India Adopts Live-Line Practices

Jun 1, 2003 12:00 PM

By L. N. Agrawal, POWERGRID
India's transmission system has encountered several problems with respect to
nonavailability for live-line work as a result of the inadequate clearances in the geometry
of the tower-top configuration. The tower-top geometry was designed based on the
weight, volume and cost of towers and foundations, not on the clearances required to
facilitate live-line maintenance work. Therefore, the availability of an adequate approach
distance dictates the use of live-line techniques.
Utilities around the country erected various configurations of transmission line towers to
optimize the cost of transmission lines. Engineers have designed several single- and
double-circuit lines with V-string instead of I-string insulator configurations. The reduced
approach distances on single-circuit lines with horizontal conductors designed with Vsuspension insulators, and for I-suspension insulator strings on double-circuit lines,
required special consideration. For these conductor and insulator configurations, Power
Grid Corp. of India Ltd. (POWERGRID; New Delhi, India) developed live-line
techniques that could satisfy its maintenance needs. Linemen can use these techniques
with ease and safety in situations with reduced approach distances. These techniques
ensure that the availability of the transmission system is comparable with the world's top
transmission utilities.

India's Transmission System

POWERGRID operates and maintains more than 39,000 circuit km (24,250 miles) of
500-kV HVDC, 400-kV AC, 220-kV AC and 132-kV AC transmission lines, and 65
substations.
Its transmission system is divided into seven regions with a management structure
established to maximize operational efficiency. Each region has a set of hotline
maintenance equipment and a team of trained and skilled engineers and technicians to
execute the hotline maintenance work. Though they vary among the regions, the number
of workers on a team, which averages four to six members, includes one or two engineers
and a lineman.
Hotline maintenance activities are planned for six months each year, with work
suspended during foggy weather and the rainy season. The range of work includes
insulator replacement and hardware tightening/replacement near the tower position.
Techniques for mid-span work such as conductor repair are under development.

Planning Hotline Maintenance

The planning of hotline work is based on the following safety and system operational
procedures:

Favorable climatic condition for hotline operation is sunny weather. If the weather
forecasts rain or thunderstorms, work will not begin.
Before going to the work site, all equipment and tools will be inspected and
checked for correct operation.

All hotsticks and ladders will be cleaned and checked for integrity by the hotstick
tester.

All linemen in the hotline team will be equipped with personal protective
equipment during the work.

No live-line team members on the tower/conductor will wear any metallic chain,
wristwatch or rings to avoid any circulating current.

Auto recloser will be in OFF position for the line at both ends.

Work permit will be taken from the terminal substations at each end of the line.
POWERGRID's live-line works require crews to practice the following on-site
briefing and safety disciplines before starting work:

The work procedure is discussed with the team members at the tower location and
the responsibility of each member is properly defined.
The land in close vicinity to the tower is cleared to provide a site area for the
required tools.

All epoxy hotline sticks are cleaned with Methyl-Ethyl-Ketone or Acitone, the
metallic sections are cleaned with kerosene and the rotating parts are cleaned with
graphite powder before preparing assemblies for the live-line work

All cleaned hotsticks, strain carrier and other assemblies are kept on the hotline
tool rack to avoid ground contact.

The team linemen will wear conductive socks, boots, helmets and hand gloves.
The hot-end lineman will wear complete barehand suit.

V-String Insulator Replacement

For the circuits with V-string insulators, the procedure to replace insulators is similar to Istring replacement with one main exception. In V-string replacement, a V-cradle
subassembly is required for removing the V-string from the yoke plate, and the working

clearance is not sufficient for shifting the hot man to the conductor. Thus, a new
method was developed for shifting the hot man on the conductor.
In this method shown on page 48, the ladder is hung on the crossarm near the conductor
alignment and the hot-end lineman climbs on the ladder near the V-portion of the tower.
The ladder is then moved away from the tower and the hot-end lineman climbs on the
ladder to move onto the conductor. After climbing on the conductor, he can crawl toward
the working point.
The hot man cannot directly land at the position where the conductor is attached to the
insulator string because the reduced approach distance (3060 mm [10 ft]) is only
available with live metal parts. Therefore, no margin is available for inadvertent
movement of the hot man. Furthermore, while working, the hot man has to use a barrier
in the form of an insulated platform so that his legs are not suspended beyond corona
ring. With the precise positioning of the hanging ladder, landing of hot man at an
accessible place (away from conductor attachment point) and restricting the leg
movements of the hot man, V-string insulators can be replaced where the approach
distance is 3 to 3.5 m (9.8 to 11.5 ft). This is somewhat less than the normal approach
distance of 4 to 4.5 m (13.1 to 14.8 ft).

Replacement of Insulators
In the case of 400-kV transmission line towers, the electrical clearances of the jumpers
and insulator strings from the live metal tower body/crossarm are designed based on
power frequency and switching overvoltages. Where no additional clearances have been
provided at the design stage, it may be difficult to carry out hotline maintenance with the
required clearances and degree of safety. It is relatively easy to access the top phase on
the tower, because the problem of electrical clearances for the cold man who will be
sitting on the top crossarm of the conductor does not exist. However, a limitation of
electrical clearances when the cold man sits on the middle or bottom crossarm is only 3 to
3.5 m (9.8 to 11.5 ft). This restricts the use of hotline maintenance by conventional
methods, so a special method has been developed to overcome this problem prevalent on
existing transmission lines.
To make more room for the cold man sitting on the middle or bottom crossarm, the top
and middle phase conductors should be pushed off the tower. This operation is easier on
tension-type towers because only jumpers not under tension need to be pushed off.
However, because of their weight and tension, it is difficult to push the conductors off
suspension towers.
Pushing off the conductor/jumper is done with the help of hotsticks that have suitable end
connections and a chain pulley block. Where crossarms can take up the load of conductor,
the operation can be performed from nearby crossarm. If not, the operation has to be done
from the tower body, which involves the use of longer hotline sticks. Linemen must make
sure that no jerk load exists on the tower and that the load is equally distributed on all the
legs of tower.

Energized Puncture Detection

The presence of punctured insulators in a string cannot be ignored, particularly on
transmission lines that have been in service for a long time. As the electrical strength of
the insulator string depends on all insulators being healthy before starting hotline
maintenance, it is essential that the integrity of the insulator string is healthy and has
adequate electrical strength. It is also important to short out the last two insulators to
equalize the potential for carrying out hotline maintenance using the bare hand technique.
Energized puncture detection of insulators, therefore, is a prerequisite for starting hotline
maintenance. To avoid permanent faults, the preventive-maintenance disciplines include
insulator scanning to identify punctured insulators.
One of the methods commonly used throughout the world is to measure the electrical
clearance across each insulator disc. This requires a scanner for detecting the electrical
clearance that should be easy to operate under live-circuit condition. POWERGRID uses
a lightweight IBM-compatible damaged-insulator scanner that is compatible with
standard hotstick mountings and has a memory capacity for recording tests on 200
strings.
The figure above shows the output of the electrical field across each insulator disc. If one
or more insulators are polluted or punctured, a sudden drop of voltage will be shown on
the graph. Defective insulators can be replaced under live conditions or during a circuit
shutdown, depending on the number of punctured insulators in a string.

Benefits of Live-Line Maintenance

The proper development of hotline maintenance techniques offer the following benefits:

Preventive maintenance of transmission lines can be done under live-condition;

shutdown is not required. This increases the availability of the line and decreases
the long-term maintenance cost.
Permanent fault outages and component failures can be reduced, thus reducing the
cost associated with major circuit outages. Probability of permanent circuit
interruptions is also decreased.

By scanning the insulators with the help of a damaged insulator scanner, the
required level of safety necessary when performing hotline maintenance work can
be achieved. It also identifies the punctured insulators, thus providing data for
planning preventive maintenance.

By developing the techniques to carry out hotline maintenance for those situations
where sufficient electrical clearances have not been provided in the design of the
transmission line, it is possible to take up preventive maintenance under live
conditions.

POWERGRID has adopted modern techniques for maintenance, including: hotline

maintenance, maintenance under induced voltage conditions on 400-kV double-circuit
lines using a special earthing system, emergency restoration system for transmission lines
and condition monitoring of EHV equipment for detecting the fault at its initial stage.
POWERGRID has maintained its line availability above 98% since its inception and is
ranked among the few top transmission utilities in the world.
Sh. L.N. Agrawal has spent 20 years in the planning, design, engineering,
quality/inspection, construction, and operation and maintenance of EHV transmission
lines up to 800 kV. Agrawal has presented technical papers at CIGR, ESMO, CEPSI and
PowerGen on the important aspects of transmission lines including emergency restoration
systems, hotline maintenance and 500-kV HVDC lines. Agrawal is a member of the
Expert Committee on Transmission Line Maintenance of the Central Board of Irrigation
and Power, India.

Hotline Washing / Maintenance:

The method and equipment used for Hotline Washing was developed by Yashmun, and has been
in use internationally for the last two and a half decades.
This process entails cleaning of Insulators and Switchyards under live line conditions

HOTLINE WASHING:
Background:
The enormous growth of industries has caused a considerable growth in atmospheric pollution in
the form of dust, coal dust, ash and chemicals in industrial areas. Along with contributing
geographical factors such as proximity of coastal areas, salt deposits, smog, rain etc. serious
damage and maintenance problems are caused for power generating units.
Despite the different anti pollution measures and devices the Government requires industries to
install,contamination is an ever increasing problem in the power industry. The pollution in form of
conducting materials affects the Insulators and hardware in switchyards, as well as on overhead
Transmission lines.

The pollution build up on these transmission lines provide a conducting path, resulting in
flashover, that in turn cause power disruptions to industries affecting production.
To arrest such contamination of Insulators, it is necessary to have a regular program of cleaning
at regular intervals. The earlier solution to the problem was to de-energize the line or Sub-station
and have workmen climb up and clean the Insulators in a tried and proven method of hand rub,
which entails physical manual cleaning. In todays ever increasing demand for electrical energy
this process proves to be un-economical as the power industry does not make money unless
electricity is flowing.
This is where the process of Hotline Washing proves invaluable, as there is no need for power
shut downs and has proved to be a safer in a more economical way.
This method developed by us at Yashmun is now extensively being used for washing almost all
Electricity Boards and Electric Undertakings in India.

Operating Principles:

Whenever a jet of water is released in the air,

the water particles split due to resistance. At a sufficient distance the jet moves in the form of
small particles separated by air ,and the water path is not continuous. This forms a product
similar to an aerosol, which in turn guarantees a sufficient electrical resensitivity, hence there is
no leakage current . This is the principle behind the Yashmun method of Hotline Washing.
The high pressure jet is produced by means of a pump. Water with conductivity of 200 micromhos
or less per cc is used for washing purposes up to 220 KV. Hence normal lake or river water or
treated municipal water that has a conductivity of 90 to 120 micromhos can be used. In the case
of 400 KV washing only by D.M water is recommended.
The specilised nozzle used is held at a distance stipulated from the live point so that no leakage
current is encountered. For safety, leakage current in the water jet and nozzle is continuously
monitored by means of a special detector, designed and made by Yashmun.

Electrically Operated Equipment:

This is operated by a 415V, 3PH, motor. The unit consists of a motor driven high pressure pump
with a starter flexible hoses and HP nozzles. All this is mounted on a trolley. A 2000 ltr water tank
is placed on another trolley .The complete washing equipment is mobile and can be taken
anywhere in the Switch yard or Tower location.

Truck Engine Operated Equipment:

This equipment developed by Yashmun is used in instances where no power is available and is
fully mobile, especially through hilly /jungle areas where Transmission lines pass. This equipment
has been developed for the washing of Transmission line towers up to 400KV.In this equipment,
the high pressure pump is operated by means of Power-Take-Off shaft (PTO). The Truck is
provided with 5000 ltr of D.M or raw water.
As the equipment is operated by means of
the trucks engine there is no need for
electricity.

Advantages:

No shut down/outages required

Time and money saved as Power
generation and Transmission are not
disrupted while the job is done.
Improves the di-electric strength of
Insulators
Increases the life of Insulators
Reduces transmission loss
Helps Switchyard / Transmission
lines function smoothly

HOTLINE MAINTENANCE:
We, at Yashmun, undertake Hot/Live line maintenance jobs upto 220 KV. We have all the
required tools and instruments imported from RITZ Brazil and A.B.Chance USA. Our certified
engineers and technicians have undergone training at the National Power Training Institute in
Bangalore.

Background:
Due to the increasing complexity of transmission networks, coupled with inter regional /inter State
ties, transporting of large quantums of power has rendered shut-downs on Transmission
lines/stations almost impossible, thus rendering a need for live wire maintenance technicians. A
network of 220 KV and 400KV Transmission lines form the backbone of the Transmission
network. Power flow from these networks are monitored and regulated by National / Regional /
State load dispatch centers. It is obvious that a constant supply of electricity is required by
consumers and for this an almost un- interrupted stable availability of Transmission lines is
required. Providing redundancy in transmission lines could be a solution, which, however is a
costly option. Therefore preventive maintenance, deploying live line maintenance techniques,
proves the best solution.

TESTING OF LIVE INSULATORS:

When testing a string of Insulators, each Insulator is consecutively brought in shunt contact with
the testing instrument prong and the meter deflection is observed. Any sudden dip in the meter
deflection across an Insulator determines the Insulator is faulty and signifies replacement.

To carry out this test we use an indicating instrument with 2 prongs in association with a hot stick .
Current passing through an Insulator is proportional to the voltage absorbed by that Insulator.