Innovative New Live Line Tool andFraming Designs Facilitating Safe and

Efficient Cross-arm Replacement

A.J. Carreira, P.Eng., SMIEEE

President

K-LINE INSULATORS LIMITED

Toronto, Canada

carreira@k-line.net

K-LINE INSULATORS LIMITED

ISSUES WITH CURRENT CROSS ARM FRAMINGS:- Limited life of wood crossarms (mainly due to rot)

- Steel crossarms susceptible to corrosion

- Fiber reinforced polymer (FRP) crossarms susceptible to surface tracking and degradation

Internal Rot

Steel Arm Corrosion

Rot

FRP DegradationInternal Rot

FRP Surface Tracking

K-LINE INSULATORS LIMITED

Demand for power increasing

Capacities of power systems pushed to their limits

Removing lines from service becoming ever increasing challenge

K-LINE INSULATORS LIMITED

The “Issues” With Existing Live Line Work Tools

Courtesy of Hydro One

Rigging equipment mechanical ratings typically require a 5 to 1 safety factor

At high loads:• Conventional Hot Line Tool Auxiliary Arm configurations for Live Line Work (LLW) can become “strained”• Pole attachments and saddles can dig into the pole & create damage

Other issues when using conventional live line tool auxilary arms include:- Setup is time consuming- Inclement weather requires removal and shutdown of the operation- Higher load capabilities rigging arrangements are required

- For longer spans- Larger conductor sizes- Combination of longer spans & larger conductors

NEW LLW EQUIPMENT IS REQUIRED TO ADDRESS THE ABOVE ISSUES

K-LINE INSULATORS LIMITED

There exists an obvious need to design new:

Tools Equipment Materials, and Work Methods

to facilitate live line cross-arm replacements.

K-LINE INSULATORS LIMITED

K-ARMTM

Auxiliary Arm

Tool designed using modular components for:

Improved installation

Transportation

Other key features of these new tool designs include:

Brace support insulators which can be used in high load applications

Offering higher working load limits (WLL)

Lightweight Aluminum Base bolts or straps directly to pole

Improved conductor support stability and performance

Silicone rubber insulators used in these designs

Eliminates issues and concerns related to inclement weather

In some designs, the K-ARMTM tool incorporates the very popular K-CLAMP®

Easily and Safely facilitates live line tool work methods

Accommodates conductor sizes ranging from #4 AWG to 1192 kcmil

(or about 6 mm diameter conductor to 34mm diameter conductor)

Live Line Tool Designs for 115 kV & 230 kV Power Lines

K-LINE INSULATORS LIMITED

115 kV Auxiliary ArmConductor Moved to

K-CLAMP®

Conductor Secured in Position Using

Grip-All Clamp Stick

Conductor Temporarily Supported

by K-ARMTM

K-LINE INSULATORS LIMITED

K-ARMTM

Auxiliary Arm with & without Brace Support

230 kV 115 kV

K-LINE INSULATORS LIMITED

TRANSMISSION SYSTEM K-ARMTM KITS230 kV

KIT115 kV

KITTool designs supplied in custom made

cases ensuring protection during:

Storage

Transportation

K-ARMTM Tool design to be:

Treated and handled using same

caution and care as with traditional

live line tools

Electrically tested

Maintained clean and dry at all times

K-LINE INSULATORS LIMITED

NOW TO ADDRESS THE ISSUE OF DETERIORATED CROSS-ARMS

TOTALLY INSULATED FRAMINGTM DESIGNS

(TIF)

The proposed TIF system designs will provide the advantages required to:

Overcome current framing design issues, and

Offer desired advantages such as:

• increased cross-arm life

• improved safety performance

• increased vertical ground clearance

• use of shorter poles or other line support structures

• increased power line operating capacity

• reduced Right-Of-Way (ROW) width requirements

• lightweight construction

• modularity

• facilitating safe and efficient installation work methods

The requirement to design the K-ARMTM live line tool was result of the need to

replace existing defective cross-arms with more robust designs and materials.

K-LINE INSULATORS LIMITED

TOTALLY INSULATED FRAMINGS(patent pending)

H-Frame Structure TIFThree Phase Single

Circuit Structure TIF

New TIF Designs combine insulators assembled

together in innovative new configurations to

perform both the:

Line Insulation Function of the Structure, and

Mechanical cross-arm function of the Structure

Typical existing cross-arm designs illustrated in

shadow form.

New replacement TIF designs superimposed.

K-LINE INSULATORS LIMITED

TIF Tri-Frame Field TrialLightweight

characterisitics

of the TIF

designs

Factory

assembled

in one piece

TIF designs offer opportunity for large cost

savings over conventional cross-arm line

designs, including a major decrease in labour:

No assembly

Reduced set up time

Six (6) minute installation time

TIF Designs

Permit use of

Conventional

Stringing

Equipment

K-LINE INSULATORS LIMITED

Major Canadian Utility Installation in Kleinberg, Ontario

TIF designs offer opportunity for large cost

savings over conventional cross-arm line

designs, including a major decrease in labour:

No assembly

Reduced set up time

Twenty Six (26) minute installation time

K-LINE INSULATORS LIMITED

ESMO 2016 FIELD DEMONSTRATION

Brace Insulators Optional for line

framings to permit:

Increased mechanical load capacity

Increase possible by up to 80%

K-LINE INSULATORS LIMITED

H-FRAME TIF

MAIN INSTALLATION LOCATION OPTIONS

A – original cross-arm location

B – original conductor attachment

K-LINE INSULATORS LIMITED

H-FRAME TIF ATTACHMENT AT ORIGINAL CROSS-ARM LOCATION

INCREASE IN SAG/CLEARANCES

OPTION A

Permits either:

Increased vertical line clearance to

ground or underbuilt facilities, or

Increased sag/line operating current

capacity

EXAMPLES

115 kV line gains about 1 meter clearance

230 kV line gains about 2 meters clearance

K-LINE INSULATORS LIMITED

H-FRAME TIF

ELIMINATES INSULATOR SWING

Elimination of the suspension insulators: eliminates insulator swing displacement

eliminates overall conductor displacement

K-LINE INSULATORS LIMITED

H-FRAME TIFOPTION A – ORIGINAL CROSS-ARM ELEVATION

ADVANTAGES- Eliminates need for suspension insulator

+ permits increase in line sag

+ permits increase in line ampacity

+ permits increase in ground and/or underbuild clearances

LIGHTNING PROTECTION ANGLE (α):- Effectiveness depends on:

+ line height

+ fault current amplitudes

+ existing shield angle

- Improved lightning protection angle with reduced phase spacing

- Eliminates insulator swing distance (DIS)

+ eliminates insulator swing angle (θ)

+ permits reduced phase spacing

+ maintains electrical clearance distance to structure (DEC)

+ reduces necessary ROW width

- Fosters lower cost framing design

+ permits shorter TIF cross-arm lengths

K-LINE INSULATORS LIMITED

DISTRIBUTION TIF TESTING

Test Set-up for Transverse Tension Load Test- minor deflection at point A- no deflections at points B, C or D- no permanent deformation on any of the components

of the assembly

Test Set-up for Vertical Load Test (Center Phase)- no deflection at points A, B, C or D- no permanent deformation on any of the components of the assembly

AC

B

D

A

BC

D

K-LINE INSULATORS LIMITED

DISTRIBUTION TIF TEST PHOTOS

Transverse Tension Load Test

Vertical Load Test (Center Phase)

K-LINE INSULATORS LIMITED

TRANSMISSION TIF TESTINGTest Set-up Drawing for Mid Connector Plate Assembly Photo of Test Set-Up

No Cracks or Deformation on the Mid Connector Plate Assembly

K-LINE INSULATORS LIMITED

Transmission TIF Cross-arm Designs can be: delivered in modular components, or

delivered factory-assembled as a one-piece system

if necessary, components can be easily replaced in situ and normally without removing the complete arm

installed with simplicity and safely hoisted to position & quickly bolted to the structure with two machine bolts per pole

installation time is minimized, thereby minimizing field personnel hazard exposure

easily be customized to the various framing arrangements and line voltages

installation cost is minimized

K-LINE INSULATORS LIMITED

TOTALLY INSULATED FRAMINGS

SUMMARY OF ADVANTAGES

- Eliminate all current cross-arm material deterioration issues

- Increase structure framing life expectancy

- Improve line safety

- Are easy to transport

- Increase ground and underbuild clearances

- Increase power line operating currents

- Require use of shorter pole or other structures

- Require reduced right-of-way (ROW) widths

- Are Modular and easy to transport

- Are Lightweight and easy to erect without heavy equipment or helicopters

- Can be customized to any structure and conductor spacing

- Are integrated line insulation solutions eliminating requirement for any additional insulators

- Can be used on new construction

- Can be used to retrofit existing conventional cross-arm line framing designs

- Protect wildlife and discourages bird nesting

- Avoid vandalism associated with glass and porcelain insulators

- Distribution & Transmission three phase line designs available

K-LINE INSULATORS LIMITED

CONCLUSIONS

Need to replace existing deteriorating cross-arms is a growing issue.

Need to develop new, safer and more efficient tools

Utilities deal with the constant need to maintain dependable and uninterrupted power

supply to Customers

Live line work methods are the preferred approach when conducting most maintenance

work activities today

New tools, equipment and materials presented offer new opportunities for field personnel to

meet these challenging maintnenance and system performance requirements:

- Effectively

- Safely

- Cost effectively