IN THIS ISSUE - Hubbell Power Systems

hubbellpowersystems .com
Vol. 18 No. 2 | november 2014
In this issue
SCE Moves Toward Bare-Hand, Live Line Work | Minimizing Outages | Fiber Storage | HPS Communications Expert
What’s New
wat c h t h e t r a i l e r at v i d e o s . h u b b e l l p ow e r s ys t e m s .c o m
Hubbell Power Systems, Inc. (HPS) announced its plan to co-produce a second film in the Storm Soldiers franchise with Tytan Creates.
Storm Soldiers II: Weather Warriors will document the story of one lineman and his two families, the one at home and the one on the line.
It is an intimate portrayal of the rigors of the job, the love, and the sacrifices made in the field and on the home front. Open casting calls
begin at the International Lineman’s Rodeo October 16. Tytan Creates will be on site to film linemen who want to star as the Storm Soldier.
Following the rodeo, the call for talent will be conducted through social media channels such as Facebook and Instagram through the end
of October. Once the Storm Soldier is selected, the movie promotion will ramp up and will include interviews and outtakes shared to social
HPS and Tytan Creates produced the original Storm Soldiers movie and since its release in 2013 have developed a strong following amongst
the linemen community. This time around the collaboration includes sponsors, Altec,® Inc. and Burndy,® LLC, to tell a deeper, more personal
story. Altec is a leading provider of heavy equipment products and services to the electric utility, telecommunications, tree care, lights and
signs, and contractor markets. Burndy, a subsidiary of Hubbell Incorporated and sister brand of Hubbell Power Systems, provides reliable
tooling, connection systems and solutions to the utility, telecommunications, data, industrial and instrumentation, and energy industries.
Ken Carlson, HPS VP of Global Sales and Marketing Services explained, “Having sponsors like Altec and Burndy that are iconic in our
industry is a testament to the spirit of the linemen community. We are working together to raise awareness about what linemen do and
sometimes sacrifice to bring power to our daily lives.” Filming of Storm Soldiers II: Weather Warriors will follow the selected Storm Solider
and weather related outages across North America. As with the first film, HPS and Tytan will seek consultation from Hall of Fame Lineman,
Mike Glueckert of NorthWestern Energy to ensure technical accuracy.
We are working together to raise awareness about what lineman
do and sometimes sacrifice to bring power to our daily lives.
- ken carlson,
VP Global sales and marketing services
hubbell power systems, inc.
Hubbell Power Systems is proud to announce our new online video channel,
HubbellTV. With a growing collection of over a 150 videos, HTV will be
your home for our videos featuring products, demonstrations, customer
testimonials and much more.
Responsively Designed
The site conforms to the screen size of your device, which
includes desktops/laptops, tablets and phones.
A legacy continues
Easy Sharing
Sharing features are built into the site so you can share videos
with colleagues through email, social sites and embed codes.
Simple Navigation
The main navigation is built for direct access to content areas
based on our product categories.
Video Optimization
Videos will be optimized for the type of device you are viewing
from for quicker and more stable downloads.
The site features search functionality to deliver specific videos
based on your keyword criteria.
life on the line
The linemen community will be in the national spotlight with the upcoming release of Life
on the Line, starring lead characters, John Travolta and Kate Bosworth. Inspired by Storm
Soldiers, Life on the Line is a Hollywood produced film about a crew of eccentric linemen who
do the dangerous high-wire work of fixing the electrical grid as they struggle to hold on to the
women they love until a massive storm threatens to rip their lives apart. The film is being
produced by Marro Films and Elite Film Productions and is directed by David Hackl. Filming
begins in Vancouver in October and is planned to release in theaters nationwide April 2015.
Representatives of Marro Films and Elite Film Productions will be present at the International
Lineman’s Rodeo to promote the film.
Hubbell Power systems, Inc. Acquires Reuel, inc.
Hubbell Power Systems, Inc. acquired Reuel, Inc. of Goldsboro, North Carolina on
April 8, 2014. Founded in 1987, Reuel is a leading supplier of custom molded electrical
products such as apparatus bushings, bus insulators, switch insulators and other
engineered components to Original Equipment Manufacturers (OEM’s) in the electrical
equipment industry.
This acquisition is part of Hubbell Power Systems’ growth strategy in engineered
components supporting the substation and generation segment. For more information
Located in St-Jerome, Quebec, our Electro
Composites™ line of bushings specializes in epoxy
molded products for the electric utility industry
and its equipment suppliers. Electro Composites
is an industry leader in high voltage solid
dielectric epoxy capacitance graded bushings,
offering solutions for applications up to 170kV, as
well as a variety of insulators and custom molded
parts. Combined with our PCORE® brand, they
offer over 5500 bushing options.
Over the summer, Electro Composites
expanded its production capacity with the
addition of its largest molding press to date.
The new press will nearly double our production
capacity for bushings rated 69kV to 138kV.
This impressive addition deserved a name of
equal magnitude. The new press will be called
the Legrand press after Electro Composites’
engineering manager and previous business
owner, Bertrand Legrand, who passed away
recently. During his eighteen years with
the company, he was involved with all key
engineering aspects of the business and was
a trusted source of knowledge for all those
who had the opportunity to work with him.
Legrand’s legacy lives on through this addition
that will support our commitment to quality and
excellence the same way he did.
For more information on Electro Composites
products, visit:
by patricia irwin, PE
all on the
Southern California Edison Moves Toward Bare-Hand, Live-Line Work
We want to be sure that we have the right
products and the right training before we begin
this work. Our employee’s safety is paramount.
- Daniel Carbajal
Transmission Construction Methods Manager, SCE
Southern California Edison provides power to 14 million
people in its 50,000 square mile territory. The utility has
12,782 miles of transmission line that has to be maintained.
Historically, maintenance work was done while the lines were
de-energized, but due to line loading constraints, it is getting
harder and harder to take transmission lines out of service.
One way to address this problem is to perform the work
while the lines are still energized, but live-line work is limited
to what an employee can do with a hot stick. Daniel Carbajal,
Transmission Construction Methods Manager at SCE explains,
“We do live-line work and we do hot stick work, but that is
not the same as bare-hand, live-line work, which is what SCE
plans to do in the future.”
Currently, SCE employees work on energized lines with
specialized tools, like hot sticks, which keep them at a safe
physical distance from the line and electrically isolated from
the line voltage. To illustrate, consider how a worker changes
out a cross arm. He uses a hot stick or rubber gloves to
lift the line off the cross arm. The line is energized and at
a certain voltage (12-kV, for example), but the worker never
experiences the line voltage. He is at zero volts, thanks to the
insulating properties of the hot stick or rubber gloves.
Bare-hand, live-line work is significantly different.
Carbajal continues, “With EHV bare-hand work, the employee
‘bonds’ to the energized line (in this case as high as 500-kV).
This matches the worker’s voltage and the line voltage.
During bare-hand work, workers wear a Faraday suit bonded
properly to the conductor and become one with the electric
field at the line voltage.”
Build a Variance
California law specifically bans bare-hand work. In order to do it,
a utility has to get permission from the California Occupational
Safety and Health Administration Cal-OSHA and meet state and
federal requirements.
“We had to demonstrate to Cal-OSHA (while meeting Federal
OSHA guidelines) that this can be done safely. We had to show
them the training that we are going to do and what tools we are
going to use. We had to explain exactly what type of work we
will be performing and at what voltages,” explains Carbajal.
The process is called ‘building a variance.’ According to Carbajal,
it is like preparing a business case, but it is not easy.
To begin, SCE benchmarked the bare-handing programs of
other utilities, including Pacific Gas & Electric, San Diego Gas
& Electric, and NV Energy. Then, the utility began evaluating
what kinds of tools and training it would need.
SCE called Hubbell Power Systems (HPS) for its expert advice.
“We’ve been working with HPS and their line of Chance® tools
for years and knew they had what we needed – particularly in the
extra high voltage (EHV) arena where strength is a critical issue.
If we need to change out a string of insulators on a high-voltage
line, a worker has to support the weight of the conductor during
the change out. Chance tools can support that kind of weight.”
Historically, maintenance work was done
while the lines were de-energized, but
due to line laoding constraints, it is getting
harder and harder to take transmission
lines out of service.
To help with the variance, HPS Territory Manager, Bryan
Jones, recommended that SCE bring in Jim McDonald,
a former HPS employee, to help with procedure writing,
training, and tool review. McDonald has years of experience
in bare-hand, live-line work.
McDonald and Jones went through all of SCE’s tool trailers to
make sure the utility had the right tools. This meant evaluating
tools that were, in some cases, 30 years old. There were even
some specialty tools from the 70’s and 80’s. Jones explains,
“We inventoried all of their trailers and materials and then
provided SCE with a list of items they needed, including
some specialty yokes that are not standard catalog items.
We also identified a large number of items that needed to be
reworked and retested.”
Unfortunately, no local companies could do the refurbishing
work. So HPS worked with SCE to identify local companies
that could be trained to do the work and arranged for those
vendors to get training at an HPS facility.
SCE purchased training materials and manuals from
McDonald to augment the materials they were preparing for
the variance. McDonald also helped SCE document all the
safety and work procedures it will use, including:
• What voltages the variance applies to
• How workers will be trained
• Safety procedures
• How worker safety will be monitored
• What tools will be used
• How tools will be used
• How the tools will be maintained
• How the tools will be tested
With the variance mostly complete and under review by
Cal OSHA, SCE turned its attention to training. Fortunately,
while working on the variance, the utility was in the process
of building a 500-kV training facility near an old power plant
near Daggett, CA.
Carbajal points out, “The facility is in the desert because
the transmission world is bigger, taller, heavier… the toys
are bigger. So, we needed space. We worked with our
transmission training organization to put up four, 500-kV
towers on a de-energized line section. Our plan is to use it
for as much training as possible – helicopter, bare-hand, and
hot sticking.”
By January 2015, SCE workers should
be ready to perform EHV bare-hand,
live-line work in the field. It took
three years of effort - working with
employees, vendors, and CAL OSHA
to get permission to do it.
Bare-handed, live-line training class at SCE’s Daggett training facility.
The 'train the trainers’ class lasted three weeks. Almost all of it was hands-on.
(NOTE: The line is de-energized.)
Working in conjunction with SCE’s Transmission Training
Organization and the Transmission Construction Methods
Group, McDonald conducted a three week training class for
SCE trainers, who will teach the lineman how to do barehand, live-line work. McDonald has conducted similar classes
for the Salt River Project, San Diego Gas & Electric, Bonneville
Power and the Western Area Power Administration.
Age is just a
“The first few days were all classroom training. We went
through all of the theory behind bare-hand work, the
equipment and all the tools. We laid out the tools and
hardware to see what SCE had and made sure it would work
for what we were going to be doing there. The rest of it was
hands on training,” explains McDonald.
“We worked on ‘V’ string configurations on the 500-kV
line. We practiced using three different methods to access
the work area. First, we worked off of a ladder to reach the
conductor. Second, we used an insulated aerial device--the
bare-hand bucket--to access the wire. And, we practiced
using ropes,” continues McDonald.
Members of SCE’s corporate safety team came out for a
day to fine tune the program, and representatives from Cal
OSHA spent a day at Daggett during the last week. They
observed the training, including the tailboard (pre-work
safety) briefing, step by step work procedures, use of the
aerial device, the inspection of tools and the use of personal
protective equipment.
McDonald continues, “After the Cal OSHA people went back
to Sacramento, they had a few follow-up questions about the
ropes and about how to test the aerial device. We addressed
their concerns and included the information in the variance,”
says McDonald.
Where it Stands Now
With the initial review of the variance complete, SCE is ready
to begin training its line workers, as soon as work schedule
allows – probably in October or November of this year.
By the end of the year, SCE will also develop a prioritized
work schedule. The utility plans to begin bare-hand, live-line
work in January or February of 2015.
Carbajal stresses, “In this case, time is not an issue: safety is
our first priority. We are trying to cross every ‘t’ and dot every
‘i.’ We want to be sure that we have the right products and
the right training before we begin this work. Our employee’s
safety is paramount.”
In rebuilding a 14kV substation in El Paso, Texas
in late fall 2013, El Paso Electric found something
quite extraordinary: a 71 year old Fargo® parallel
groove clamp. “I collect antique electrical parts,”
said Salvador Gonzalez, the lineman that found the
connector, “so I knew it was old.” Gonzalez sent the
clamp back to Hubbell Power Systems in Leeds,
Alabama where the age was verified. Not only was
this elder clamp still in service, but it would have
remained in service had the substation not been
rebuilt. “I attest the clamp’s duration to the quality of
how products used to be made. The clamp was made
out of copper, which is less prone to expand and
contract with temperature,” remarked Gonzalez.
“although we’ve simplified some parts in
our clamps, they are virtually made the
same way today as they were when this
clamp was manufactured.”
-arnie cobb, product manager,
distribution connectors
Hubbell Power Systems’ commitment to quality
begins with our people and expands to all
products we manufacture. To learn more about
the Hubbell difference, check out our policy at
Hubbell Power Systems Introduces the
USCO Motor
Did you know that surge arresters are designed
to withstand many lighting
surges and survive?
For Group Operated Switches
We do.
A common industry misperception is that an arrester fails and
needs to be replaced after diverting a lightning surge.
Our Metal Oxide Varistors (MOV) are part of our core technology
at Hubbell Power Systems - unlike many other manufacturers
has over 30 Million
distribution arresters in
who do not produce their own MOV blocks. We continue
service with less than an
to drive this technology forward with strict control of MOV
0.02% failure rate, providing
quality and performance.
Hubbell Power Systems, Inc.
critical protection, longer.
Customizable to fit customer specifications | High torque output for easy operation of large switches
Suitable for ambient temperatures as low as -50C | Easy access to internal components for installation and adjustment
Weatherproof enclosure | Internal heater controls condensation
Features and Benefits of PDV-100 optima Arresters
IEEE heavy-duty, normal & riser pole rated | Universal wildlife protective cap
Excellent performance history | Improved isolator reliability
To watch a comparative video on our surge arresters, visit the arresters tab at
by patricia irwin, PE
Designed to keep
linemen on the line
In an industry driven by performance
indices, minimizing the size of an outage
is vital. Alabama Power does this by adding
interrupting devices to the lines.
insulator enhanced crating system
1 Low Profile
Compact storage | Lower transportation cost per unit
Stackable – 3 high in 90" | 4 way access
5 Slide in separators
Removable without tools | Ergonomically friendly
Re-sealable package
2 Fully Framed Lids
Increased rodent resistance | Easy removal | Re-sealable
6 Notched Rails
Separates and protects insulator | Guarantees proper count
3 Uniform Dense Pack
Up to 60 insulators per crate | Efficient transportation
Efficient use of storage space
7 Space for Accessories
Secure enclosed space for corona rings
4 2x4 Construction
Fully framed perimeter | Increased strength durability
Increased rodent resistance
Alabama power,
see previous page
Alternating Sectionalizers & Reclosers
“Just like everyone else, we’re driven by SAIDI, SAIFI, MAIDI, and
MAIFI. So, we’re taking a hard look at our system and figuring out
what we can do to improve those numbers,” points out Robert
Cheney, Team Leader of Test Lab, Alabama Power.
At Alabama Power, line devices and protection schemes can
usually handle three or four, time-coordinated devices on a
feeder, while still maintaining proper separation between the
tripping curves. However, if you use a combination of both
sectionalizers and reclosers you can add more devices to the line.
The most obvious approach is to add fuses, reclosers and
switches to the line, but there are limits to the number and types
of devices that can be added. Sectionalizers are another option
and they can provide a number of benefits to a utility.
Fuses: Consider the simplest of line interrupting devices: The
fuse. They are inexpensive and do not require any special training
to replace, but have limitations when used as a sectionalizing
If a line has a 40-amp fuse, downstream from a 70-amp fuse,
downstream from a 100-amp fuse, the appropriate fuse(s) should
blow in response to a fault current. But if the short circuit is too
high, they are all going to blow, cutting power to many meters.
Reclosers: For time coordinated devices, like reclosers, there are
are a number of timing issues to consider. First, there is a little bit
of error in the timing of any device. Second, there is mechanical
operating time (the interval between tripping-initiation and fault
clearance) to consider, as well.
John Thorne, Senior Engineer, Alabama Power explains, “Let’s
say you allow 160 milliseconds for operating time of a single
recloser. If I have three reclosers strung out along a line, those
times add up. The first only needs 160 ms to operate. The second
needs 320 ms and the third needs 480 ms to operate. That’s
half of a second. Back at the substation, you have to decide how
long a transformer can safely experience a fault current before
the breaker should trip. If I set the breaker to operate after one
second and each device takes 0.16 seconds, there are only so
many devices that I can fit under that one second time limit.”
Sectionalizers: Thorne continues, “A lot of times we would
prefer to install a time-coordinated interrupting device, but we
can’t because we need to maintain an acceptable separation
between the operating curves. A sectionalizer allows us to add
more devices.”
The Alternating Approach
A sectionalizer has to open while the line (or line section) is deenergized. If you have a recloser just outside a substation and
three sectionalizers downstream, you have to coordinate the
four devices so the furthest sectionalizer opens during the first
recloser operation. The second sectionalizer opens during the
second recloser operation and the closest sectionalizer opens
during the third recloser operation.
In this arrangement, there is no opportunity to automatically
clear a temporary fault. So, it is not a great plan, either.
Cheney has a better idea. “Outside of the substation, we put
in a recloser and a sectionalizer that is programmed to open
during the third open interval. This provides two opportunities
for the line to clear temporary faults, before the sectionalizer
“Further out we install another recloser, and then another
sectionalizer. Those two sectionalizers are not directly underneath
each other, so we can maintain that third-open interval operating
characteristic. By alternating sectionalizers and reclosers, we can
double the number of devices on the line,” continues Cheney.
figure 1 - Hubbell’s three-phase sectionalizer is relatively inexpensive. And, it is a good way
to prevent ferro-resonance problems for industrial customers with three-phase service.
figure 2 - PRS Sectionalizer with Polymer Cutout
The Advantage
“We have a lot of reclosers, fuses, and sectionalizing devices to
help keep our line segments small. At the end of the day, we do
it to reduce the number of customers that are affected by any
one outage,” says Thorne.
Where does this arrangement work well? Just about everywhere.
Thorne explains, “it’s not necessarily a long or short feeder
solution. We use this configuration on feeders that branch
frequently. Our distribution system looks like a spider web. At
every single intersection there is a split or fork and the line goes
here and there. Those are the feeders that are candidates to
have a lot of devices on them.”
Alabama Power tries to limit the number of customers on each
device to about 500, where it can. This is no small task, since
the utility (headquartered in Birmingham, Alabama) provides
electricity to 1.4 million customers.
Decide Where
Finding a good place to add a sectionalizer is often easy.
Cheney explains how to do it: “If you look at the feeder map, you
can see places that look like a good spot to stick a sectionalizer.
Branching feeders make good locations but geography is also
important. If there’s a river or impediments that a repairman
would have to drive a long way to get around...that is also a
good spot.”
Like other utilities, Alabama Power also looks at the indices for
its feeders. Every feeder is ranked, based on performance, and
money is appropriately allocated.
Alabama Power experiences its share of outages. Many are
caused by lightning, but the primary cause is animal outages.
“Down here in the south, we have these things with four little
legs and a bushy tail. It is amazing what a squirrel can tear up.
And, we have enough animal related problems that ‘Possum’
is a valid code in our outage management system,” expounds
Single and Three-Phase Sectionalizers
The utility has been using Hubbell Power Systems’ single-phase
sectionalizers for the past 15 years. And it has just started
installing Hubbell’s three-phase units as well.
figure 3
The utility has over 500 single-phase sectionalizers on its system.
It only recently started installing Hubbell’s three-phase units but
plans to add more.
Cheney points out, “In the past, we used another vendor’s threephase sectionalizers, but they quit making the 200 amp model.
The only alternative they offer is a 400 amp sectionalizer. So,
we went with Hubbell because the device does what we need
it to do and we’ve had a good history with Hubbell. They are
especially good when it comes to technical support.”
We have a lot of reclosers, fuses, and
sectionalizing devices to help keep our line
segments small. At the end of the day, we
do it to reduce the number of customers
that are affected by any one outage.
(Alabama Power has relatively high, short-circuit currents on its
system. It is a densely populated area and the substations are
closer together. The utility’s short-circuits currents are typically
in the 2,000 to 3000 amp range.)
Alabama Power typically uses three, single-phase sectionalizers
on a three-phase circuit, but it depends on the situation.
“Sometimes we need a three-phase device to avoid single
phasing a customer. In that case, we use the Hubbell’s threephase sectionalizer,” says Cheney.
Most of Alabama Power’s large, commercial customers are
served by a 2,000 to 2,500 amp padmount transformer. The
bayonet fuses in those transformers will not coordinate with
upstream line devices. So, the utility often uses a sectionalizer to
help with coordination.
Cheney adds, “we can put a fuse on the risers because it would
have to be smaller than the bayonet fuses. We like to have our
underground system protected or at least be able to disconnect
it if there is a fault. Reclosers are expensive. And we can’t use
fuses because of the size. So the only thing that’s left really is a
According to Thorne, “the three-phase device is desirable from
a price standpoint and it is an appealing addition for mediumsized pad mounted transformers for our industrial customers.
When our engineers want to provide the customer some type
of three-phase protection, Hubbell’s three-phase sectionalizer is
significantly cheaper than the other options.”
The utility also has problems with ferro-resonance, which can
occur when a three-phase load is served by a Y-Delta transformer.
If you lose one phase of the line, the neutral can shift on the Delta
side. “It doesn’t happen a lot, but when it does, we don’t want to
smoke our customer’s motors,” says Cheney.
Cheney continues, “The three-phase sectionalizer is another tool
we can use. It gives our engineers a little more flexibility.”
Fight The Pressure
Pole Bearing Plates help prevent sinking and uplift
caused by water pressure and wind
hot line tap clamp
for easier installation
A bill that is nearly 3/4"
longer than our standard BC20
The Anderson™ BC20LD has all the same great features of the BC20.
now with a longer bill to land onto the conductor or stirrup bail.
Installed in pairs using 7/8” bolts | One or two pairs of pole bearing plates can be used |
Kits available, include 7/8” bolts and lag screws
Body - BC-Bronze alloy BC-FTP-Bronze alloy - tin plated | Eyestem - Bronze alloy or Stainless steel
Keeper - Bronze alloy | Washer - Stainless steel
Note: For connector with sealant in main jaw and plastic bag, add suffix “XB” to catalog number.
Hubbell Power Systems built its reputation on quality, and has endured for more than a century.
Investing in our facilities is just part of the continuous improvement process in our pursuit of
excellence – in everything we do. As a manufacturer of mission critical infrastructure and
components that support the delivery of power, failure is not an option. This year, we have
made remarkable improvements to our Customer Service Center that houses the F. Gano
Chance Engineering Research Laboratory.
Centralia, MO Testing Capabilities
The historic building in Centralia, MO has undergone extensive renovations to accommodate present and future needs.
More than $7M was invested to refurbish the new customer service center and to upgrade the electrical and mechanical
testing laboratories known as the F. Gano Chance Engineering Research Center. The center was first constructed in the
mid 1960’s, and is one of very few labs that are owned and operated by a manufacturer. When complete, HPS will have
increased testing capabilities to include short circuit, high current and high voltage testing as well as high-speed video
broadcast capability. “When we finish, we will have a new control room with monitors for visual analytics, state-of-theart short circuit test capability, as well as increased high voltage and mechanical strength testing abilities. We’re taking
this lab and tapping out to its fullest potential,” said Jeff Kester, HPS Engineering and Technology Director. Investments
are expected to continue through 2016 with updates and renovations to the Ohio and Alabama based test facilities.
In support of our growth and our commitment to continuous improvement, we will make
significant investments in our other US-based lab facilities. As a market leader in the
power utility industry we take pride in providing the highest quality products and services.
Investments in people, facilities and testing capabilities speak to the value we place on quality.
- Gerben Bakker,
President of Hubbell Power Systems, inc.
Test Labs - $4.4M+
Part of insuring that our products meet our quality standards is regular testing. There are only around 40 short circuit test labs
in the world, and Hubbell Power Systems is one of very few manufacturers to own and operate one. Through our investments,
we now have 12,000 amperage heat-run capacity and have made the following additions to our control room:
Broadcasting Capability | Full Range Hertz Capability | High Speed Video | Improved Analytic Capability | Remote Tie-In
The use of our testing facilities is open to our customers, and we encourage you to visit and take a tour. To use the HPS testing
facilities, contact your territory manager to complete a test request form.
Customer Service & Engineering Departments - $2.7M
Upgrades to one of our Centralia, MO facilities included renovations of the following areas:
Customer Service | Engineering | Main Lobby | Interactive Training | Product Display Room
Beyond the aesthetic improvements, the upgrades to the customer service center allowed for continued growth – as we seek
to offer a robust department ready to serve the needs of our customers. The training and product display room – slated for
completion by end of 2014 – will be equipped to host product and market training as well as display a sample of HPS products.
Other HPS Investments in Quality
- Total Connector Investments: $1.3M
- Cut Yoke Plate Investment: $1.5M
- Investments in presses/molds: $12M
- Investments in automation since 2007: $10M+
hps testing
Short Circuit Testing Capabilities
• Interruption Tests
• Fault Making Tests
- Voltage frequency control with up to 0.3Hz variability
-Meets the operating frequency requirements of many
new industry standards and customer demands
• Peak, Momentary, and Short Time Current Withstand Tests
•Capacitor Switching, Load Switching and Cable and Line
Charging Tests
• Dual Source/Thermal Kill Arrester Performance Tests
• Insulator Power Arc
Test Lab Features:
Short Circuit Control Room
• Continuous observation during tests for visiting engineers and
• Remote oscilloscopes
• High speed photography – Uses a Vision Research M310 High
Speed Camera to record high power tests at megapixel
image quality with recording rates exceeding 16,000 frames
per second
• Generator Control HMI – Generator terminal voltage typically
reaches the desired test voltage within 5 seconds of the exciter
start command
Data acquisition
• Hioki 8741 Memory Recorder Records:
- Up to 20 MHz sample rate
- Voltage A-D conversion of 2,000 levels
- Voltage resolution from 0.05 mV to 200 mV per
sample level
• Digital waveform data is stored in .csv format readily
shareable with customers and engineers
Timing Control
Control of breakers, closing switches and other test timing
devices are integrated into a single PLC control system
high power test capabilities
high current grounding test capabilities
Test Voltage, kV
Max Symmetrical
Current kA
Max Asymmetrical
Current kA
Peak Current kA
Test Voltage, V
Current kA
180 Cycle
Current, kA
Power Lab Testing Capabilities
• Primarily for arrester tests
• Equipped with a high energy alternating current source
200 kV impulse generator supplies the energy for lighting impulse tests
• Capability of measuring power loss on varistors and arresters up to 115kV
High Voltage Testing Capabilities
• Primarily for insulator and arrester tests
• 60 Hz Withstand Dry and Wet
• 60 Hz Flashover Dry and Wet
• Lightning/Switching Impulse – Positive and Negative
• Front-of-wave Impulse Test
• Internal-ionization Voltage and RIV
• Contamination Test
• Seal Integrity Test
• Ferris Wheel Test
• Leakage Current Test
• Power-frequency Test
Polymer Lab Testing Capabilities
• Q-U-V accelerated weathering tester
• Corona cutting tester
• Salt fog chamber
• Housing tracking and erosion ferris wheel test
• Incline plane tracking tester
• 10 station accelerated aging tester for surge arresters
Mechanical Testing Capabilities
• 75,000 lb Horizontal Tensile Testing
• 75,000 lbs. Vertical Tensile-Suspension Testing
• Vibration Testing
• 200,000 lbs. Horizontal Tensile Testing
• Hydraulic Compression- #10 AWG to upwards of 3,000 kcmil conductor with 100 ton press
• 75,000 Horizontal Sustain Load Testing
Environmental/Temperature Testing Capabilities
• 5000 hour accelerated weather aging tests on polymer
insulators and arresters test applies UV, rain, salt fog, dry
and damp heat, and high humidity to the test samples in a
24 hour cycle
• Xenon Arc – UV source
• Heat: up to 50 °C,
• Humidification: up to 100%,
• Rain: 4 spray nozzles,
• Salt fog: four adjustable nozzles.
• Up to 6 test samples
• 5,000A Heat Cycle Testing
a r e yo u do i n g it wro n g?
In the early years of fiber optic cable storage,
linemen had no reasonable way to store cable other
than to simply coil it up on the line and create a
“rats nest”. This method leaves the cable vulnerable
to the elements and creates a tendency for the cable
to migrate. Contractors were constantly revisiting
these ineffective storage locations and wasting
valuable time and money trying to correct an issue
that could be solved with proper planning.
Utilities and communications construction companies often
make financial cutbacks on the front end of a project, only to
find out that conservatism causes higher costs on the back end.
After concluding projects, Project Managers realize that those
expensive corrections could have been avoided if the right
products and procedures had been used to facilitate a clean and
safe cable environment.
Now, storing, installing, and maintaining cable in a cost effective
way is easy. Instead of using financial shortcuts on the front end
of a project, engineers are now opting for a more economical
way to store fiber in a manner that keeps it protected, thus
saving money overall.
In Alaska, the 115-kV Quartz Creek transmission line connects
two hydroelectric dams on the Kenai Peninsula with the
‘rail-belt’—an area containing Alaska’s railroad, its most
populous cities and about three-fourths of the state’s
population. A fifteen mile section of that line was rebuilt last
November, in an area where snow storms regularly drop feet
of snow throughout the winter.
While not a technically challenging project, Hubbell Power
Systems TowerPak® solution was a great benefit. The
hardware arrived on time, properly kitted and… nothing
got lost. This is a big deal when you are working in a snowy
mountain pass in Alaska in the winter.
The Quartz Creek line is 90-miles long and is operated by the
state’s largest electric utility—Chugach Electric Association,
based in Anchorage, AK. Shawn Wendling, senior project
manager, explains the situation. “The line was originally built in
1962 to connect the Cooper Lake Dam to the rail-belt. In 1991,
the state brought online the substantially larger Bradley Lake
Hydro Project, which also uses the line. The Quartz Creek line
is critical because it is the only transmission line connecting
the two dams to the rail-belt and because that generation is
our cheapest source of power. It is also important because
we use our hydro resources to adjust for system variances,
so that gas consumption at our combustion turbines stay on
The line and its structures are now over 50 years old and
the cooperative keeps an eye on structure integrity. In 2007,
Chugach performed a detailed helicopter survey, which
revealed some deterioration of the wooden, H-frame towers.
The cooperative then verified the damage with a climbing
survey. “During the summer of 2008, we sent crews down the
right-of-way and tested the arms and poles. About 50% of
the poles surveyed showed signs of rot,” explains Wendling.
opti-loop ™ FOs features
multiple sizes
Sizes that will accommodate
all types of cable up to 1.50"
Some units can be stacked
for even more versatility
Offered in aluminum and plastic
made of polypropelene
containing UV inhibitor
Compact and lightweight to
minimize stress and ice loading
on the fiber cable
The benefits of fiber storage loops have made them a preferred
industry method for storing and protecting reserve lengths of
lashed fiber and ADSS fiber. Hubbell Power Systems’ OPTILOOP™ Fiber Optic Storage (FOS) solutions are the standard
for aerially storing and protecting fiber optic cable in the field.
OPTI-LOOP is neatly stored, and there are no coils, boxes,
“arm” assemblies or unsightly cables running down the pole.
They provide a convenient and safe splice closure mounting
point because splice closures are mounted directly to the
dead-end hardware, keeping it neatly secured with no load
on the fiber cable. OPTI-LOOP is approved for use in both
the communication and supply regions of the pole. There is
no limit on amount of cable that can be stored, and they can
be used on wood, steel or concrete poles.
In some regions, cable storage is attempted with a device
as shown in Figure 1.1. At first glance, this product seems
to justify itself by essentially providing a storage area, as
opposed to simply “looping” cable on a line. However, this
method leaves the cable exposed and potentially hazardous,
costing an exorbitant amount in repair and lost service time.
Installation of the OPTI-LOOP ™ system is
designed to be a one man, one tool, one truck,
30-45 minute operation. The stored length of
figure 1.2
This “garden hose” method of storing cable encourages
cable twisting, which results in attenuation and diminished
signal strength. The preferred method of storage needs to
address this concern and enable a safer method that will
prevent twists in the fiber sheath when the cable is retrieved
for later use.
Because of its construction, cable has a natural tendency
to take on the shape to which it’s molded. When cables are
stored in a tight coil, uncoiling affects the cable memory.
When contractors try to re-straighten that line, the tiny
optical fibers have a tendency to migrate. An alternative
method of storing cable would preserve cable memory by
allowing the cable to bend naturally according to the outside
When cable is stored in a method that does not support and
protect it, cable stress occurs resulting in broken fibers and
diminished or interrupted signal. It’s always best to store
cable inside a protective channel (Figure 1.2) so that you
create a smooth transition to the messenger. An outward
or inward facing channel also safely and securely protects
cable from direct contact with harsh weather elements.
Always be sure your method of storing cable is approved
for use by the manufacturer of that cable. Otherwise, when
damage occurs from using ineffective methods of storage,
the warranty will be void.
One-size-fits-all is never a good rule of thumb when storing
cable. Bend radius is a real, ever-present issue that must
be observed in order to protect the integrity of the cable.
By tightly coiling cable in a device that isn’t engineered to
protect specific sizes of cable, all of the previously mentioned
factors (twisting, memory, stress, etc.) can become a huge
problem on your line. Additionally, those tender fibers will
likely be broken.
Every fiber cable storage scenario must consider that one
day, that particular cable will need to be revisited for service
and/or splicing for new builds. When it’s time to add new
lines, splicing is one of the most expensive tasks. When
systems are installed in ways that don’t take future splicing
into consideration, new problems arise. By storing fiber
aerially on the line with reserve cable protected, splicing can
be simplified.
Large coils of fiber on a pole are an eye sore and get in the
way of a lineman working at that pole. Storing the cable
safely on a line creates a much more pleasant appeal.
By storing cable in a Figure “8” storage pattern, it prevents twists
in the fiber sheath when stored cable is retrieved for use. The
fiber resists attenuation and it will prevent outages resulting from
damaged cable. The plastic direct-attach models of OPTI-LOOP
units contain minimal conductive materials, and therefore may be
used above ground neutral. Standards engineers use OPTI-LOOP
to help eliminate fiber optic cable storage problems.
Notice the way that the cable
is installed on the device in
Figure 1.1. Tie wraps are directly
attached to this large bundle
of cable. When this method is
implemented, it pinches down
on the cable causing damage to
fragile fibers. Similar to twisting,
the result is attenuation and lost
figure 1.1
signal to the customer. Cable
needs to be stored in a way that
minimizes contact with tight tie-wraps so that no pinching
occurs. If cable is nestled into a channel (see Figure 1.2)
and the tie-wraps cover the surface of the storage device
as opposed to direct contact with the fiber, pinching is
completely avoided.
cable can be lowered and reinstalled in minutes
without disturbing the main run. The reduced
cost associated with hardware, labor and
equipment saves time and money.
PLASTIC Fiber Optic Storage System
Direct attach ADSS Fiber Optic Storage System
Opti-Loop Fiber Optic
Storage Systems
Plastic Fiber Optic Storage System
The plastic Opti-Loop™ FOS for strand and messenger mounted cable is available in a variety of sizes.
They provide a convenient, economically priced and industry approved method of storing extra length of fiber optic cable.
Design features and benefits
• Utilizes self-aligning tap brackets
• Requires only one tool for installation
• No "fishing" tie wraps through holes or slots
• Can be stacked if necessary
• Contains UV inhibitor
• Cut away channel creates a smoother transistion to messenger
• Minimal surface area minimizes stress and ice loading
Direct Attach ADSS Fiber Optic Storage System
Cutout covers
new flexible rubber selection
class 2 type II rubber cover
The Opti-Loop™ ADSS Direct Attach unit uses the patented bowtie double deadend process for storing ADSS fiber.
This system provides maximum protection for fiber cable, and contains no conductive properties.
Design features and benefits
• Utilizes self-aligning “Direct Attach” mounting brackets
• Requires only one tool for installation
• No “fishing” tie wraps through holes or slots
• Cut away channel creates a smoother transition to messenger
• Fabricated using a high-pressure injection molding process
• Contains UV inhibitor
features and applications
For use on Overhead Cutouts | Conforms to ASTM D1049 | Dimensions of 24” x 15” x 3.75”
do you see the telecom industry changing
Q How
in the next 2 years, and how does your
company plan to stay ahead of the curve?
an interview with an
HPS Communication leader
Our great ideas come from
listening to our customers
In addition to the incoming customer information, we spend a
significant amount of time reading industry trade publications,
industry standard committee notes and talking with parallel
industry suppliers about what’s next. My role at HPS is to evaluate the data and manage new product development projects
so that HPS will have products that are relevant keeping us
ahead of the technology curve. Our internal product development and acquisition related activities are focused at helping
HPS build our product portfolio so we can offer the market
relevant products that are needed for building next generation
solution you and your company developed to
solve a non-traditional problem.
Our great ideas come from listening and communicating with
customers. Our team is using an innovation strategy called
Need-Seeker, which focuses development efforts on anticipating future market needs through better understanding our
customers’ applications, and the challenges they routinely
A recent example is a customer who wanted a universal
antenna bracket for small cell applications. Once they
approached Hubbell with the need, we assembled a team, held
regular calls, and conducted on site meetings with them for
the purpose of mapping out which features were important
for small cell applications. I spent time with the radio frequency
engineers who really helped us better understand antenna
placement. Our team collaborated with several antenna
manufacturers and cable assembly suppliers, which led to
designs with modularity and cable routing features to help
the construction crews. All of the great ideas originated from
communication with our customer and parallel suppliers for
this small cell bracket project, which solved their problem and
answered market needs.
about small cells and your company’s
Q Talk
role in that area.
It means finding a better way. Being innovative is in our DNA
at Hubbell Power Systems. Our company founders were
inventors like Harvey Hubbell, who invented the
electrical plug and pull chain light socket and Albert
Bishop Chance, who invented the first practical earth
anchor that we still use today to secure poles. I am
fortunate to work with a team that continues building on the
legacy of developing innovative products to help our
customers solve problems and improve their network
installations. Our sales and engineering team listen to our
customers and spend time learning about our customers’
applications. We share our ideas on possible solutions
with our customers and make adjustments based on their
feedback. Innovative ideas come from being collaborative and
responsive to our customers and helping them find better
Where do the great ideas come from in your
Q organization?
Tell us about an innovative
- kevin matsui
Q What does it mean to be innovative?
The US added 12 million new wireless subscribers in 2013
with the majority being non phone devices. Mobile data
accounted for 4% of revenue for wireless carriers in 2004. In
Q4 2013, mobile data accounted for 50% for the first time.
Small cell growth is driven by consumers who are connecting
more devices to their carrier’s networks while demanding
faster data rates. HPS’ product focus for small cell is building
antenna brackets. We believe there is tremendous upside for
these product lines.
are the most important decisions you
Q What
make as a leader of your organization?
As new product development opportunities come up, our
sales team and I are listening our customers trying to determine the scope of the project and what resources will be
required for a successful outcome. It is easy to get caught up
in the excitement during customer conversations with new
opportunities so it is important for us to keep our emotions
in check and stay focused on getting the relevant data to
determine if the project is going to be viable. One given is
there will always be a some level of uncertainty and risk for
each project we take on. The key to making a good decision
is to trust your intuition. You have to trust your training and
past experiences to guide you and not allow fear of failure
to drive your decision making.
network evolution technologies
Q With
moving so quickly, how do you and your
company plan to stay relevant?
We are fortunate at HPS to have a skilled and experienced
field sales team who does an outstanding job at positioning themselves as the “go to guys” with our customers. The
HPS sales team has created a situation where our customers
are continually coming to us with new product develop opportunities. My challenge is to identify the best fit opportunities
that will bring the best results for our customers and help
grow HPS’ market share.
210 N. Allen Street
Centralia, MO 65240-1395 USA
Columbia, SC
Permit No. 1183
Hubbell TIPS & NEWS is published to inform
personnel of electric utilities and associated
companies of new ideas and techniques in
electric utility and communication practices.
The magazine, under different titles and
formats, has been published since 1932.
Your suggestions, editorial or photographic
contributions are invited and may be
submitted to [email protected]
©Copyright 2014 Hubbell Incorporated
NOTE: We have a policy of continuous product
improvement. Please visit
to confirm current design specifications.
210 N. Allen • Centralia, MO 65240 Phone: 1.573.682.5521 • Fax: 1.573.682.8714 E-mail: [email protected]
MEXICO S.A. DE C.V. • Av. Insurgentes Sur # 1228, Piso 8
Col. Tlacoquemecatl Del Valle • Mexico, D.F. 03200
Phone: 52-55-9151-9999 • Fax: 52-55-9151-9988
VOL. 18 No. 2 | november 2014
h u b b e l l p o w e r s y s t e m s . c o m
main red
PMS 1815C
C0 M0 Y0 K0
C100 M100 Y100 K100
on dark backgrounds
no gradients
no gradients
stacked logo (for sharing only)
stacked logo (for sharing only)
gradient bottom
PMS 1795C
C0 M96 Y90 K2
on light backgrounds
C13 M96 Y81 K54
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