unit Installed on a Deadend

Several applications have given rise to the need for this new design. While the standard “CSF” ClampStar units can be installed on deadends and suspension clamps, it is more difficult than installing them over splices, as the torque nuts must be tightened from above. This new “CSS” design allows the installer to approach from below, with the fasteners positioned downward as well, allowing the same easy access to tightening them as that of a traditional ClampStar over a splice. Read More......


Line Crews Repair Failing Splices with No Power Interruption!

May 01, 2010, Transmission & Distribution World, By Mike Dario, Los Angeles Department of Water and Power

Corrosive salt water and high winds in Los Angeles' beach areas were wreaking havoc on the Los Angeles Department of Water and Power's automatic quick sleeves. Linemen were noticing more failures of these sleeves, which are spring-loaded with jaws that grip the wire. To solve the problem, linemen had to support the wire with a hoist and grips, and install a temporary jumper to maintain electrical Read more....


Los Angeles Department of Water & Power corrects failing splices in record time!

On a recent Tuesday morning at 10:00, two linemen from LADWP, Mike Traweek and Sammy Sempelsz lifted off the ground in their new Altec bucket truck to begin the first round of ClampStar® installations. They completed the first 6 installations in 55 minutes, moved the equipment about ½ mile down the street to the next location, waited a few minutes for someone to move a vehicle that was parked in the way, and installed the next 6 in only 25 minutes. Mike said, “I guess we just needed to get used to them a little bit”.

Crew Foreman, Mike Dario said replacing these 12 splices on energized 795 conductor would normally have taken 7-8 hours in these locations, and basically would have been an all-day job doing it the old-fashioned way with jumpers and come-alongs and it certainly would have been more dangerous. Beginning at 10:00 AM and having both jobs, at two separate locations, completed before lunch, including travel time, Dario was very pleased to have these finished quickly allowing his crew to move onto another project.

Be sure to view the installation photos in the Classic Connectors Photo Gallery.


ClampStar makes line up-rates possible!

Major Breakthrough With New Cost Saving Connector Technology Propels Classic Connectors, Inc. And Their Revolutionary Product “ClampStar®” Into Electric Utilities Must-Have Product For 2010

For the past several years, utilities have been under considerable pressure to operate aging power lines and equipment at higher levels, forcing them to transport large amounts of energy over an aged and antiquated system. Many of the components that make up the power grid are approaching their 30−50-year useful lives. Utilities therefore are constantly searching for cost-effective alternatives while maintaining technical and safety requirements as well as reliability. Enter “ClampStar®”! READ MORE....


Dominion VA Power installs ClampStar in Grandy, NC

The unit was installed on a 477 ASCR conductor, 34.5kV L-L, 19.9kV L-N, over an automatic splice.

Including the time for set up, and covering/uncovering the adjacent conductors, the install took 25:19. Once the ClampStar® was loaded in the bucket, the actual install of placing the unit over the splice and tightening the bolts took about 3 minutes.


Introducing the Classic Connectors Blog

Welcome to the new Classic Connectors blog. This is where we will post industry related items as well as new product introductions and company achievements.

Please feel free to post comments and ask questions. Our connector and industry experts are happy to respond.

Visit often, we intend to add new content regularly.

Regards,

Chris Costanzo
Director of Marketing and Communications
[email protected]
800-249-1462 Ext. 1


Introducing ClampStar from Classic Connectors

There is a serious problem in the electric power utility industry that is getting worse every day. Almost half of the installed infrastructure has reached the end of its original design life. Because the assessment and replacement of these components is expensive and difficult, and because it is very challenging for new installations to keep up with new demand, there are many that fail in-service causing power outages and other consequences. But if mitigation steps are not taken, or repairs are not performed, the potential liability when components fail is huge. A ClampStar® applied to a deteriorating fitting is not only the most economical means of preventing a premature and unexpected failure but also prevents potential injury to the public and avoids the extraordinary costs associated with the liability issues.

Read more