Issue 9 30 Jun 2009

PLANT UPDATE
1. New HV and LV bonding methods
Pole top fires on Distribution structures are primarily caused by leakage current across the surface of insulators and into the wood. The continual leakage currents
concentrated at a specific point on the wood surface which leads to ignition of the wood resulting in a pole top fire/ burning. Photo 1.1 shows an example of charring and
Photo 1.2 shows the result of sustained burning and subsequent pole head failure, ie the pole head has burnt-off.

Photo 1.1

Photo 1.2

Photo 1.3

In an initial endeavour to prevent pole top fires, a method of dispersing the concentration of the leakage currents over a larger area was introduced. The dispersion was
achieved using of bonding kits, which had gang nails to dissipate the heat and copper conductor to short out insulator studs and cross-arm bolts. The existing bonding
kits are shown in Photos 1.4, 1.9, 1.10 & 1.15. The existing bonding kits are electrically connected, via the copper wires, with automotive type slide on connectors. The
problem with the existing bonding kits is the slide on connectors are disconnecting from their attachment points or corroding and thus not shorting out the insulator studs
and cross-arms as required. Photo 1.3 shows an example of where the bonding wire has become disconnected on the right hand insulator.

To eliminate the problems with the existing bonding kits the following changes are being made to the bonding kits.

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Issue 9 30 Jun 2009

Existing HV intermediate structure bonding for new construction

New HV intermediate structure bonding for new construction

Existing bonding kit CE7553 (see photo 1.4) that was used for application on
intermediate steel cross arms.

The new bonding method is to fit bolts through the dispersion plate with the bolts
being fastened to the steel cross-arm. The bolt is held under constant pressure via
the coil spring washer. This arrangement will provide a solid electrical connection
between the insulator studs and wooden pole head.

Previously the gang nail plate did not have the pole bolts passing through the
circular hole (approx 25mm diameter). The gang nail plate was simply nailed to the
pole and the electrical connection was made via the copper conductor to the pole
bolts.

An example of the above bonding method is given in Photos 1.5 and 1.6. The
drawing showing the bonding is given in the Distribution Construction Standards
Handbook (DCSH) in R2/1.

Photo 1.4 CE7553

Photos 1.5

Photos 1.6

Initially we will continue to use the existing dispersion plates as shown in Photo
1.7, as we have a large number already in stock. When the existing dispersion
plates have been consumed they will be replaced with dispersion plates that have a
central circular hole, as shown on Photo 1.8.

Photo 1.7 CE7541 (Old style)

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Photo 1.8 CE7541 (New style)

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Issue 9 30 Jun 2009

Existing Running disk angle bonding for new construction

New Running disk angle bonding for new and existing construction

The bonding kit as shown in photo 1.10a (CE7551) and Photo 1.10b was used for
application at a running disc angle structure.

The existing bonding kit has been replaced with the bonding kit shown in Photo
1.11 (CE7542). The bonding kit assembled as shown in Photo 1.12 and
Distribution Construction Standards Handbook drawing (DCSH) R2/3.

Steel wire
Dispersion plate
Bonding clip

Photo 1.10a

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CE7551

Photo 1.10b

Photo 1.11 CE7542

Photo 1.12

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Issue 9 30 Jun 2009

Continued - New Running disk angle bonding for new and existing
construction

Left blank intentionally.

Photo 1.13

Photo 1.14

Photos 1.13 and 1.14 show the arrangement of the galvanised wire U bonding
clip to the phase insulator eye bolts. The 7/1.6 galvanised wire is passed through
the U end of the bonding clip with its 17mm diam hole. On the bonding clip of
the top and bottom phases a short section of wire must protrude at one end of
each clip. This assembly is then placed directly onto the protruding thread of each
eye bolt onto the existing nut and secured in a vertical position with the 16mm
lock nut provided.
During the securing process the lower nut of the eye bolt must be held while
tightening the outer lock nut. This is an essential action for ensuring the contact
is well established. Electrically this does not have to attain a given ohm value.
The stay wire eye bolt is not attached by bonding apparatus. The bonding wire
must be kept 100mm away from the stay wire eye bolt.

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Issue 9 30 Jun 2009

Existing Retrofit bonding for existing Intermediate wood cross-arm New Retrofit bonding for existing wood cross-arm Intermediate
structures
structures
Photo 1.15 shows the bonding kit (CE7550) that was used for application on
existing HV intermediate wood cross arm structures. Photo 1.3 shows an existing
intermediate wood cross arm structure with bonding kit CE7550 applied.

Photo 1.16 shows the bonding kit that is applied to the metal hardware on
existing intermediate wood cross arm structures in the fashion seen in Photo1.17
and the Distribution Construction Standards Handbook drawing R2/5.

Photo 1.16 CE7543.

Photo 1.17

The insulator studs of the two outer phases are bonded to the king bolts by
means of a 7/1.6 steel wire and bonding clips.
Photo 1.15 CE7550

Onto the existing nut of the protruding thread of the upper 16mm king bolt of the
cross-arm place two bonding clips with the 17mm diam. holes. Into the U end
of each of the bonding clip the 7/1.6mm galv. wire is placed and secured with one
of the M16 nuts provided. Install the other 17mm diam. hole bonding clip onto
the lower king bolt after the galv. steel wire has been assembled as in Photo 1.18
and secure it with the M16 galv. nut.
Assemble the 7/1.6 galv. wire into the two 25mm diam. hole bonding clips for the
outer phases so that the wire is passed through the U end of each bonding clip.
Ensure that there is protrusion of the galv. wire at each end on the outer clips
while at the centre clip the wire passes through. The length of the assembled
wire and clips is the distance of the cross-arm from outer phase to outer phase
plus 10mm protrusion. The outer phase clips with the galv. wire inserted is then
locked onto the existing studs protruding thread with the M24 nuts provided.

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Issue 9 30 Jun 2009

Photo 1.18 CE7539

Photo 1.18 shows the final connection mode to ensure that a thorough electrical
contact is established between the outer phases and the king bolts.

Left blank intentionally.

Note that on the existing network there are insulators studs with various diameters
and field staff must carry a range of nuts that will fit the old insulator studs.

Photo 1.19 CE7539

Photo 1.20 CE7540

Photo 1.9 and 1.20 show the 17mm and 25mm diameter bonding clips with their
stock codes.

New Retrofit bonding for existing Wood Strain structures

For retro fit bonding of the hardware on existing wood strain structures the stock
code CE7542 (see photo 1.11) is applied.
The application assembly is in
principle the same as for the running disc angle with the exception that it is
applied onto the cross-arm eye bolts and not the pole.

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Issue 9 30 Jun 2009

2. Eye Bolt Galvanising

The current welded eye bolts used on strain structures, running disc angles and stays, as shown in Photo 2.1, are being replaced by a forged eye bolts as shown in
Photo 2.2. The current supplier is experiencing problems with the turn-around/ processing time taken by the only galvanising spinning plant. To get past these issues
the supplier is supplying an alternative designed eye bolt as shown in Photo 2.2. The new forged eyebolt has passed the loading tests and is suitable for strain and stay
applications.

Forged

Welded

Photo 2.1

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Photo 2.2

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Issue 9 30 Jun 2009

3. Spreader Rod and Clip

In an endeavour to prevent LV conductor clashing a PVC spreader rod, as shown
in Photo 3.1, was introduced many years ago.
This rod was attached to the
conductor by means of a galvanised stainless steel clip see Photo 3.2. and
assembled is as shown in Photo 3.3. Although the spreader has been highly
successful in eliminating LV conductor clashing it has unfortunately, in time, been
damaging the conductors as shown in Photo 3.4.

The contributing factors leading to damage/ failure of the conductors were found to
be the high leakage currents due to poor insulating properties of the PVC rod, a
corrosive chemical reaction between dissimilar materials (aluminium and stainless
steel) and the presence of saline moisture or industrial pollution.
There is an ongoing need to prevent LV conductor clashing, thus an alternative nor
reactive spreader has been developed.
The new spreader consists of a Ethylene Vinyl Acetate (EVA) rod and stainless
steel clip with plastic inserts. The new spreader is shown assembled in Photo 3.7
The EVA rod, shown in Photo 3.5, was tested in accelerated polluted conditions
and performed excellently.
The stainless steel clip (see photo 3.6) was also re-developed and a plastic insert
was added to provide a bigger contact area and insulation between the stainless
steel clip and the aluminium conductor. The plastic insert will help prevent galvanic
action.

Photo 3.1

Photo 3.2

The new spreader was also subjected to a five million cycle vibration test and no
mechanical wear was evident.

Photo 3.5
Photo 3.3

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Photo 3.6

Photo 3.7

Photo 3.4

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Issue 9 30 Jun 2009

4. Brass Clip
Stock code: CE0300
Photo 4.1 shows an earth rod for uni & mini pillar with both the 210 clamp and
brass clip installed.

Left blank intentionally.

Photo 4.1

Due to the large number of the brass clips being returned to store and not used, the
supplier has been requested to supply future earth rods with the 210 clamps only.
The brass clips will be discontinued.

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Issue 9 30 Jun 2009

5. Krone LV Fuses
Krone supply the existing LV 400A fuse box as a single 3 phase unit, as shown in
Photo 5.1 (GS0111). This unit is susceptible to contamination in heavily polluted
areas resulting in shorting out the phases. The unit has shorted out as the base is
common and tracks over.

The new unit will be rated for 400A, replaces both the existing 400A unit (GS0111)
and the 160A (GS0110). The 160A unit has been replaced as it is rarely used.
The new model fuse box is shown in Photo 5.3 & 5.4.

.
Photo 5.1 GS0111
To eliminate problem single three phase unit being compromised by pollution three
separate unit will be used. That is, one unit per phase ganged for simultaneous
operation.

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Photo 5.3

Photo 5.4

The new fuse box model GS0111 uses the following fuses:
GF2130 (100A)
GF1100 (160A).and
GF1101 (315A)

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Issue 9 30 Jun 2009

6. Surge Diverter in Nulec Control Box.

The Nu-lec reclosers and Load break switches are currently protected against
voltage surges and spikes by means of a 275V (Uc) 80kA (see Photo 6.1)
surge diverter installed in the control box.

Over the last few years Western Power experienced failures of these units and
subsequent damaged to the control boxes. Evidence showed that these
failures generally occurred in areas where the control box was supplied via
bare overhead LV conductors. In some cases dead birds were found on the
ground close to the installations which indicate some short circuit activity which
could have let to higher voltages across the surge diverter and subsequent
failure.

Photo 6.1

The surge diverter has been upgraded to a 460V (Uc) and 100kA energy level,
as shown in Photo 6.2. The frame size has remained the same and thus this
unit fits onto the existing mounting plate.

Network Performance has advised they will be developing a program to

replace the surge diverters in all Recloser and Load break switch control
boxes.

Photo 6.2

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