Partial Tension – Northeast, USA

The Challenge:

DMC Power was approached by a major utility company in the Northeast USA facing critical challenges in their partial tension system. During a routine thermal inspection of their 115kV transmission lines, this longtime DMC Power client noticed an older loop splice utilizing a competitor's component was running hot and required replacing. The client sought a reliable solution to enhance grid stability, minimize downtime, and accommodate increased energy demands within the region.

A fast, reliable solution was needed for both product delivery and installation.

  1. Limited Access to Installation: The 115kV line runs parallel to the Right-of-Way of Commuter Railroad tracks and next to Interstate I-95. With tight restrictions on disrupting regular commuting services, installation was required to take place outside of the morning rush hour.
  2. High-Impact Timeframe: In the congested Northeast, disabling the railroad's main commuter line for maintenance longer than the allotted one-hour outage window was not an option.
  3. Zero Margin for Error: A splice failure would put tens of thousands in the New England region out of power.
  4. Integration Awareness: The operation of the main communication trunk line was integrated into the 115kV OPGW static line requiring the Utility & Railroad protocols to provide redundancy box grounding around the area where the work was being performed.

The Solution:

DMC Power devised a detailed plan to revamp the partial tension system, leveraging expertise in high-voltage connectors and custom electrical components.

  • Comprehensive Strategy: Three remedial options were discussed during conference call held between the Utility Engineering Department and DMC Power's team which included the Engineering Manager, Full Tension Product Manager, Area General Manager, and Territory Manager.
    1. Remove the existing jumper conductor and failed splice and replace with two DMC Power loop splices. This option proved concerning given the short length of tail conductor from the bolted shoe and the unknown “heat effected” zone of the conductor.
    2. Apply two new DMC Power Tee Taps on the main line and shunt the existing jumper with a new 1590 ACSR conductor as well as two new DMC Power terminals.
    3. Design a new reduced length Splice for the Partial Tension application.
  • Innovative Engineering: Understanding the intricate needs of the utility, DMC Power devised a comprehensive strategy to revamp the partial tension system. Leveraging our expertise in high-voltage connectors and custom electrical components, we meticulously designed and implemented an innovative solution. Our team engineered and installed state-of-the-art tension accessories, including compression fittings, for superior connectivity and durability in challenging environmental conditions.
  • Geographic Adaptability: To address the specific challenges of the Northeast climate, we introduced corrosion-resistant materials and enhanced insulation in our custom components. This ensured prolonged lifespan and resilience against harsh weather conditions, meeting the demands of the client's geographic area.

The Results:

The contracting company was very familiar with DMC Power products and recommended us for our fast turnaround on made-to-order fittings as well as the engineering & field support that would be provided throughout this time sensitive project.

  • Reduced Lead Times: DMC Power is an ISO certified company with strict protocols in place when creating an entirely new connector. From initial design to manufacturing, this entire project was compressed from 6-8 weeks into 3 days without compromising quality standards DMC Power has in place.
  • Streamlined Installation: After the failed splice was cut out during the outage, it was determined the dead-end tail conductor was long enough, and the existing jumper was replaced using (2) modified DMC Power loop splices. The loop splices were Swaged, redundant box grounding removed, the ground line was retracted, and the line was energized faster than the 1-hour maximum allotted time with no disruptions to train or Interstate traffic.
  • Quality On-Site Customer Support: Assisted by on-site training, an optimal installation processes minimized downtime during the upgrade.

The implementation of DMC Power's custom solutions resulted in a transformative impact on the Northeast USA grid system.

  • Reliability Enhancement: The upgraded partial tension system significantly reduced downtime and minimized disruptions, ensuring a more reliable power supply.
  • Efficiency Improvement: Enhanced connectivity and smart grid technology improved the overall efficiency of the power distribution network, optimizing energy transmission.
  • Adaptability to Growth: The newly integrated partial tension components accommodated increased energy demands, paving the way for future scalability.

All parties were extremely pleased with the efficiency, safety, and reliability of the DMC Power Swage System. The successful collaboration between DMC Power and the Northeast utility not only resolved the immediate challenges but also positioned the client for long-term success in navigating the evolving energy landscape.

"I want to thank you and your group for the continuous support.  Your involvement with this particular hotspot repair made it all possible.  Thank you and I look forward to working with your company on future transmission maintenance projects" -System Maintenance Lead Engineer

Have a challenge in need of custom solutions? Contact a DMC Power Territory Manager today!

(2) DC92-225-76 Split Run Tee
Cable to Pad
(2) DC94-225-76 -00Partial Tension Terminal
15° Each (30° Total)

 (2) DC91-225-76-S1

Partial Tension Splice
Reduced Length

(Click to enlarge gallery images)