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Reducing Wire-Down Incidents
It's a fact, the frequency of downed power lines has been increasing, especially within the last few years as much of the equipment in many power grids enters the half century and older point. According to federal data, the U.S. electric grid loses power 285 percent more frequently than in 1984, when the data collection effort on blackouts began. That’s costing American businesses as much as $150 billion per year, the DOE reported, with weather-related disruptions costing the most per event.
The root causes of the increasing number of blackouts are aging infrastructure. Also, demand for electricity has grown 10 percent over the last decade, even though there are more energy-efficient products and buildings than ever. And as Americans rely increasingly on digital devices, summers get hotter (particularly in the southern regions of the U.S.) and seasonal demand for air conditioning grows, the problem is only getting worse.
The power grid, which could be considered the largest machine on earth, was mostly built after World War II from designs, equipment, materials, and technology that primarily date back to the '60s and '70s. Its 7,000 power plants are connected by power lines that total more than 5 million miles, all managed by 3,300 utilities serving 150 million customers, according to industry group Edison Electric Institute. The whole system is valued at $876 billion.
In the last few years a tremendous emphasis supported with billions of dollars in investment has been spent on “Smart Grid” technology with the focus on detecting or monitoring problems in the grid. Unfortunately, not much of that money or effort is spent PREVENTING the problems in the first place. If the true goal is to extend the life of aging transmission and distribution equipment, the best method for doing so will be to prevent failures from occurring. There really is a lot of truth in the old adage, “an ounce of prevention is worth a pound of cure”.
Here are two relatively inexpensive solutions to this potentially deadly problem; When analyzing wire down incidents, our research shows us that about 1/3 are related to connector failures. This can be an in-line splice, deadend, suspension clamp, T-Tap, etc. Connectors are not designed to last forever so in order to make sure they stay in the air where they belong, it only makes sense to protect and reinforce them and the best way to do that is with an engineered mechanical and electrical shunt like ClampStar®.
My second suggestion relates to line uprates. Many presently installed high voltage transmission lines can carry more power than the existing splices and other connectors, clamps and fittings used in their construction. Shunting these connectors with ClampStar® increases their performance such that they will now exceed ANSI C119.4 Class AA, extra heavy duty standards while meeting NERC requirements.
When it comes to extending the life of overhead conductors, it’s pretty simple, ClampStar® is an engineered mechanical and electrical shunt that significantly reduces whole-span wire replacement cost when installed over a connector or on a damaged portion of conductor to function as a permanent bypass electrical connection while maintaining tension in the conductor. ClampStar® eliminates replacement of overhead splices and repairs damaged bare conductors through an easy, quick, and permanent fix. ClampStar® is also used to increase the performance of existing splices and other connectors, clamps and fittings for the purpose of increasing line ampacity that may presently be limited by such devices.
The Best Method For Repairing Overhead Connectors
This video shows a typical scenario using infrared inspection of an overhead transmission line to identify a hot splice and then the proper correction of that hot splice using a ClampStar engineered mechanical shunt. ClampStar, along with proactive maintenance practices improves safety and prevents unplanned outages. ClampStar is the industry’s only PERMANENT solution for protecting overhead splices and connectors. Click to watch video
How To Find And Fix Failing Overhead Splices
PPL Utilities shows a shunt splice applied to an overhead line via helicopter, to repair a failing splice.
Increasing power flows on some of the oldest lower-voltage circuits, especially during emergencies has put significant pressure on a power grid that was built mainly to serve local markets. ClampStar is necessary to help bring the power grid up to a level of acceptable physical soundness and reliability. Click to watch T&D How video
Can ClampStar® installations be budgeted as a Capital Expenditure?
Yes, because ClampStar® significantly reduces whole-span wire replacement cost and is the industry’s only PERMANENT life extension solution for virtually all overhead conductors of any voltage class, and ClampStar corrects, preserves, and maintains the electrical and mechanical integrity of new and weathered conductors, clamps, connectors, and structures to better-than-new condition.
Sources:
IRS clarifies capital improvement vs. repair expense
Internal Revenue Bulletin: 2012-14
We highly recommend that ALL utilities identify splices, deadends and suspension clamps located on critical lines and cover them with ClampStars. There's little reason to spend the additional money and time to evaluate the condition of splices in critical locations. In most cases, it's cheaper, faster and easier to just put ClampStars on them. 20 years is a long life for an automatic splice on a distribution system, and 40 years is an eternity. They will not last forever! If an overhead line falls on a sidewalk, or area frequented by pedestrians, the likelihood of a fatal injury increases exponentially.
Examples of critical line feeds and where they may be located:
| Freeway crossings | Schools/playgrounds | Hospitals |
| Railroad crossings | Stadiums | Airports |
| River crossings | Pumping stations | Emergency Stations |
| Convention centers | Shopping malls | Churches |
ClampStar® is proud to be part of the Weather Channel's new show titled "Top 10 Extreme Jobs"
It's no surprise that Helicopter Lineman made the list! The show is currently scheduled to air on Thursday, Oct 27 at 12am EST. Just set your DVR!
Click here to watch a preview
Classic Connectors USA introduces the new ClampStar® Repair Unit
The new ClampStar® Repair Unit quickly and easily corrects damaged conductor, great for gunshot or other types of damage on conductors sized from 2/0 – 2515 kcmil. After brushing the conductor, ClampStar is placed over the damaged area and is installed with only a nut driver.
ClampStar, an engineered mechanical shunt is the industry’s only PERMANENT, life extension solution for virtually all overhead conductors of any voltage class. ClampStar easily installs with NO power interruption and NO mechanical grips, come-alongs, jumper cables or cutters are needed. ClampStar exceeds ANSI C119.4 Class AA, extra heavy duty and restores both electrical and mechanical integrity on weathered conductors.
Additional ClampStar models are also available for correcting failing splices, deadends and suspension clamps on transmission and distribution conductors from #6 AWG thru 2750 kcmil AAC and 2515 ACSR. And ClampStars are also available to handle Overhead Shield Wire and OPGW. ClampStar also increases ampacity allowing for system up-rates to help meet NERC's maximum conductor operating temperature requirements.
ClampStar® THE BEST METHOD TO PERMANENTLY REPAIR & PROTECT DAMAGED CONDUCTOR
ESMO 2016 - The Demo You May Have Missed
If you attended the ESMO show in Columbus, Ohio 2 weeks ago then you may have seen a Haverfield aerial line crew performing some fantastic demonstrations. Click the image below to see a short video of a couple of their demonstrations.
And for those of you who stopped by the ClampStar booth, "thank you!" We appreciate your time and trust that we were able to satisfactorily answer all your questions.
As the grid ages, many electric utilities are experiencing a large increase in downed lines due to overhead connectors reaching the end of their service life. Installing ClampStars on them before they fail is the best way to prevent outages and protect the public. ClampStar provides a Life Extension solution for virtually all overhead conductors.
Here's What To Do After Finding Hot Connectors
As the grid continues to age, many utilities are increasing connector inspection frequency with a main goal of preventing outages and wire down incidents. One simple and relatively inexpensive line inspection method utilizes Infrared (IR) technology.
The above images were provided by a utility located in Pennsylvania.
Image #1 in the IR photo below shows the interface of the conductor at the entrance of the dead end body at a significantly high temperature.
Image #2 shows the same DE in the Visual Spectrum.
Image #3 shows the same DE cooled following ClampStar installation.
Image #4 shows the now corrected DE in the Visual Spectrum.
When helicopters are used to perform line inspections they should be equipped with appropriate ClampStar units so damaged and degraded connectors can be immediately corrected. This results in substantial cost savings compared to returning at a later date and immediately reduces the possibility of downed lines caused by failed connectors.
ClampStar....
- Lightweight design installs in less than 10 minutes!
- Permanent installation for deadends, inline splices, suspension clamps, OHSW and damaged conductor
- Easily installs over existing connectors
- No mechanical grips, Come-Alongs, jumper cables or cutters needed
- Installs with hot sticks or barehand
- Available for copper, composite core and all aluminum stranded conductors
ClampStar units are readily and quickly installed from any aerial platform (including helicopters, click here to see a video).
ClampStar shunts provide an excellent solution for PERMANENT mechanical and electrical upgrade to existing overhead connections. ClampStars are also used to increase the performance rating of existing splices and other connectors, clamps and fittings for the purpose of increasing line ampacity that may be presently limited by such devices.
Each unit is prefilled with proprietary CC² inhibitor to prevent galvanic corrosion and is designed with an integral fastening assembly that provides a high conductivity path and incorporates flat and Belleville washers to maintain compressive force regardless of thermal contraction and expansion.
NOTE: Safe-T-Link Tether assemblies are available for deadend and suspension clamp applications requiring additional mechanical support.
As the grid ages, many electric utilities are experiencing a large increase in downed lines due to overhead connectors reaching the end of their service life. Installing ClampStars on them before they fail is the best way to prevent outages and protect the public.
The smartest grid in the world looks pretty dumb when it is lying on the ground!
Many Utilities Ban The Use of Automatic Splices
There are estimated to be 250 million automatic splices installed on overhead power lines in North America. The majority of which were installed over 30 years ago.
A variety of reports in the field indicate the service life of automatics is as short as five years up to, and perhaps surpassing 30 years.
A recent event, where an automatic splice, installed for only 5 years, let go and dropped a line on a woman, ultimately resulting in her tragic death. The lawsuit resulted in an award of $105 Million!
Unfortunately, due to the advanced age of the power grid, overhead splice failures are increasing at a rapid rate putting the safety of the unsuspecting public at risk.
Google “Swingset Electrocution” to see a video of an overhead power line that came down on top of a metal swing set. Luckily, no children were in the area when this potential catastrophe took place.
As a result of this steadily increasing problem, many utilities have completely banned the use of automatic splices or are limiting their use only for the purpose of emergency restoration.
Many utilities are also correcting and protecting existing splices and overhead connectors by installing permanent ClampStar® shunts on them. ClampStar installs in a few minutes, is relatively inexpensive, and results in a connection of significantly higher integrity than even that of an original, properly installed connector!
ClampStar® is intended to correct and reinforce the deteriorated electrical and mechanical performance of hot-running, aged or degraded splices and other connectors.
ClampStar, along with proactive maintenance practices improves safety and prevents unplanned outages. ClampStar is the industry’s only PERMANENT solution for protecting overhead splices and connectors.
ClampStar is the least expensive insurance you can buy!
Classic Connectors USA Introduces Overhead Shield Wire (OHSW) Protection And Correction
When attending the upcoming IEEE show in Dallas, please visit the Classic Connectors booth #4736 to see the new ClampStar® for Overhead Shield Wire. This new ClampStar is designed for both tangent and deadend applications as well as splices. Full tension on galvanized and HSS, as well as Alumoweld and OPGW! Both insulated and non-insulated versions are available. An option for copper is also offered. All the features you’d expect from ClampStar: prefilled with a proprietary inhibitor, torque-shear fasteners, First Class, High Integrity Solutions!
- Lightweight design installs in less than 10 minutes!
- Easily installs over existing connectors
- No mechanical grips, Come-Alongs, jumper cables or cutters needed
- Installs with a hot stick or barehand
ClampStar OHSW units are a permanent repair fitting composed of an attachment head, which connects to the OHSW and a connecting link that attaches to the tower bracket. This connecting link is available in either an insulated or non-insulated design based on the application. A custom bracket is included to anchor the assembly to the tower. This unit serves as an OSHW safety catch to prevent the shield wire from falling into the energized conductors or substation bus below.
ClampStar units are readily and quickly installed from any aerial platform (including helicopters). ClampStar units may be used for a variety of repair situations, at splices, dead-ends, suspension systems, or wherever conductor or attachment hardware damage has occurred, or may occur.
ClampStar shunts provide an excellent solution for PERMANENT mechanical and electrical upgrade to existing OSHW connections. ClampStar will meet NERC's requirements for OHSW safety anchors without costly replacement, repair or expensive downtime.
Each unit is prefilled with proprietary CC3 inhibitor to prevent galvanic corrosion and is designed with an integral fastening assembly that provides a high conductivity path and incorporates flat and Belleville washers to maintain compressive force regardless of thermal contraction and expansion.
As the grid ages, many electric utilities are experiencing a large increase in downed lines due to overhead connectors reaching the end of their service life. Installing ClampStars on them before they fail is the best way to prevent outages and protect the public.
The smartest grid in the world looks pretty stupid when it is lying on the ground!
Other ClampStar distribution and transmission products will be on display. There will also be a hands-on demonstration. Come on by and discuss your specific application with our engineers.
We look forward to seeing you in Dallas!