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Industrial Systems : Development of High Voltage Transmission Line Connectors

Client

Power-Line Corporation, Boston, MA.

Problem

Market research showed that utilities wanted a line splice or connector that would give full line strength tools on a live line. Power-Line Corp. was formed to develop such connector.

Solution

The transmission cable supplied was a 2/0 ACSR, an aluminum conductor steel reinforced. The connector had a steel-gripping central splice of the automatic type for the core wire, and an aluminum case with two compressible ends for the aluminum cable. Upon introducing the core wire it was instantly gripped. The two end nuts of the aluminum sleeve were then tightened and bit deeply over the cable. The strength was close to 100%, and the conductivity was far in excess of an equal length of cable (see the top 3 cables in the picture). The utilities then revealed that they were not interested in ACSR connectors any longer. Now they wanted all-aluminum conncectors. The two samples in the picture show the design of the new AA connector for a 336,400 cable, almost 7/8" diameter. They also wanted to be able to install the unit under emergency conditions and without special tools. The new design did all that and passed severe field tests. It was designed for the cable at the bottom of the photograph. It had one single flexible aluminum sleeve compressed by two end nuts and sealed at both ends with a plastic dip to prevent corrosion in storage.

New England Power Corp. bought several hundred but refused to put it in their standards book despite the insistence of the field crews.

Picture of the High Voltage Transmission Line Connectors