HELIO

ENERGIES

Overhead Transmission Lines

Live Maintenance:
Increasing Uptime, Production
and Reliability HELIO
ENERGIES
 The Company

• HelioEnergies is a Free Zone company

registered under the laws of Egypt
• Its operation yard is in Al Amreyah Free Zone,
Alexandria. HELIO
ENERGIES
 Power Services Sector
HelioEnergies Power Services Sector
offers a wide range of services for
the Power Industry.
The range of services includes, but is not
limited to,:
1. Preventive Maintenance Services such
as Hot Washing, Silicone RTV Coatings.
2. Energized Predictive Maintenance
Services such as Infrared Imaging.
3. Energized Corrective Maintenance
Services such as Live Maintenance &
Repair.
HELIO
ENERGIES
 THE CHALLENGE
Overhead Transmission Lines (OHTLs)
are exposed to:
• Very harsh environmental conditions
• High levels of pollution
• Cyclic loads
• Loose connections due to poor
maintenance
• Improper rating of network components
That normally leads to either Scheduled or
Unscheduled Shutdowns.

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ENERGIES
 SCHEDULED SHUTDOWNS
• Scheduled shutdowns before
routine maintenance
operations result in:
o Lost Production.
o Interrupted Power Supply.

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ENERGIES
 UNSCHEDULED
SHUTDOWNS
• Unscheduled shutdowns
result in:
o Increase in cost and time for
repair
o Decrease in designed
operating life or damage of
equipment
o Casualties or Fatalities
o Lost Production
o Interrupted Power Supply
HELIO
ENERGIES
 THE SOLUTION
HelioEnergies offers an integrated
solution for the Power Challenges:
A. Preventive Maintenance:
1. Hot Washing
2. Silicone RTV Coatings

B. Energized Predictive Maintenance:

1. Infrared Imaging

C. Energized Corrective Maintenance:

1. Live Maintenance & Repair HELIO
ENERGIES
A. Preventive Maintenance
1- Hot Washing
2- Silicone RTV Coatings

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ENERGIES
WORK PROCEDURES

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ENERGIES
FLASHOVER MECHANISM
Accumulation of Contaminants

Water Filming

Leakage Currents

Dry-band Arcing & Flashover

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ENERGIES
 POLLUTION SOURCES FOR
FLASHOVER
• Sand storms
• Ocean or saline spray
• Salt fog
• Industrial pollution, including petro-chemicals,
metal ores, coal and cement dust
• Automobile
• Airborne
• Agricultural from fertilizers and other pollutants
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ENERGIES
 HOT WASHING
• Pollution, dust & humidity
all lead to “Flashover”.

• Power Insulators have to

be routinely washed using
high pressure water jets.

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ENERGIES
 SAFETY FACTORS
• Working Distance

• Water Pressure

• Nozzle Diameter

• Water Resistivity

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 SAFETY FACTORS
• Wind Speed & Direction

• Grounding

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BUCKET TRUCK

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OPERATOR’S SAFETY GEAR

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PREPARING TO WASH

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WASHING

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WASHING

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BEFORE & AFTER

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BEFORE & AFTER

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BEFORE & AFTER

HELIO
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BEFORE & AFTER

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ENERGIES
BEFORE & AFTER

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A. Preventive Maintenance
1- Hot Washing
2- Silicone RTV Coatings

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ENERGIES
 METHODS OF PROTECTION
AGAINST POLLUTION
• Greasing:
Using hydrocarbon or arc track resistant silicone grease -
these become saturated and have to be removed and
replaced every few years.

• Silicone Elastomeric RTV Coatings:

High Voltage Insulator Coatings (HVIC) are potentially the
lowest cost and most reliable maintenance-free solution
available.
HELIO
ENERGIES
 Sylgard HVIC+
• In response to electrical utilities requirement for long term
protection against pollution induced flashovers, Dow Corning
pioneered the concept of an RTV elastomer in 1970 – the
outcome was Sylgard® HVIC
• Internal laboratory trials/tests 1970 – 1974
• 10 years of field evaluation with major US electrical utilities
1974-1984 – excellent maintenance-free results with no
flashovers ( PGE, Southern Californian Edison, Florida Light
and Power)
• Sylgard HVIC commercially available since 1984

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ENERGIES
 Sylgard HVIC+
• Sylgard HVIC is a patented formulation specifically designed
to the electrical industry.
• Sylgard HVIC used the same formulation since 1974.
• Over 25 years of severe on site testing and experience from
11kV to 500kV.
• Extensive independent industry testing (Lab & Field)
• Successfully evaluated by major global test facilities
• Used at hundreds of problem sites in the USA, UK, Europe,
Africa, Middle East and Far East
• HelioEnergies is the EXCLUSIVE Distributor & Applicator
for Sylgard HVIC+ in Egypt.
HELIO
ENERGIES
 Sylgard HVIC+
• Original Sylgard HVIC has provided excellent and
unparalleled field service life globally for 25 years.
• 5 years ago – Dow Corning used advances in silicone
technology to develop a new generation silicone RTV
coating.
• RTV competitors have appeared in the last 15 years, but no
effort has been made to improve their original technology.
• Dow Corning’s new generation material is Sylgard HVIC+.
• Currently available in White, Grey & Blue.

HELIO
ENERGIES
 Superior Technical Properties
Sylgard HVIC + has been thoroughly examined over a range of
tests and has proven superior when compared to similar
products:
• Best wet & dry electrical performance
• Fastest hydrophobic recovery
• Best acid rain resistance
• Highest thermal conductivity
• Lowest application cost
• Longest field service life
• Longest proven history
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ENERGIES
Superior Technical Properties
• Hydrophobicity
• Long-term Weather Resistance

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ENERGIES
 HYDROPHOBICITY
• Hydrophobic surface prevents water
filming by forming separate water
droplets.
• Silicone oil transfers to the surface and
coats contaminant particles and renders
them hydrophobic.
• This reduces the contaminants ability to
combine with water to form an ionic After 10 years, highly
polluted surface with no
solution and interrupts the potential maintenance
flashover mechanism at an early stage.
• Sylgard maintains these features over the
long life of the installation and does not
require cleaning or maintenance. HELIO
ENERGIES
 LONG-TERM WEATHER
RESISTANCE
• UV Resistance - Silicone material has a backbone structure
composed of Si-O bonds with a bond energy higher than that
of sunlight. Therefore, it is resistance to UV degradation.
• Water absorption – The ability of the RTV coating to limit
water absorption is key to it’s long-term performance and
retention of the basic electrical properties.
• Acid Rain resistance – Sylgard HVIC+ shows the least
absorption and damage to the coating for Acid Rain
simulation.

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ENERGIES
APPLICATION OF SYLGARD HVIC+
• High viscosity which improves
thickness build up and reduces
slippage, drips and runs.
• High percentage solids content
which provides good value and limits
weight loss from wet to fully cured.
Easy Application, Less
• Smooth surface finish achievable. Maintenance Needed
• No mixing or dilution required.
• Even suspension and dispersion of
ATH.
• All of this results in a quality coating
with fast application time
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ENERGIES
B. Predictive Maintenance
1- Infrared Imaging

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ENERGIES
INFRARED THEORY

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ENERGIES
 Sir Isaac Newton, 1666
• White light is composed of a spectrum of
colors
• Light is not perfect or indivisible, as once
thought

PRISM

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 Sir William Herschel, 1800
• Do colors of the spectrum vary in
temperature?

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 Herschel’s Observations:
• Blues are coolest, reds are warmest
• Beyond red is warmer still!

Visible
Visible Infrared

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 Electromagnetic Radiation
• Infrared Radiation is similar to light
• It travels through space at the speed of light
• The difference between light and IR is
wavelength
• The Electromagnetic Spectrum defines other
kinds of electromagnetic radiation in our
environment

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ENERGIES
 Electromagnetic Spectrum

Microwaves
Visible

Gamma Ultra- Radio

X-Rays Infrared
Rays Violet
UHF VHF

Visible 2 5 8 Infrared 12 micrometers

SW LW

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ENERGIES
 Infrared Radiation
• Emitted by all objects
• Generated by vibration and rotation of
molecules within a substance

• Molecular activity increases

with heat
• Infrared radiation increases
with molecular activity

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ENERGIES
 Why does Infrared work for Predictive
Maintenance?
• Non Contact Temperature
Measurement
• Excessive Heat Frequently
Indicates Problems
• Corrosion and Loose
connections Impede current,
Producing Heat
• Trend Analysis

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ENERGIES
APPLICATIONS

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 Transmission
• Splices, Line Clamps, Insulator Connections

*>59.1°C

50.0

40.0

30.0

20.0

*<18.2°C

HELIO
Line clamp with connection problem

ENERGIES
 Substations
• Strand Heating

*>110.0°C

100.0

80.0

60.0

40.0

20.0

*<15.0°C

Single wire strand carrying disproportional current

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ENERGIES
 Substations
• Bolted Connection Problems

*>57.4°C *>60.6°C

60.0
55.0
55.0
50.0
50.0
45.0 45.0
40.0 40.0

35.0 35.0
30.0
30.0

*<29.2°C *<26.6°C

Poor bolted connections impedes current, causing hot spots on these current
transformer (CT) bushings
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ENERGIES
 Substations
• Bolted Connection Problems
*>53.0°C

50.0
45.0
40.0
35.0
30.0
25.0
20.0

*<19.5°C

Loose/Corroded bolt on connection pad to wave trap

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ENERGIES
 Transformers
• Overloading or Connection Problems

*>65.3°C *>120.0°C
65.0 120.0
60.0
100.0
55.0
50.0 80.0
45.0
60.0
40.0
35.0 40.0

*<31.5°C *<29.0°C

Bolted connection problem on bushing of large transformer

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ENERGIES
 Electrical Panels
• Bus Connections
*>76.1°C

75.0
70.0
65.0
60.0
55.0
50.0
45.0

*<42.3°C

Three phase bus connection with center phase indicating

overheating caused by bolted connection problem
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ENERGIES
 Electrical Panels
• Cable Connections *>61.0°C

60.0

55.0

50.0

45.0

40.0

*<35.2°C

“Blue” phase of these cable connection

demonstrate a crimped connection problem

HELIO
ENERGIES
 Fuse Panels
• Improper load balance, poor connection at
“stabs”, or bad fuses can cause
overheating
*>65.0°C

60.0

50.0

40.0

30.0

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*<21.6°C

ENERGIES
C. Energized Corrective
Maintenance
1- Live Maintenance

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WORK PROCEDURES

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 LIVE MAINTENANCE
METHODS
• Working At Ground Potential
(DISTANCE METHOD)

• Working At Line Potential (POTENTIAL

METHOD)

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ENERGIES
 DISTANCE METHOD
The workers are located on an
insulated ladder or platform and
remain essentially at ground
potential. Workers perform their
work with insulated tools and
equipment.

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ENERGIES
 POTENTIAL METHOD
Workers are bonded to the
energized device on which work
is to be performed and are
insulated from grounded objects
and other energized devices that
are at a different potential.

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ENERGIES
 USED EQUIPMENT
• Insulating Ladders
A single or multiple-section
ladder is used for personnel
support during energized line-
work. This ladder may be
structure mounted, base-
supported, or cable-supported by
a crane or similar device.

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ENERGIES
 USED EQUIPMENT
• Insulating Tools
Insulating tools made of FRP are
used for work on energized
devices while the worker is at
ground potential or at an
intermediate potential.
Insulating Rubber Blanket

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ENERGIES
 USED EQUIPMENT
• Nonconductive Ropes
Nonconductive rope is used in
rigging support platforms for
positioning personnel, controlling
conductors, and raising or
lowering tools and equipment
whenever work is being done on,
or in, the vicinity of energized
lines or devices. It can be used
alone or in series with an
insulating tool or an insulator.

HELIO
ENERGIES
 USED EQUIPMENT
• Insulating Covers
Insulating covers are used to
insulate energized lines and
devices from the worker. When
the worker is at the conductor
potential, the cover-up
equipment may be used to
insulate the worker from ground
potential.
Insulating Cover

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ENERGIES
SAMPLE PROBLEMS

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Flashed Insulator

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Insulator Installed Upsided

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 Insulator Damage

Horizontal Post Severe Erosion

Damage

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Flashed Insulator

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ENERGIES
Insulator Installed Backward

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Horizontal Post Damage

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SERVICES

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ENERGIES
 SERVICES
• Live Maintenance Services:
• Retighten all connections per post & tension pole
• Retighten all connections per H-type pole
• Repair defective cable
• Repair damaged conductor
• Install split pin for tension insulator
• Bypass hot point in conductor
• Change jumper
• Change fuse holder
• Change tension clamp
• Remove free clamp on conductor
• Adjust reversed tension clamp HELIO
• Install jumper over broken parallel grove ENERGIES
 SERVICES
• Live Maintenance Services:
• Replace/Install earth wire
• Replace/Install lightning arrestor
• Replace/Install armor rod
• Replace/Install cross arm
• Replace insulator top tie
• Replace guy wire
• Replace defected insulator
• Replace defected normal isolator (disconnect)
• Replace defected distribution isolator (disconnect)

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SITE IMAGES

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Fuse Changing - Mobilization

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Fuse Changing - Bypassing

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Fuse Changing - Replacing

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Fuse Changing – Bypass
Removal

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Fuse Changing - Demobilization

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ENERGIES
THANK YOU

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ENERGIES
QUESTIONS?

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ENERGIES