P.O.

Box 504 Waddington, NY 13694

Tel (315) 388-4082 Fax (315) 388-4253
Web Site: www.ktpower.com Email: ktpower504@verizon.net

OPPORTUNITIES FOR LIVE LINE

WORKING IN NEW ZEALAND
 KT Power, Inc.

Table of Cotents
Table of Cotents ................................................ 2
List of Figures ................................................. 3
1. INTRODUCTION ............................................... 4
2. OPERATIONAL EXPERIENCE OF KT POWER, INC. ................... 5
History .................................................... 5
Techniques and Safety ...................................... 5
Past Contracts ............................................. 6
Clients .................................................... 6
3. TECHNIQUES FOR LIVE LINE RECONDUCTORING .................... 8
The Barehand Technique ..................................... 8
Using Helicopters ......................................... 11
Using Insulated buckets from cranes ....................... 13
Hot-Stick Technique ....................................... 17
4. REVIEW OF LIVE LINE RECONDUCTORING BEING CARRIED OUT IN NEW
ZEALAND ........................................................ 20
Islington Kikiwa 220kV double circuit line .............. 20
Blenhiem Stoke 110kV double circuit line ................ 20
Conductor joins (sleeves) ................................. 20
5. ISSUES AND PROCESSES SURROUNDING LIVE-LINE RECONDUCTORING ... 23
6. SPECIFIC ISSUES SURROUNDING THE OTAHUHU HENDERSON 220KV
DOUBLE CIRCUIT LINE ............................................ 25

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List of Figures

Figure 1 Barehand techique from an insulated bucket (replacing a

joint/sleeve). .......................................................... 8
Figure 2 Barehand technique from an insulated bucket .................... 9
Figure 3 One of KT Powers bucket trucks. ................................ 9
Figure 4 Barehand and hotstick techniques? ............................. 10
Figure 5 Helicopter replacing cross-arm? ............................... 11
Figure 6 Cross-arm replacement using a helicopter. ..................... 12
Figure 7 Cross-arm replacement using a helicopter. ..................... 12
Figure 8 Live line switchgear maintenance out of insulated bucket. ..... 13
Figure 9 Live line tower replacement using insulated bucket trucks (1). 14
Figure 10 Live line tower replacement using insulated bucket trucks (2).
....................................................................... 14
Figure 11 Live line tower replacement using insulated bucket trucks (3).
....................................................................... 15
Figure 12 Live line tower replacement using insulated bucket trucks (4).
....................................................................... 15
Figure 13 Crane holding conductor while insulator is replaced? ........ 16
Figure 14 Classic hotstick technique (1). .............................. 17
Figure 15 Classic hotstick technique (2). .............................. 18
Figure 16 Combination of barehand and hotstick techniques. ............. 19
Figure 17 Example of sleeve / joint replacement using insulated bucker
truck (note: wooden matting). .......................................... 21
Figure 18 Live line conductor sleeve / joint replacement from insulated
bucket trucks. ......................................................... 22

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 KT Power, Inc.

1. INTRODUCTION

Live line work can be an economic way to Upgrade and maintain high
voltage transmission system components while still in operation.
In some circumstances this may be the only possibility, aside from
customer or system disconnection 1 .

This document reviews relevant live line technologies and the

maintenance achievable with different techniques. Each technique
is more or less suited to different types of maintenance
procedures.

For example, live-line barehanded techniques out of helicopters

can be an efficient and fast technique for testing conductor
sleeves / joints (Transpower is currently undertaking such live
line work). However, with the current live line techniques used
in New Zealand it is likely that any faulty joints / sleeves will
require the outage of the line or circuit for maintenance. Using
insulated buckets from cranes equipment with hydraulic pressing /
crimping devices (such as those used by KT Power, Inc.) could mean
much of this work is also achievable live.

An additional complexity in New Zealand is the substantial under

build (residential homes and industrial / commercial premises)
beneath certain transmission lines in urban areas. One example of
this is the 31km, 220kV double circuit Henderson Otahuhu
transmission line in Auckland. At some stage in the future this
line will require reconductoring and the Electricity Commission of
New Zealand has contracted with KT Power, Inc. to undertake a
desktop review of the likely issues surrounding the reconductoring
of this line. One key issue will be whether the double circuit
line can be reconductored with one circuit remaining live.

This report outlines the issues and the processes required for the
live line reconductoring of such a line.

1
The New Zealand grid owner and operator, Transpower, has recently stated that it intends to do more live-line
work into the future. http://www.transpower.co.nz/f1958,14940295/14940295_eea-19-june09.pdf
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 KT Power, Inc.

2. OPERATIONAL EXPERIENCE OF KT POWER, INC.

History

KT Power, Inc. was founded by William (Bill) Tiernan of

Waddington, New York in April 1998. Tiernan worked as a lineman
for over 15 years for the New York Power Authority before going
into business and is well versed in safe work practices. It was
started after a 10 year not-to-compete clause expired whereas the
Owner, Mr. William Tiernan, had sold his previous powerline
company, Northeastern Live Line Maintenance, Inc.

KT Power, Inc. is a family owned business run by Bill Tiernan, his

wife Marcia, and their sons, Jeffrey and Marshall, from their home
base in Waddington, New York. Sons, Jeff, James and Marshall work
for the company as operators, linemen or supervisors. Bill is
usually in the field working as the project manager while Dick
Rieker, a native of Oklahoma, handles field operations. Rieker
has over 40 years of experience on high voltage maintenance and
construction of all types of transmission lines.

Techniques and Safety

KT Power, Inc. used the barehand technique or hot stick

technique to work on energized lines. In the barehand technique
our linemen wear conductive suits, gloves and socks along with
specialized boots to ensure that the safety of the workers. These
conductive suits combine interwoven microscopic stainless steel
fibers and Nomex material to provide fire protection.

Safety is of the utmost concern with KT Power, Inc. We strive to

provide our employees with the best on-the-job / hands-on training
to ensure the safety of everyone involved in any project we
perform. There have been no lost time accidents in the companys
11 year history. The development of standard procedures that work
and have been proved are essential.

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Past Contracts

In 1998, PPL Electric Utilities Corporation (PPL) awarded KT

Power, Inc. its first contract, a one year renewable contract. KT
Power, Inc. continues to perform various energized tasks for PPL
under a renewable three (3) year contract.

In the year 2000, PPL contracted with KT Power, Inc. to remove

several GIS leads under energized conditions at one of its 500kV
switchyards. The energized work consisted of the removal and
replacement of the GIS leads.

Performing the work energized saved the utility several million of

dollars, since the switchyard did not have to be taken out of
service.

In 2001, KT power, Inc. was awarded a contract with National Grid

USA for the upgrade of 265 structures on a 230kV transmission
line, covering a thirty mile stretch, in Eastern Massachusetts.
This project was compelted ahead of schedule, in a safe manner,
with no punch list items, and to the satisfaction of the Owner and
the Environmental firm overseeing the work.

KT power, Inc. was awarded a two phase contract in 2006 for the
replacement of 138 single circuit steel lattice towers on an
energized 345kV line, stretching about 83 miles in New York State.
The first phase of 25 structures was successfully completed on
time. The second phase of 114 structures was completed in
December 2008. This was 6 months ahead of schedule (except for
the ground restoration), with no injuries and to the complete
satisfaction of the owners.

Clients

National Grid USA

. Massachusetts Electric
. New England Power
. Niagara Mohawk Power Corporation
PPL Electric Utilities Corporation
New York Power Authority
Conective Power Delivery
Brookfield Power (Reliant Energy)

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 KT Power, Inc.

Live Line work is carried out by line workers who have been
trained in working live line / energized lines. A work procedure
shall be developed prior to the start of any work and understood
by all team members and include the work environment. All crew
members must be competent and capable of performing their share of
the work. Ensure reclosures are available from the owner /
electrical utilities. These steps are mandatory to safety of all
workers.

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3. TECHNIQUES FOR LIVE LINE RECONDUCTORING

The Barehand Technique

New Zealand is relatively well versed in bare hand techniques,

especially from helicopters However, to date there has been no
experience in New Zealand using insulated bucket trucks.

Using standard procedures, and applying the work environment to

these procedures, the barehand technique can be completed safely.
Live line workers must maintain a safe separation distance (OSHA
1910.269 Regulations) from the live conductor(s) though the use of
Barehand suits.

In the barehand technique our linemen wear conductive suits,

gloves and socks along with specialized boots to ensure the safety
of the worker. These conductive suits combine interwoven
microscopic stainless steel fibers (18%+/-) and Nomex material
(72%+/-) to provide fire protection.

Do not cut corners, nor expedite a job for the risk of any worker.

Figure 1 Barehand techique from an insulated bucket (replacing a joint/sleeve).

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Figure 2 Barehand technique from an insulated bucket

Figure 3 One of KT Powers bucket trucks.

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Figure 4 Barehand and hotstick techniques

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Using Helicopters

The use of helicopters in line work can improve costs, speeding up

the process and reducing access time / set up time, where limited
use of ground equipment makes it feasible. Companies that have
skilled pilots can safely place a live line worker on a tower or
platform.

Disadvantages include;
access to steep hill sides that could interfere with the
rotating blades.
Limited clearance issues like working on middle and
bottom conductors where distance is minimized.
Inclement weather conditions like wind and rain also
limit the use of a helicopter.

Figure 5 Helicopter replacing cross-arm

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Figure 6 Cross-arm replacement using a helicopter.

Figure 7 Cross-arm replacement using a helicopter.

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Using Insulated buckets from cranes

Cranes are designed to lift heavy loads and also have a lengthy
reach. When they are adapted with an ANSI A92.2 certified
insulated boom section that enables them to be used on energized
lines, it can make the job at hand a lot easier and safer.

Often the issue of reaching out on hard to access work positions

is overcome. The problem encountered most is getting site access
and setting up the crane. Cranes can be heavy and large timber
mats for access are often used to bridge wet areas. These mats
can be very costly to install. It is very important to have a
smooth, well experienced operator (certified & licensed and who is
used to working around energized lines).

Figure 8 Live line switchgear maintenance out of insulated bucket.

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Figure 9 Live line tower replacement using insulated bucket trucks (1).

Figure 10 Live line tower replacement using insulated bucket trucks (2).

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Figure 11 Live line tower replacement using insulated bucket trucks (3).

Figure 12 Live line tower replacement using insulated bucket trucks (4).

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Figure 13 Crane holding conductor while insulator is replaced

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Hot-Stick Technique

Hotstick techniques for live line work can be used in parallel

with barehand work if the crew has the means and the skills.

The advantage of this is the ability to work on the hot end

without being separated by the clearances required to be
maintained. The higher the voltage, the further the clearance
required.

Keeping a safe distance from the live conductor, the use of

hotsticks (tools mounted on an insulated fiberglass stick) can be
used for many live line tasks.

For Example: Pulling a cotter key with a 12 foot stick compared

to using a pair of pliers. Using an insulated ladder or platform
to work the conductors or on the pole itself.

The key is to maintain sufficient separation of the line worker

and his/her tools and the live conductor(s) and the path to earth.
Follow all procedures developed prior to the start of any work.

Figure 14 Classic hotstick technique (1).

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Figure 15 Classic hotstick technique (2).

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Figure 16 Combination of barehand and hotstick techniques.

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4. REVIEW OF LIVE LINE RECONDUCTORING BEING CARRIED

OUT IN NEW ZEALAND
Bare hand live line techniques were introduced into New Zealand in
the early 1990s as part of the HVDC upgrade project. Here live
line techniques were used to replace insulators on the HVDC link

Islington Kikiwa 220kV double circuit line

Transpower has recently (2006) strung a second circuit on the

Islington Kikiwa 220kV double circuit line. This transmission
line was built with double circuit 220kV towers but only one
circuit was originally required. The second circuit was strung
with the other circuit live (with auto-reclose blocked). The
Electricity Commission considers this to be live-line work as one
circuit was energized and carrying current while the other circuit
was being strung.

Blenhiem Stoke 110kV double circuit line

Similarly, The Blenhiem Stoke 110kV transmission line,

originally built with double circuit towers had an additional
circuit added in 2006 / 2007 with the other circuit live (again,
with auto-reclose blocked).

Conductor joins (sleeves)

Since the line break in early 2009, Transpower has commenced live
line work (bare hand from helicopters) to test all conductor
joins (sleeves) using the ohm stick technique. There are
thousands of sleeves to be tested of which around 6,000 have been
tested to date (from discussion with Ray Basher on May 26, 2009).
As part of the testing on circuits into Auckland, it was more
efficient to test multiple lines (up to three separate
transmission lines) simultaneously. This was achieved with a
helicopter leap-froging men between and along lines 2 .

It is unclear how Transpower intend to replace any damaged sleeves

they find. One technique would be to use live-line techniques
such as those used by KT Power, Inc. from insulated bucket cranes,
equipped with suitable hydraulic crimping tools / presses which
2
It should be noted that during this procedure, all three lines had they auto-reclose blocked.

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are required to compress the sleeve / joint. Alternatively these

could be repaired de-energized using explosive impact joining
techniques.

The thermal upgrade of the double circuit 220kV Whakamaru

Otahuhu C line, between Ohinewai and Whakamaru is running into
problems (participants in the Upper North Island not satisfied
with the security margin (N) required to complete this work).
There may be scope for live line re-tensioning? Again this may
not be possible without the techniques used by KT Power, Inc.
using insulated buckets from cranes.

Figure 17 Example of sleeve / joint replacement using insulated bucker truck (note:
wooden matting).

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Figure 18 Live line conductor sleeve / joint replacement from insulated bucket trucks.

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5. ISSUES AND PROCESSES SURROUNDING LIVE-LINE

RECONDUCTORING
The general process for reconductoring a double circuit
transmission line, with one side live, would be for each section,
as follows:

.
1. Initial Planning: decide where to start and what part of the
line can be accessed. Public parties / Landowners involved
would have to be approached and issues would have to be
addressed for gaining access to the lines.

2. Identification of work sites. Work Sites need to be

identified for pulling and tensioning. Houses and other
buildings that obstruct the progress of the job will need to
be dealt with. Man hours and job scope would be relative to
being able to access and apply work procedures. Once defined,
develop work procedures / contacts / contact numbers.

3. Removal of spacers. Spacers need to be removed prior to job

commence. If need be the spacers can be removed section by
section to minimize the time that the line is affected, while
reconductoring is talking place.

4. Remove splices/sleeves. When the line is de-energized, the

splices (sleeves) need to be removed and replace with a pair
of wire basket grips (Kellum grips) connected with a solid
link. Note: This can not be done live because the current
will not be able to flow through these. The tension should be
relieved to accommodate for the length of the sleeve being
removed.

5. Unclip and install travelers. Unclip wire from the insulators

and install travelers. Conductor suppliers usually have a
standard minimum size recommendation for wire installation.

6. Install puller and tensioner. Install puller at pulling site

and tensioner at tensioning site. Tension must be lowered to
reduce strain on equipment.

7. Connect wire to deadends wire needs to be cleaned and

prepared properly to be spliced to carry current.

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8. Tension needs to be determined. Wire manufacturers have

tension recommendations and charts that help to determine sag
and tension criteria.

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6. SPECIFIC ISSUES SURROUNDING THE OTAHUHU

HENDERSON 220KV DOUBLE CIRCUIT LINE

In Auckland, New Zealand there is one main transmission line

feeding the North Auckland and Northland region. Although the
Electricity Commission has given recent approval for a new 220 kV
cable route into the region, at some point in the future the
existing transmission line will require reconductoring.

The OTA-HEN 220kV double circuit line is approximately 31km long

strung with duplex Zebra at 120 deg. C. There are approximately
100 towers on this line and for most of its length there is
significant under-build. This is likely to result in access
problems with pulling, tensioning etc.

Aside from these access issues, reconductoring should be able to

be performed as normal with skilled personnel. The development of
residential housing and any other buildings under the power line
is a hindrance to the maintenance and future access of the line.

One option is for Transpower to start assessing pulling and

tensioning sites with the possibility of purchasing property that
may be required. Another option that KT Power, Inc. is looking
into is the possibility of engineering equipment to aid in the
process of reconductoring in access limited applications such
as the Otahuhu-Henderson line. Further research and developments
are in order.

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