Tips & News - Winter 2017

Tips & News - Winter 2017

T I P S A N D N E W S W I N T E R 2 0 1 7


IN THIS ISSUE: Storms Cause Chaos - Xcel Energy ROCK-IT™ Anchor for Extreme Conditions Welcome Meramec Instrument Transformer Company

Believe it or not, that’s not a pop-up camper but rather a trailer designed for storing hot line tools and cover-up equipment. For nearly 100 years, we’ve been devoted to linemen and the equipment that protects them. Have a vintage photo that you’d like to feature? Visit to submit a photo. THE YEAR WAS 1963

For more information on how to take care of your cover-up equipment, visit:



In The News


Thank you for visiting us at the Lineman’s Rodeo! This year we launched our first event Snapchat filter and introduced our 85th anniversary commemorative linemen poster. To order a FREE POSTER , go to, request literature and check the tools literature tab.

Check out the videos below and more at

2018 OHIO BRASS® PRODUCT TRAINING WEBINARS Evolution of Surge Arrester Technology 02/13 @ 10am EST 02/22 @ 2pm EST

Arrester Selection

03/13 @ 10am EST 03/22 @ 2pm EST

Distribution System Reliability Arrester 04/10 @ 10am EST 04/19 @ 2pm EST

Line Performance Improvement

05/08 @ 10am EST 05/17 @ 2pm EST

Substation Arrester Selection

06/12 @ 10am EST 06/21 @ 2pm EST

Email Vanessa Taylor at VTAYLOR@HUBBELL.COM the webinar you wish to attend.

Hubbell Power Systems - Communication Overview


DistribuTech (DTECH)

January 23-25

San Antonio, TX

BICSI Winter

February 5-7

Orlando, FL

Doble (Life of a Transformer)

February 19-23

National Harbor, MD

Tech Advantage

February 26-28

Nashville, TN


March 16-19

Denver, CO

Northwest Public Power Assn (NWPPA) April 10-12

Tacoma, WA

Chance® - Low Voltage Rubber Gloves



STORMS CAUSE CHAOS In July 2016, a storm with high winds hit the Twin Cities area, about 30 miles (48 km) northwest of Minneapolis, Minnesota, U.S. After the storm passed, repair crews found multiple distribution lines blown down. Out in the countryside, two 8.5-mile (13.7-km) parallel sections of 345-kV line — with 54 H-frame structures on each line —were on the ground in what was clearly a cascading failure. Fortunately, the dead-end structures contained the cascade. The transmission damage was quickly repaired, and — thanks to the hard work of Xcel Energy employees, crews and contractors — both transmission lines were rebuilt and back in service by the end of December 2016.

WOOD WORKS The two transmission line sections are 100 ft (30.5 m) apart and run between the Minneapolis suburbs of Maple Grove and Rogers. The terrain is primarily wetlands, ponds, marshes and agricultural land. The transmission lines carry power from substations near Xcel Energy’s Monticello and Sherco power plants. As soon as the storm passed, Xcel Energy and its regional transmission authority began deciding which transmission line needed to be rebuilt first. The construction department was involved to determine how fast rebuilding could start. Thanks to added redundancy on the grid — created by several large capital transmission projects built over the




last five years — power still could be transmitted around the damaged lines, so the rebuilds were considered important but not an emergency. However, there was an urgency to restore one of the two lines as quickly as possible to help with system reliability and redundancy. Therefore, wood construction was chosen to rebuild the Monticello line based on material availability and past experience with wood construction in these wet conditions. Because of the terrain and soil conditions, everyone knew the project was going to be difficult. The failed H-frame structures were installed in 1971 on wood pile foundations. Large wood poles were driven into the ground until they hit soil with

sufficient strength to support the H-frame structures. The piles were then banded together and the aboveground structures were built. Some of those piles were driven 50 ft (15.2 m) into the ground. The utility expected supporting the new H-frame structures in the deep, peaty soil was going to be a challenge. As there were enough wood poles on hand to rebuild the Monticello line, Xcel Energy decided to go forward with wood replacement. Because the Sherco line rebuild could wait, the engineering department had time to explore other options for its replacement.


that. Engineers could calculate the necessary installation resistance and installation crews would install the piers to specification. Second, the utility wanted to minimize the impact construction would have on the wetlands and agricultural land. Work took place during the growing season in the summer and fall of 2016, and the utility sought to reduce any damage to or interference in the fields. Helical piles could be screwed into the ground quickly, while wood piles would have to be pushed into the ground with a backhoe, sometimes by being vibrated into the groundwith a special attachment to the backhoe. Matting also was a significant issue. To prevent damage to the land and keep vehicles from getting stuck in the mud, matting was required any time a vehicle had to cross wet ground or farmland. Since most of the right-of-way is boggy, there are many drainage ditches and drain tiles under the ground. (Farmers use drain tiles to direct ground water from their fields.) Also muddying the waters was the fact that 2016 was an extremely wet season, which raised the water table to almost ground level. This resulted in contractors matting into most, if not all, of the structures. Putting mats down is expensive, but helical piles can be installed with much smaller equipment and that translates intosignificantly lessmatting. This lowerscostsandreduces field impact, which is especially important on agricultural land. As it was, crews used nearly 7800 polymer mats to ensure safe access to the structure sites. Thehelical pileswereaquicker, better andmoreeconomical solution for the Sherco line. Additionally, HPS helped to locate local contractors with experience installing the piles.

Matting was necessary to get vehicles and workers to almost all tower foundation sites.

STEEL AND HELICAL PILES While work began on the Monticello line, engineers reread reports and sifted through papers and brochures. Steel towers sounded like a good approach for the Sherco line. Also, helical pile foundations were a design option the engineering team wanted to consider. The driving consideration was the prevention of possible future cascading failures. Reports indicated steel poles were better at preventing cascading failures. If another powerful storm occurred in the future, although it might take out the wood line, engineering wanted it to be unlikely that both lines would fail. The second problem to address was the piles. Driving wood poles into wet, peaty soil takes time and big equipment, which has a significant impact on the surrounding environment. Helical piles can be screwed into the ground quickly with a special drill head on a small backhoe, minimizing environmental impact. Among the vendors with helical solutions was Hubbell Power Systems (HPS), which had recently provided Xcel Energy information on its helical solution. Two Xcel Energy principal engineers, Jeff Gutzmann and Tony Moore, contacted HPS and continued to examine alternatives. Ultimately, CHANCE helical anchors and quadrupod grillages were used on the Sherco line. MARSHES AND MATTING Xcel Energy had several reasons for using helical piles. First, while there was some historical information from the original build, there was no detailed soil information for each tower location. But because soil conditions varied so much over the length of the rebuild, the utility needed a solution that would work anywhere, even in deep peat. Helical piles would do

Helical piling supports the second steel pole line. These piles are in- stalled with a drive head attached to a small digger and work well in poor load bearing soil, even marshland.


SHARING THE ENGINEERING Engineering the design was a collaborative effort. Jeff Gutzmann worked with HPS on the helical pile design. The final design called for four piles per foundation, each with five helicals — one at 10 inches, one at 12 inches and three at 14 inches (254 mm, 305 mm and 356 mm, respectively). Depths varied from pile to pile and location to location but were typically between 25 ft to 35 ft (7.6 m to 10.7 m). Xcel Energy’s construction department selected a contractor with prior experience working with CHANCE helical foundations, and the contractor purchased and installed the specified piles from HPS. Once the piles were driven into the ground, a grillage was attached to the top and grouted into place. The grillage is like a cap. It is welded together, and there are holes for the tops of the helicals. These are filled with grout to hold down the grill and a baseplate. The grouted pockets were used to create a moment connection between the piles and the grillage. HPS designed the grillage and an Xcel Energy engineer inspected the material as it arrived, checked the welding and oversaw the installation. As work began, Xcel Energy principal engineer Brad Hill identified a problem that required the grillage to be modified. Hill visited the HPS manufacturing plant in Centralia, Missouri, U.S., and worked with HPS to modify the design. After that visit, there were no further issues. Overall, the result of using the helical pile foundations was excellent. The base section of the steel shaft had a base plate welded to it and the grillage had a flange plate

welded to it, which allowed for a bolted connection between the grillage and the shafts. PLS-CADD was used to create the above-grade designs and specify the steel poles. TIMETABLE The storm took out the Xcel Energy structures in early July 2016, and the first line was returned to service on Sept. 1. Xcel Energy started designing the second line and working with HPS at the end of July. The contractors began work in late September when the steel poles began to arrive. All belowground work and grillage was completed by mid- October 2016, and the line was energized in December 2016. In total, Xcel Energy replaced 108 structures and 718,080 ft (218,871 m) of conductor, shield and optical ground wire. Within Xcel Energy’s service territory, there are a lot of wet locations. The helical pile foundations are a solution Xcel Energy will use again in a similar situation. The cost of this second line was competitive with the cost of using wood, and it was a fast, easy installation that minimized the project’s environmental impact. ACKNOWLEDGEMENT The author appreciates the assistance of Gary Seider, engineering manager of civil and construction projects at HPS, in the preparation of this article. FOR MORE INFORMATION Hubbell Power Systems | Xcel Energy |


Hubbell Power Systems, Inc. expands its product offering to now include 15kV Termination Kits. This new offering provides a turnkey solution for terminating outdoor, medium voltage, solid dielectric cables. Termination kits include Anderson™ tin-plated annealed stem connectors for #2 - 4/0 cable sizes, and NEMA 2-Hole lugs for 4/0 - 1000kcmil cable sizes. All compression lugs are fully rated for use on aluminum conductors and meet the requirements of ANSI C119.4. All Hubbell Cold Shrink Terminations meet the requirements of IEEE Std. 48, Class 1. New Product Expansion 15 kV COLD SHRINK TERMINATION KIT

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ROCK-IT ANCHOR SUCCEEDS IN EXTREME CONDITIONS The cover image looks like a moonscape, but, in reality, it is the Atacama desert in Chile. It is the driest, non-polar, desert on Earth, receiving only 0.2 inches (5 mm) of rain per year. In 2017, Hubbell Power Systems (HPS) sent a team there to test a newproduct, the ROCK-IT™ anchor*, in soil that backhoes can barely scratch. After several days, the testing was complete and successful. At each of the three test sites, 15 to 20 miles (25 to 30 km) apart, the ROCK-IT anchor penetrated to an acceptable depth and provided 45 tons of tensile strength. NATURAL CEMENT West of the Andes mountains, the Atacama desert covers 41,000 square miles (105,000 sq km) in a long, thin strip along the Pacific coast. Despite being desolate, construction is currently booming there. Massive solar farms dot the barren landscape and high voltage lines stretch from the power rich areas in southern Chile to the north.

Project Manager for HPS. Both approaches would be a logistical challenge.

So helical piles would be a good idea, if they could be used. The problem is the soil in the Atacama. It is called Caliche (pronounced ka-lee’- chee) and it is a natural cement found in various regions around the world, including Charleston, WV and Denver, CO in the US. In Chile, the Caliche also contains salt and is almost as hard as rock. That is why the HPS team made the trip--to find out if a helical pile would penetrate the dense soil. HPS has a line of helical piles under the brand, CHANCE ® , including the Helical Pier Foundation System, which comes in two styles: hollow, round shafts and the more robust, solid steel, rectangular shafts. CHANCEpiles aremade for strength. The square shaft is fabricated from low-alloy, high-strength steel. The helical plates are made from 80-grade steel with a yield strength of 80,000 PSI. For comparison mild steel has a yield strength of 36,000 PSI. This is strong enough for most jobs, but HPS has a new product that is even stronger. The ROCK-IT™ anchor is designed specifically for very dense, hard soil. It is a standard, square shaft, helical pile, but it has a carbide bit welded onto the tip of the shaft. A ROCK-IT anchor is a standard, square shaft, helical pile, but it has a carbide bit welded onto the tip of the shaft.

Francisco Carcamo, International Business Development Manager for Hubbell Power Systems, Inc. (HPS) explains, “right now, there is a lot of business coming in from Peru to the north and fromBolivia to the north east. In response, Chile is building new infrastructure and expanding its ports and the free trade zones. The north needs electricity, so Chilean companies are building new power lines and solar farms.” Next year, Transelec, the largest transmission company in Chile, plans to add to its existing 5,100 miles (8,200 km) of transmission lines by building a new 220-kV line through the Atacama. The line will be supported by more than 300 towers and Transelec is very interested in a solution that can provide tensile strength to support the towers, without relying on concrete foundations. Consider that the proposed tower locations will be, at a minimum, a two-hour drive from the nearest city (and significantly further in some locations). “For transmission towers, you need tension anchors, which traditionally means large concrete foundations. If the concrete was mixed at the tower sites, water would have to be transported to 300 towers locations. The other option, of course, is to transport pre-mixed concrete for several hours, through the desert, to the sites,” explains Shawn Downey, The Caliche can best be described at salt-cemented sand. It is very dense and hard.

PROBLEMS FOLLOWED BY SUCCESS The test team arrived at the first site after driving for two hours from the nearest city, Iquique (ee-KEE-kay). To test the soil, a backhoe operator did his best, but only managed to dig a shallow hole, a little over a foot deep in the Caliche, before giving up.

Then, it was the team’s turn. As expected, the regular, square shaft, helical pile failed to penetrate the soil. And, when the crew tried the ROCK-IT™ anchor, there was a problem. Shawn Downey provides the details, “The ROCK-IT anchor is being used in the US, but this was the first time we tried it in Chilean soil, which is really very hard. For our first attempt, we used a pile with a steel shaft and three helicals: 8, 10, and 12 inches (200, 250, and 300 mm) in diameter. It did not work; The Caliche soil is very dense so digging is difficult, even with a backhoe

*The ROCK-IT anchor can also be used as a pile


the helicals were too big. So, I marked up the helicals and took the anchor to a fabricator in the city. He cut them down to 6, 8, 10 inches (150, 200, 300 mm), which is a standard configuration. We just had not brought any with us to Chile. The following day, we successfully installed the ROCK-IT™ anchor.

installation depth depends on the diameter of the top helical. To function like a deep foundation, the top plate should be under the surface by five times its diameter. So, a pile with a 10 inch (25 cm) diameter, top helical should be in the ground at least 50 inches (130 cm).“ This minimum depth was not quite reached in a few places but testing showed the pile was secure and able to provide 45 tons of tensile strength, which was more than sufficient. MULTIPLE ADVANTAGES The successful tests were very good news for future construction projects in the Atacama desert. Using ROCK-IT anchors would simplify logistics. Supplies for multiple foundations can be transported to the tower sites on one truck and there is no need to mix large amounts of concrete or bring in water tankers. Another advantage is speed. The ROCK-IT anchor can be installed relatively quickly (compared to other options). More importantly, loadcanbeapplied immediatelyafter installation. Concrete takes time to set and reach maximum strength. “Cure time would result in considerable delays in loading for concrete and for micro-piles, which is another foundations option. To construct a micro-pile, a hole is augured into the ground, a steel rod is inserted, and then grouted into place. The tensile strength of this type of anchor comes from the friction between the grout and soil. The problem is you cannot load micro-piles right away. Optimally, you wait 28 days for the grout to fully harden,” says Downey. Also, to install concrete foundations and micro-piles, a contractor would need to bring in large construction equipment, like backhoes. ROCK-IT anchors are installed with a small digger with a drive head attachment. There is one last advantage, which is not at all obvious from looking at the pictures. Despite appearing to be a forsaken desert, every once in a while, it rains in the Atacama and, for a brief time, the desert blooms. The last time was in 2015 and camera crews from around the world flew to Chile to photograph the intense colors. Although it is lifeless most of the time, the Atacama is a environmentally protected area and therefore ground disturbances need to be minimized. Installation of ROCK-IT anchors does not displace soil, so the environmental impact is significantly lower than for other foundations.

Using ROCK-IT anchors would minimize the amount site deliveries, greatly simplifying the logistics of building a long transmission line.

Since we only had one with that configuration, we used it repeatedly. We screwed it in and out several times at three different test sites. It worked perfectly.” The smaller helical diameter did not limit the ROCK-IT anchor’s use in this application,” Downey explains, “To choose a helical configuration, we use a software package developed by HPS called HeliCAP ® software. It is available to our customers through any of our distributors. The software calculates load capacity, which is dependent on the soil strength and the total area of the helicals. If the soil is dense, you need less helical area and this soil was very dense.” [In theory, a single large helical plate will provide as much compressive and tensile strength as an arrangement of smaller helicals. In reality, it is much easier to drive-in a shaft with multiple, small helicals than a shaft with one large one.] DRIVING IT HOME At the three test sites, the team installed and removed the ROCK-IT anchor several times. TheROCK-IT™anchor augured through the top layer of Caliche and then screwed into the lower layers of soil. “A helical pile is meant to screw into the soil. Each helical has a three-inch pitch and will advance three inches (7.5 cm) per revolution. The ROCK-IT anchor will sometimes penetrate less than that. In the cemented sand we encountered, the ROCK-IT anchor augured through, penetrating about one quarter inch per revolution. The shaft twisted but neither the strength nor the integrity of the steel was effected. (For proof, consider that the team repeatedly used the same anchor and then successfully performed a 45- ton tensile test at the last test site.) Once we were through the hard layer, the anchor screwed in at the proper three inches per revolution,” says Downey. From site to site, the depth of the Caliche varied. In some areas, it only extended down 30 inches (75 cm) or so. At other sites, it extended to about 15 feet (4.5 meters) and installation took longer, but all test installations reached an acceptable depth. Carcamo points out, “The minimum

Preparing for tensile testing.



Welcome to Hubbell ®

MERAMEC INSTRUMENT TRANSFORMER COMPANY On November 17, 2017, Hubbell acquired Meramec Instrument Transformer Company, a manufacturer of current measurement devices. Located in Cuba, MO, Meramec produces instrument current transformers for the power generator, power transformer, and the high and medium-voltage circuit breaker markets. “Meramec is a premium brand with a 40 plus year history of designing, manufacturing and delivering high quality bushing current transformers. This is a welcome addition to the HPS product portfolios,” said HPS Group President, Gerben Bakker.

To learn more about Meramec, Contact your Territory Manager or visit their website at



In response to customer input, Hubbell Power Systems, Inc. made a significant investment to bolster the proven RFL™ GARD 8000® hardware platform by improving the product user interface. The resulting new product is the GARD Pro™ system.

The GARD Pro™ system is designed with ease-of-use in mind. While high functionality and great detail is provided, the GARD Pro™ user interface makes interaction with the device highly intuitive and handling greatly simplified.

To register for a live demo, visit



THE MASTER OF DISASTER TAKING THE INDUSTRY BY STORM WITH MATT MONTIE, DISTRIBUTION MANAGER With fall 2017 being one of the most active storm seasons in US history, the HPS distribution center found itself on the front lines as record numbers were without electricity. Matt Montie, the HPS Distribution Manager shares how HPS prepares and reacts to serve our customers during these critical times.



THERE ARE MANY TYPES OF STORMS (TORNADOS, HURRICANES, ICE, ETC.). IS ONE CATEGORY MORE CHALLENGING THAN OTHERS IN TERMS OF STORM RESPONSE? Each typeof emergencyhas its’ ownnuances toaddress. However, hurricanes and ice storms present the most challenges. Hurricanes affect wider areas, are slower moving and impact a greater number of customers. During ice storms, the ice may linger well after the initial storm causing travel and work to remain hazardous for a long period of time. The experience of the HPS distribution center load planners and managers allows us to navigate the chaos of a storm and communicate issues and concerns to customer service and the customer in a timely and concise manner. Many utilities may experience an emergency outage once every four to five years, but during that same timeframe HPS has responded to 16-20 emergency events throughout the US. With that experience and our drive for continuous improvement, each and every emergency provides an opportunity to implement improvements. We understand that everyone wants the “easy” button and our job is to figure out what that button is for each customer. We are continuously looking at process, documentation and communication methods that can help make working with HPS easier. MANY OF OUR EMPLOYEES IN THE DISTRIBUTION CENTER AND IN CUSTOMER SERVICE VOLUNTEER DURING STORMRESPONSE. WHATWOULD YOU SAY IS THE DRIVING FORCE BEHIND THAT GENEROSITY? The employees in the distribution center have all personally experienced power outages for varying lengths of time, so they understand the hardships even with a short term loss of power. That experience helps drive them to provide a quick response to our customers. We know our work directly helps people. We are not delivering a toy to a store shelf or a bolt in a hardware store, but rather getting the lights back on, making sure food doesn’t go bad, keeping people warm, clean and dry. We are helping people in our communities. “ WHAT IS THE ONE THING THAT YOU THINK HPS DOES, LOGISTICALLY, THAT SETS US APART?


OVER THE YEARS, YOU HAVE MADE CONTINUOUS IMPROVEMENTS TO OUR DISTRIBUTION CENTER, HOW DO THOSE BENEFIT OUR CUSTOMERS? The foundation of our approach is if we can be safer, have a higher quality, and be more productive that will lower the costs of warehousing and shipping material to our customers while also saving our customers time trying to correct our issues. Some of our recent improvements include: Customized our Warehouse Management System (WMS) for greater efficiency and quality thereby supplying our customers quicker with fewer errors to chase down. Implemented a Transportation Management Software (TMS) to increase our efficiency selecting carriers and increase responsiveness to customer needs. Implemented a “Push System” of picking and process automation to respond to customer priorities and demands in a more timely and effective manner with a high level of quality Developed a menu of customer selections of documents, labels, and electronic transactions that match the wide variety of customer needs 1 2 3 4

THE DISTRIBUTION CENTER HAS ACHIEVED AND MAINTAINED HIGH LEVELS ON ON-TIME-PERFORMANCE OVER THE LAST 10 YEARS. HOW WILL YOU LOOK TO IMPROVE SERVICE TO OUR CUSTOMERS? First of all, safety is always our first priority. Our employees must go home in the same health as when they arrived. Next is accuracy. It is not very useful to our customer if the material shipped quickly but it was the wrong material. Our ultimate accuracy goal and target is a 6 Sigma level of accuracy: 3.4 errors per million or 99.99966% accurate. That is a very lofty goal and hard to achieve but that is what we are striving towards. Next, but not least, is our on-time performance. We have an excellent on-time performance which is driven by a partnership between our manufacturing capabilities and planning and the distribution center. We routinely breakdown and investigate the small number of on- time failures to expose our opportunities for improvement and build a roadmap to correct. 5M STORMSTATS 2017HPS Hurr icane I rma, Hurr icane Harvey, Hurr icane Mar ia, Cal i fornia Wi ldf i res Visit about-hps to take a virtual tour of our distribution center!

DO YOU SEE OUR INDUSTRY STARTING TO MOVE OR EVOLVE FASTER IN TERMS OF ADAPTING NEW SYSTEMS AND SOFTWARE? The electrical utility industry is commonly conservative when approaching new technology, especially in support services like warehousing and material movement. The general warehousing industry is moving forward with increasing availability and decreasing expense of automation. HPS must continue its drive for innovation or risk being outmoded, outdated, and out of touch. The need for quicker and more effective material movement is only going to increase, so we must continue to look for, and incorporate best practices. For instance, we may learn a more cost effective way to handle large volume of piece picking from a publishing company or a streamlined method to stretch wrap and label pallets from a toothpaste manufacturer. Bottom line: we need to continue to investigate our opportunities to streamline processes and introduce automation where it makes sense.

pounds shipped

1000 l ineman care packages 400+ trucks




FEATURES AND APPLICATIONS • Blanket clamp for in-line use with a grip-all clamp stick

• Maximum opening of 2.0 inches (51mm) • For use with rubber blankets and cover up






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VOL. 21 NO. 2 | WINTER 2017

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