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Names of parts on electric pole
"...largest most complex machine ever built"
power generation Power Generation Book
Co-generation is growing market as demand for reliable energy grows.
Book by Singh covers the basics, and the engineering math. Future business and industry leaders should be aware of the complexity and variability of electricity.

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electric book Lineman's Books
Practical application and terminology/ not mathematical

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Learn the basics with tips and help for professional and beginner alike

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Ugly's Electric book series
Basic electricity book/ very detailed
Wiring a house
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Water heater formulas/ pdf
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What is 3-phase
See inside household electricity
Basic home electricity
Figure volts amps watts

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2021
Power plants are rated by megawatt MW output, or 1000 kW or 1,000,000 watts (power) or 1,000,000 VA (volt x amps = watts or power).
1 MW can supply power to 400-600 homes. Or 200 homes on hot summer day, since air conditioners (loads) are pulling more amperage, but also because high heat reduces the amp-carrying capacity of power lines, transformers, solar panels etc. How much amperage does house use   Amp rating of power lines
A gigawatt GW is 1 billion watts = 1000 megawatts (VA volt amps) What is power factor  Power factor and solar
 
Up to 25% of a conventional power plant (synchronous ac rotating machine) generation can be used to operate plant .... to power the electromagnet, to run the pumps needed to circulate water used for cooling, etc. ResourceWhat is 3-phase electricity  Power-Plants.pdf
Unlike wind and solar (inverter-based) generation that must be changed into matching voltage and frequency (oscillations of electrons in AC electricity) as conventional generation, the coal-fired plants require large number of employees to keep plant operational, including welders, bulldozer operators, trainloads of coal etc.
Offsetting job losses as more renewables and DERs come on-line is the need for grid reliability ... specifically to keep voltage "within ±10% of nominal at all points across the grid." Keep in mind the grid is cris-crossed over millions of square miles, with millions of poles and transformers and customers ... comprising a system that might not be fully mapped at the local distribution level in 2021. Read
The grid must hold voltage steady. Power (wattage) is equal to volts x amps. Voltage is the force that pushes amperage or current of electrons across the wire. Even though power plants are interconnected, each power plant can only energize a certain distance or area. If several power plants go offline, or demand exceeds supply, then power must be shut off (load shed) to some customers so voltage levels can be maintained for remaining customers. If voltage drops below nominal, then your 115 volt refrigerator and 240 volt AC cannot run without damaging the motor. Why? Two reasons. 1) Lower volts reduces the magnetic field needed to spin rotor. Motor slows down and overheats. 2) Volts and amps are inversely proportional. If volts drop, then loads will draw more amps to meet the amount of watts (power) shown on product label. Wires are rated by amperage, and are generally not oversized (larger wire carries more amperage but costs more). Exceeding the amp rating means too many electrons are moving through the matrix (atomic structure) of the conductor (wire), causing more resistance from wire which causes heat which overheats design parameters of wires, motors etc... affecting substation relays that will trip off ... and can affect power plant generators that will automatically shut down to avoid damage.

Utility-size generation from renewables like wind and solar has a large footprint (as does coal, oil and gas) that hinges on large-scale land acquisition usually located far from end users ... which requires further land access (permits) to build transmission lines to urban centers over objections by landowners etc. Read.  The less reliable renewables come with a "reduction in fault currents and short circuit strength" ... meaning that "voltage support might be a vital ancillary service to prevent voltage instability and ensure good power transfer." Renewables require gas-fired (and coal-fired) generators that sit idle but have fast ramp-up (startup) and turndown as needed (viewed as uneconomical or impractical?) .... but also require retrofitting the grid with capacitor banks, voltage regulators, tap changers, advanced inverters... and innovations such as massive installation of 'voltage smoothing batteries' (that can hold charge for limited time etc), compressed air storage, solid state transformers etc read  read2 read3 read4 read5 Resource: Electrification magazine

Utilities are challenged by aging networks ... challenged because grid updates are expensive, labor-intensive and often dangerous ... challenged by economic growth ... challenged by changing resource mix from solar and wind ... challenged by change from 'fuel-intensive emphasis into a “material-intensive” system' Read .... but also challenged by electric vehicles that will try to replace the entire gasoline resource with electric resource, etc. Read Read Read Read.pdf Utilities are also challenged by the perception in some countries that gas pipelines, LNG (liquified nat gas) and related infrastructure are a menace at same time natural gas (and gas of all types) is a primary source of energy for baseline power generation across the globe, see image and back-up generation for intermittent renewables Chart Chart Chart Chart ... and gas is predicted to be a primary source of energy for electric generation over next 20 years despite expectation that 'renewable generation will double by mid-century.' Image Image Chart  Image  Source ResourceDallas Federal Reserve Research

The future will need .... new skills from labor ... innovation using electronics that are more vulnerable to lightning, solar storms and cyber attack ... changing standards to meet reliability goals ... protecting appliances with voltage monitors that shut off appliance if voltage drops ... implementing technologies ... all indicating that considerable costs will be passed onto customers ... and arguably 25% of the energy will be used to manufacture, retrofit and maintain changes.
In my opinion, the promise of 'lower costs' and 'money-saving' from renewables (low-cost variable renewable energy or VRE) might not happen in the long run, and ultimately less-reliable renewables will be an expensive way to generate electricity if the purpose is to supply power to everyone. Read   Image  Read  Why? If too many renewables are supplying power at same time, there will be a glut of power ... and prices will fall below profitability. This will force utilities to install costly batteries ... while demand for batteries is spiking across globe ... skewing the cost of renewable generation. Without batteries, the renewables cannot withhold dispatch of power until after dark, or when wind dies down, when power is scarce and prices increase. The uncertainty in generation will be hard to regulate, at a time when regulation is often seen as dis-incentive, leading to fragmented (PPAs etc) and unpredictable grid, eventually causing shortage of affordable power.   Video   PowerOutage.us
Strong regulation, mandated demand response for homes and business, and real-time data, microgrids etc (distributed energy systems) might solve issue if available everywhere, but would be a steep incline from today and add considerable costs to gain participation by power producers and users. The capital expenditure and political compromise are unlikely without agreement that some will not get power. Read   Read
It should be noted that the promise of 'high-paying jobs in renewables' is not consistent with 'lower cost electricity.' Either you have good paying long-term jobs supported by rate-payers, or you have cheap electricity. These two things are opposites. In any case, there are few jobs once renewables are installed, and transmission lines built. Getting your picture taken wearing a white hard hat in front of a windmill does not equal a 'good job.'
'
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Steam turbines are designed for various uses, including to spin a generator to produce electricity. How it works: Water is boiled into steam using coal, atomic power, exhaust from gas turbine etc. The steam explosion releases massive energy that is used to rotate the turbine, and turbine spins generator.

Thermal generation from coal, atomic power ... oil, NG, LNG, LPG, hydrogen, gasified coal, ethanol, syngas, biodeiesel, alcohol, kerosene, steel mill gasses, etc image ... plus hydroelectric installations ... accelerate a turbine ... and the turbine rotates the generator to produce electricity.
Read more
Read more
https://www.powermag.com/
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Trailer-mounted turbine and generator
Gas turbine aero-derivative gas turbines
Gas turbines are designed for many uses, including to spin a generator to produce electricity. The gas turbine is basically a jet engine. How it works: Filtered air is sucked into the compressor and fed into the combustor where expanding gasses from ignited fuel cause the turbine to rotate at high speed. Gas turbines rotate at 3600 rpm (example) are made for wide variety of generating capacities, ranging from 35,800 hp to 345,600 hp (26,000 kW to 255,600 kW), and are regulated for NOx emissions, with 30-40% thermal or fuel efficiency. Source
Technologies are advancing to reduce CO2 emissions.

Combined gas and steam  (COGAS) Combined cycle gas turbine (CCGT)
Advances in technology and research have produced the economical Combined Cycle Power Plant where the 800-1,000°F exhaust heat from one or more gas turbines (topping cycle) is recaptured and used to boil water into steam (heat recovery steam generator HRSG). The steam is then used to rotate a steam turbine (bottoming cycle) that spins a 2nd generator (double-shaft configuration image) ... or to run a shared generator (single-shaft configuration image). A combined cycle can have 50-60% (63% on some new GE turbines) thermal efficiency, depending on ambient air temperature, contaminants in air, humidity, elevation, fuel type, age of turbine, condition, degradation etc. Image  Image   Video: combined gas and steam  Video combined cycle  Chart with cost comparison

"Total efficiency is defined as the sum of the net electricity generated divided by total fuel input to the system." This means the 60% thermal efficiency of a gas turbine is not same as the total efficiency. Total efficiency is unique to each turbine design, installation, fuel, etc. Total efficiency would be lower than thermal efficiency.
For example water heaters: A condensing gas water heater has 96% thermal efficiency, but overall efficiency of 82% because of various losses. Read

Typically, anything that obstructs or slows hot exhaust gasses from turbine or gas appliance etc, will cause the gas to burn slower and with less efficiency ... or extinguish the flame. The combined gas and steam (combined cycle) technology has solved problem and is being used to replace single-cycle gas generation around the globe where applicable.

Gas turbines can be massive or smaller units made for innovative fuels such as methane from a coal mine, gasified coal, biomass etc.
ANSI B133.6 Ratings and Performance defines base load as operation at 8,000 hours per year with 800 hours per start. It also defines peak load as operation at 1250 hours per year with five hours per start.
2015: "Combined cycle turbine plants (50-60% efficient) contribute to base-load power needs, while single cycle turbines (30-40% efficiency) are used for meeting peak-load," or used for smaller operations, including portable generation. For example, "utilities often place a single-cycle gas turbine in the 5 to 40 MW size range at substations to provide incremental capacity and grid support."  Source
A single-cycle turbine is typically necessary to compliment intermittent generation from renewables, affecting overall efficiency and CO2 production attributed to renewables. "Efficiency of a turbine at part load can be substantially below the 30-40% efficiency at full-power," while continual stops and starts degrade a turbine more rapidly ... causing more non-recoverable losses and higher maintenance to repair recoverable losses. Gas turbine failure modes .pdf     Read advancements in turbomachinery
2018: "The IEA projects that total electricity demand will rise by nearly 60 percent through 2040, with total 8700 GW of power expected to be added in next 25 years." Source GE.

Since turbines, gas engines (shown below), etc are designed to operate 25-30 years or more, the capability of burning multiple fuels gives 'flexibility to continue operating plant (with hydrogen, ammonia, synthetic methane etc), even in a decarbonized world.' .... Siemens is planning to make all their turbines capable of burning hydrogen (and other available gasses) since hydrogen produces no CO2, and is absolutely clean fuel while "electrolysers that produce hydrogen has risen greatly and the cost of renewable electricity to power those electrolysers is falling." IEA 2021
Resource: Manual
Siemens generatorLarger image
Reciprocating gas engine

This is a massive V18 cylinder piston engine with approx 40% efficiency. Also called, simply, gas engine. The gas engine spins a generator to produce AC electricity.
The plant can also be set up to recapture and reuse exhaust heat, improving efficiency.

Like gas turbines shown above, the piston engine can come online quickly (20 minutes) from a cold start or black start to meet intermittance from renewables, can be repaired to help maintain efficiency, and are usually designed to burn different gasses, including the methane content from natural gas.


Siemens generator
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Generators come in different sizes and types depending on requirement. Generators produce AC electricity.
They can be water cooled, air cooled, hydrogen cooled etc ... made to be powered by gas or steam turbines etc, ... made with different MW output ... available for 50 Hz or 60 HZ (frequency, or number of back-n-forth oscillations per second of electrons in alternating current) depending on country.
Generally, generators run with 96-99% efficiency.
Turbines shown above and generators shown here are repairable. For example, the central stem or rotor of a generator can be replaced along with bearings etc to provide longer life and updating.
.
GE generator
Generating alternating current
The grid delivers alternating current (AC) to homes and businesses. Solar and wind generation must be converted into same voltage and frequency AC power before being dispatched to the grid. All appliances, computers etc are rated for AC power as shown on product label.

''At the center of nearly all conventional (coal, oil, gas, atomic, hydro) power stations is a generator, a rotating machine that converts mechanical energy into electrical energy by creating relative motion between a magnetic field (north and south pole magnet) and a conductor (coils A B C).''

The 3,653 Megawatt WA Parish power plant site has coal fired (steam) generation where burning coal is used to boil water into steam using a boiler, and the steam explosion is used to accelerate a turbine that spins an electromagnet located inside the generator. See image of coal plant   Parts for coal plant .pdf  
WA Parrish also has gas fired generation where burning gas accelerates a turbine that spins the generator. Gas generation has fewer emissions than coal (when methane releases are not considered read), and is considered "quickest to sync and reach full load for daily and seasonal intermittence." and uses four times less water per megawatt-hour generated than coal-fired counterparts.'' Emission chart    Power plant types .pdf   Advancements have shown that coal generation can also be responsive to intermittence (the unpredictable on-and-off of renewable generation).
Note that stop and start operation requires more maintenance and will shorten life of turbines, generators, bearings etc as metals expand and contract with heat caused by operation. Manufacturers are improving this aspect.

In all cases, coal, oil, gases, atomic, hydro, the electromagnet inside generator spins past 3 coils (or windings) of wire that are spaced exactly 120° apart inside the generator.
As the electromagnet passes each coil, the coil becomes energized with a pulse of electric power that reverses each time the north and south poles pass. Back and forth, the electrons race down the wire, momentarily stop and then race back the other direction, creating what is called alternating current.
A wire is connected to one end of each of the 3 coils, and those 3 wires leave the power plant and become the 3 Hot wires found in 3-phase power that is transmitted across the grid.
The other ends of the 3 coils are joined together to form the Neutral wire that travels with the hot wires, and is bonded to the ground rod array located under the power plant and switchyard, and is bonded to a ground at each tower, pole, substation, and installation along the way. See image
Since the generator magnet passes each coil at a different moment, each wire carries power that is 'out of phase' with the other wires. When out of phase wires are connected to a load, the back-n-forth motion of electrons between wires delivers power to load. How are wires out of phase
Batteries
Storage of power via batteries has 2 measures:
Energy capacity or how much power is stored (measured in MW or GW), and Power capacity or amount of power that can be dispatched or released to grid over time (measured in MWh or GWh).
Watts are a measure of power. MWh or megawatthour is measure of wattage per hour.

'The success of renewables is reliant on long-duration energy storage' using batteries, pumped hydro, compressed air (mechanical battery), hydrogen fuel production etc. Read  Read
Note that storage of hot water at each home can be considered a 'battery.'
Connect AC water heater to low voltage DC    Connect AC water heater to high voltage DC

According to EIA in 2021, the US has '1.6 GW of utility-size battery capacity that is expected to increase 4-fold by 2022.' Image
Battery manufacturing has increased worldwide as technology works to develop higher density materials that will deliver lower cost per kilowatt hour at same time the world strains to provide enough minerals (and food, water etc) needed for growth in rennewables (and human substance). Read

Currently, peak electric consumption (maximum usage on hottest day) in US is about 800 GW per hour, and expected to increase with economic growth, government mandates for 'all-electric' homes and buildings, plus manufacturing goals for electric vehicles, higher global temperatures etc.

Right now, 2021, the 1.6 GW energy capacity of batteries in US is equal to .2% of total power needed for 1 hour of 800 GW peak, or equal to a mere .12 minutes of electric consumption before all battery capacity would be depleted. Calculation Afterwards, batteries would need to be re-charged before dispatching another 7.2 seconds out of a 24 hour day. Usage of power in US is less than peak most days of year.

Batteries are not designed to power the entire grid.
For example compare 50 MW gas turbine generator vs 50 MW battery installation. Both appear to offer same power, but the gas turbine will deliver 50 MW of continuous power, 24 hours a day. While a 50 MW battery installation can deliver 50 MW once and then must be re-charged.

Batteries have various functions that make them important. They can be charging and discharging throughout day as renewable output varies. They can respond quickly to help "balance momentary differences between electricity demand and supply." They can be used to store power for later in day when prices are favorable. Often, the power capacity from batteries is used to level (smooth) intermittant dispatch and avoid curtailments of solar panel generation etc. battery-applications.pdf
"Overall, batteries are expected to help utilities avoid need for load shedding." Source
[Chemical] Batteries have high efficiency, but are expensive (all costs are energy), have finite lifespan, have power dropoff with higher elevation and at temps over 104°F, with steep decline as temperatures rise, and total loss at 131°F image. Note also that power cannot be stored indefinitely.
Pie chart image from OECD
In 2021, renewables (Hydro, wind, solar) generate about 29% of world production, while Fossil Energy (FE) generates 53%, and atomic contributes 17%. Image Image Image
Wind and solar rely on weather to produce electricity, and to a large degree, so does hydroelectric. Weather is unpredictable and might be best strategy to meet global warming objectives, but poor choice to meet reliability and electric goals, particularly since batteries cannot energize the grid nor meet current usage nor sustain growing demand for electricity.

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''Steel lattice towers (vs wooden and concrete) are used for the highest voltages.''
The plant includes "generator step up transformers, collector system feeders, grounding transformers, substation buses, reactors, capacitors, main substation transformers, tie lines and points of interconnection."

Helical Rod Spacers hold the double-bundled wires apart from each other while stabilizing the lines.
In this photo, each tower carries 2 Neutral wires located at top of each tower and 12 Hot wires. We can see the transmission lines are bundled by two wires. We know 3 phase power is transmitted in multiples of 3 hot wires. Since the hot wires are bundled in pairs, this means each 3-phase line or 3-phase circuit is using 6 wires. The tower has 12 hot wires, which tells us the tower is carrying two separate lines (or circuits) of 3-phase power.

3-wire, 3-phase is most efficient method for transmitting electric power.
3-phase is a commercial voltage used for motors, AC equipment and large area uses ... requiring 3 out-of-phase Hot wires to operate load ... and is more efficient than using single-phase.
3-phase is not available for residential homes. Residential appliances are rated for single-phase which is derived by taking 1 Hot wire and a Neutral off the 3-phase line. Read about
Resources:
Transmission-Structures.pdf
Transmission-Structures-811.pdf
Difference-between-single-phase-and-3-phase.html
Power plant switchyard    
to   3-phase 220,000-500,000 volt Transmission

Image shows power lines leaving plant ... with coal-fired power plant and switchyard in background.
"The switchyard delivers generated power from the power plant to the nearest grid or transmission line.''

Image shows Vertical transmission structures

The lines shown in this picture are estimated to carry 220,000+ volts (220kV) en route to Houston and surrounding area.
EHV or extra high voltage, is roughly defined as 345,000– 765,000 Volts.
UHV or ultra high voltage is > 800,000 volts.
HVDC or high voltage DC 100,000+ VDC is 'more efficient for long distance transmission over 300 miles' because lower line loss, but requires costly converter stations to change DC (direct current) into AC (alternating current). Image

Parts needed for transmission, such as insulators, wire, bolts, assemblies etc are rated by voltage and strength.
Resources:
Overhead-Installation-Guide.pdf
Mechanical design of overhead power lines
Hubbell suspension support .pdf


Helical Rod Spacer
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3-phase high-voltage transmission
''Transmission structures support the phase conductors (12 hot wires) and shield wires (2 neutral or static or ground wires) of a transmission line.''
-Power lines and towers are designed to withstand load factors such as heat, ice and high wind.
Image shows Vertical transmission structure
It takes 3 wires for a 3-phase line or 3-phase circuit. "Towers can carry one or more circuits, depending on the design (e.g., single-circuit vs. double-circuit towers)." Image above shows a double-circuit tower. "For voltages up to 200 kV, a phase is typically a single conductor (3 wires total per circuit). For voltages over 200 kV, bundled conductors are often used to increase the current, or amp carrying capability of the line and reduce power loss caused by heat. Bundled conductors consist of two or more conductor cables connected by spacers. 220-kV and 500-kV (220,000 and 500,000 volt) lines often have two conductors per phase (6 wires total per circuit).''
Source  Transmission-Components-Fact-Sheet.pdf
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Example single circuit, horizontal configuration, self-supported lattice tower w/ approximate dimensions

Illustration shows single-circuit transmission with 3 bundled conductors that are suspended 119' above ground.
Horizontal lattice tower is 'cheaper to build than Vertical transmission structures' shown above, but horizontal can be limited to a single circuit while vertical towers carry 2 circuits.

Each conductor bundle is suspended 32' away from other bundles using V-string suspension insulators. Insulators hang downward when power lines travel straight forward .... or are installed horizontal when power lines make a turn or come to deadend.

The steel towers are flexible and bend with loading. Problems can occur if footings sink unevenly. Concrete and steel poles are being used more and more for transmission since they are more attractive than lattice towers, except poles are limited by their ground line moment ... reference the amount of force that causes them to break off at ground level.
 
Power line design is done via computer program today, unlike earlier times when designs were calculated for each tower.

Source with more terminology
Transmission-Structures.pdf
vibration damper

3-phase Transmission

Vibration dampers
are added to each line as it nears a suspension point. Dampers are used to reduce line movement caused by wind loading.
Note that parts and assembly are done by men using tools. Building, repairing and updating the grid is labor intensive, so each part must be carefully engineered and then installed correctly to ensure decades of service.

Other protections include armor rods installed where the wire is held by the suspension clamp.
''ARMOR RODS are designed to protect cable against bending, compression, abrasion, and flash-over. They are also used to repair damaged aluminum-based conductors and restore the conductors' mechanical strength and conductivity.''

Resource:
Vibration dampers
Hubbell damper-armor-rods-line-protection.pdf
Armor rods .pdf
Transmission line repair manual

2 Conductor Horizontal I-String
Materials for power line assemblies vary by need and include:
Polymer, Toughened Glass
Galvanized Forged Steel, Steel, Galvanized Ductile Iron, Aluminum,  Aluminum Alloy
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3-phase Transmission
Suspending dual wires from transmission tower
Image shows Assembly for suspending a two conductor bundle from a transmission tower.
The dual wires are held 18" apart using two suspension clamps attached to a yoke plate.
Transmission wires are protected from damage using armor rods and vibration dampers.
The assembly is designed to move and sway with the wind load encountered by all overhead electrical installations.
Resources:
Hubbell damper-armor-rods-line-protection.pdf
Hubbell-suspension-clamps.pdf
Hubbell-suspension-assemblies.pdf
Hubble yoke plates
Transmission connectors .pdf
MPS_transmission-catalog-web.pdf

Note that parts require a man or men to install and tighten bolts.

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3-phase transmission
Overhead conductors are exposed to wind and other conditions that can damage the wire.
To prevent damage, utilities install vibration dampers, armor rods, and in this example, a suspension clamp with helical cushion to absorb movement while protecting the wire.

''Suspension clamp with helical cushion is designed to provide enhanced conductor support and protection."

"The rubber inserts are assembled directly onto the conductor and are held in place with the helical rods. The clamp assembly is then bolted around the helical wrapped rubber supporting inserts to compete the install.''
Corona ring
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"Unlike ceramics, polymer insulators have relatively shorter life."
3-phase Transmission
Corona ring/ Corona shield
"... use of corona ring at the HV (high voltage 220kV+) end fitting for improving the electric field and potential distributions and then for minimizing the corona discharges'... protecting insulators from corona degradation.
2006 Corona-effects.pdf'
Hubble corona rings pdf

When polymer insulators are "exposed to intense electric fields, insulation failure and loss of hydrophobicity (water should not be able to penetrate surface of insulator) may occur."
"These problems are caused due to non-uniform electric field distribution along the insulator, which tends to intensify the electric field on the sheds nearest to the phase terminal (connection point of conductor and insulator). Non-uniform electric field distribution can be minimized using suitable (correct design, size, and placement) corona rings."


There are "36 different shed profiles for composite insulators. There are four categories for the 36 profiles depending on number of different shed diameters within each unit:  .... Category 1.) alternating one large and one small; 2.) one large, two small; 3.) one large, one medium and two small; and 4.) one large, one medium and four small."
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3-phase Transmission
Vertical Bundle Suspension on rebuilt Subtransmission line. This is a single circuit line, with 6 hot wires or phase conductors and a single Neutral or shield wire.

There are 6 wires in 2-wire bundles, making this a single-circuit transmission line

Polymer line post insulators hold wire away from pole.

The 3 insulators are attached to spun concrete pole with a base that is bolted into the pole. Each base is connected to the ground wire that starts at the Neutral wire at top of pole and terminates at a ground rod located at base of pole.


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3-phase Transmission
Horizontal line post insulator with polymer sheds attaches to spun concrete pole with a base fitting or gain that matches diameter of pole.

Bundling Yokes are suspended from the line post insulator via a Y-clevis. "Bundling yokes can vary in width, 2-1/2" to 4-1/4" and length 9"-12"-18". Image shows 18"

Armor rods are installed to protect installation. The double-bundle wire and lack of corona ring suggest that voltage is at or near 220kV ?
Resource:
Line post insulators pdf
''Prestressed concrete poles are more durable than wood or steel poles and more aesthetically pleasing.
The reinforcing of poles consists of (a) spiral wire cage to prevent longitudinal cracks and (b) high strength longitudinal strands for prestressing. The pole is spun during manufacturing to achieve adequate concrete compaction and dense smooth finish. A concrete pole typically utilizes a high strength concrete.
Standard concrete poles are limited by their ground line moment capacity (breaking off at ground level).
Concrete poles are much heavier than steel or wood poles. Their greater weight increases transportation and handling costs. Thus, concrete poles are used most cost-effectively when there is a manufacturing plant near project site.''
Each spun concrete pole has an embedded label showing weight, height, date of manufacture, serial number etc.
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3-phase transmission
Steel tower near downtown Houston lays on the ground after being replaced with concrete poles. Each suspension disc is designed for voltage rating 11KV or 11,000 volts each disc. Insulator voltage range can be from 10KV to 1000KV.

Image shows two sets of dual porcelain strain insulators, each string about 8' long. Note the flexibility of the insulator string, helping absorb the effect of wind on the conductors (hot wires).
"A porcelain insulator consists of a number of porcelain discs connected in series by metal links in the form of a string.''
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The steel towers were replaced by concrete poles, while porcelain insulators were replaced by newer type, lighter weight composite or polymer insulators.
Toughened-glass-insulator.pdf
Failure-of-High-Voltage-Porcelain-Insulators.pdf

"A suspension insulator is an insulator which can be assembled with other metal parts and provide the means for non-rigidly supporting electric conductors.' This includes both the older ceramic and newer polymer types. Insulator types

Insulators can be divided into two types: porcelain insulator and silicon rubber insulator according to the material." "Unlike ceramics (including porcelain or glass), the newer type polymers (composites with silicone rubber) have relatively shorter life."
850,000 
"Silicone rubber has more advantage over the porcelain, so more and more countries are choosing the silicone rubber insulator vs porcelain"
"Polymeric composite insulators consisting of core fiber reinforced polymer insulators covered with polydimethylsiloxane (PDMS) housing are now replacing conventional ceramic insulators especially for high-voltage outdoor (above ground) power transmission lines due to some specific advantages."
Advantages-polymer-vs-ceramic-insulators.pdf

Resources:
Porcelain-Suspension-and-Struts.pdf
Orient-suspension-insulator-definition.pdf
Toughened-glass-insulator.pdf
2018 Degradation-and-stability-polymer-insulators.pdf
2006/ polymer-vs-glass-insulator.pdf
1991, LAPP insulators
Two men connect flexible porcelain insulator to a rigid strut insulator
Note weight of insulator with 16 porcelain discs.

The connectors are installed as much as possible while the pole is on the ground before pole is lifted in place.

2021, many installations and upgrades today use less expensive, lighter weight polymer insulators.

Note that the grid requires strong, skilled men who perform the same high risk installation, pole after pole, until project is complete.

While the poles, parts and wire can be manufactured by computers and robots, the actual field installation requires a labor force that can assemble parts to specification.
The grid is put together with nuts and bolts that are tightened by men.

Source
Porcelain-Suspension-and-Struts.pdf
High voltage tools High voltage tools

Buy:
High voltage tools
Electrician tools kits
Klein tools
Tools kits
Transmission tower
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Stafford Texas

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Transmission-level voltages are usually considered to be 110 kV and above.
Lower voltages such as 66 kV and 33 kV are usually considered sub-transmission voltages.
Voltages less than 33 kV are usually used for distribution.
Transmission ground

3-phase 2-circuit Transmission/ Grounding
The grid carries 3-phase power that is delivered via groups of 3 hot wires (phase conductors) that are accompanied by the Neutral.
The Neutral wire is visible at the top of the steel tower where it is bonded (connected to) the steel tower and subsequently to the ground or earth.

The wire at top each pole or tower goes by different names and has different functions.
It is called a static wire because it is bonded to the grounding rod located at bottom of each pole, and will discharge the build-up of static charge that occurs naturally in the environment.
For transmission towers, the line is called the ground in most resources because it is bonded to the ground rod, giving a low resistance pathway to earth.
It is called a shield wire because it 'shields' or protects the grid from lightning strike by deflecting the energy at downward angle away from the phase conductors, at same time it directs excess charge into the ground rod. A shielded line is vital for grid reliability.

For consistency and simplicity, this website (perhaps erroneously) refers to the wire at top of both transmission towers and distribution poles as a Neutral wire.
At the end user location, the distribution pole carries a Neutral that is needed for many commercial 3-phase transformer configurations and voltages, and needed for many single-phase household and commercial voltages. 

Across the entire grid, the Neutral (or static wire, shield wire) is bonded to the ground at each tower, pole, substation, and user location. This forms a giant array of grounding that stabilizes the grid from lightning and overvoltages that are safely absorbed into the earth to minimize damage.

Electricity is the flow of electrons between unequally charged materials.
Insulating materials including air will stop the flow of electrons until the charge becomes great enough to overcome the insulation.

When different temperature air masses collide, the opposing movement of air (or shear) strips electrons away from protons, causing pockets of charged particles to develop in the clouds. Each pocket carries a charge that is 'unequal' with the charge on the ground.
The result is a buildup of electrical potential to the point where the flow of electrons will pass through the insulating effect of air via a cloud-to-ground lightning bolt. The lightning will often strike highest point like a tree, hilltop, or power line, releasing massive electric power.
The energy released is generally referred to as the Ground Flash Density.

The shield wire or static wire or system neutral located at the top of transmission and distribution poles etc is directly bonded to a ground wire or rod, that is driven into the earth. This ground wire gives the lightning a low resistance path to earth thus reducing damage to poles, conductors, transformers etc.

If the lightning carries more voltage than the ground wire can absorb, there can be a flashover onto the conductors, or hot wires. The flashover can cause substation breakers and relays to activate and shut down the line.
To prevent this, areas with high flash density might need arresters that protect insulators from 'lightning induced flashover.' Image

Resource:
Porcelain-Suspension-and-Struts.pdf
Failure-of-High-Voltage-Porcelain-Insulators.pdf
Ball eye, ball clevis, socket eye, socket tongue, socket clevis, socket thimble, anchor shackle, twisted shackle, Anchor shackle, Bow shackle, Chain, and D Shackles, twisted strap, clevis eye, eye chain link, chain link, clevis tongue, extension link, U-bolt, adjusting plate, yoke plate, turnbuckle
Pole-and-Line-Hardware.pdf
Suspension clamps .pdf
Transmission connectors .pdf
Power-pole-parts-and-specifications.pdf
Suspension clamp U bolt type
Preformed armor grip suspension clamp
Strain clamps
Strain clamp for ACSR, AAAC, steel wire
Hydraulic compression type
Deadend bolted type
Transmission and distribution lines
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Rosenberg Texas

Note that the commercial three-phase transformer bank in the foreground is connected to the distribution lines, drawing a hot wire from each of the 3 lines. The transformers then supply power to local business.

This is called 3-phase electric service.

Distribution Transformers are designed to convert distribution voltage into usable, safer, low voltage for homes and business.

Because volts and amps are inversely proportional, then the safer lower voltage at home and business comes with higher amps. To solve problem of higher amperage, correctly-sized wire and circuit breaker are required, and distance the electricity can travel before voltage falls below nominal can be reduced to a few hundred feet.

Electric service at home or business would not connect to high voltage transmission or subtransmission voltages.
3 categories of power lines:
1) Transmission lines (not shown in image) might be 270,000 to 500,000 (775-500-270 kV) volts. Generally transmission is anything over 115 kV.
Voltages are measured Hot-to-Hot, also called the line voltage ... contrast with Hot-to-Ground phase voltage which is line voltage divided by square root 3.

2) Subtransmission lines might be 69,000 Volts (110-69-33 kV), and travel from substation to local substation and are located higher off the ground than local distribution lines.
Transmission and subtransmission make up the bulk power system.

3) Distribution lines travel from local substation to each home and business, and are much lower to the ground and carry less dangerous 12000+ volt, measured between hot wire to hot wire ... and 7200 volts (7.2 Kv) measured between hot wire to ground.

"The distribution voltage classes for most utilities can be 5 kV, 15 kV, 25 kV, and 35 kV." Voltages are determined at local substation transformer and vary depending on local demand, distances etc.

Below 4000 volts (4kV) on in-town distribution line can become inefficient because large number of loads will pull large amount of power (watts). If volts are too low, then the loads will draw too many amps from the distribution line, causing higher resistance on lines, heat loss and ultimately damage to power lines, motors etc.
Because volts and amps are inversely proportional, then raising voltage at the substation transformer will deliver the needed wattage (power) for each load on the distribution line, but at lower amp draw, resulting in less heat loss, higher efficiency and more reliable power.
Raising voltage on distribution line might require larger wire, higher poles, different insulators etc depending on expected loading.
Lower voltages can be used on distribution lines that serve very few homes.

Local distribution lines can be less than a mile to more than 20 miles long. There are generally 3 categories for distribution: Radial, Loop, & Network (not discussed further).

Resource:
Design-overhead-distribution.pdf
Mechanical design overhead lines pdf
Electric-power-distribution-system-operation.pdf
Wood pole with porcelain insulators
Wood poles and crossarms are made from yellow pine, cedar, and spruce ... with yellow pine being the strongest. Wooden structures are economical to install vs steel and concrete poles, but are not as sturdy against load factors such as high wind and generally have shorter lifespan.

Note the insulators have 7 sections, @ 11 Kv each.
7 x11 Kv = 77 Kv or 77,000 volts max.approximately.

There is voltage potential between any Hot wire and any other Hot wire, called the line voltage.

There is also voltage potential between any Hot wire and the Neutral, called the phase voltage. This is because each hot wire is one phase out of the 3-phases .. so each hot wire is one of the 3 phase conductors ... and each phase conductor has voltage potential with the Neutral and thus same voltage potential to ground.
Read more

This subtransmission line was replaced with new spun concrete poles with composite insulators.
The lines were replaced with larger wires that were double-bundled for higher amp carrying capacity.

Why use higher voltage? Generally higher voltage lets power company transmit larger amounts of power longer distance without heat loss.
Electric power is volts and amps. When volts are raised, then amperage falls. Amperage, or flow of electrons on wire, causes heat. Raising voltage will reduce amperage which means less heat loss, higher efficiency and lower cost.
How do higher volts affect cost? Higher volts and lower amps means more force is pushing fewer electrons across the wire. This reduces heat loss, but also allows power company to use smaller wires since wires are rated by amperage, with larger wires capable of carrying more amps. Smaller wires weigh less and can be suspended from poles that are spaced farther apart... which reduces weight and cost of materials, and cost of installation.
Wires are also rated by volts. When power company installs larger wire, then it can deliver larger amounts of voltage without causing voltage drop as distance increases. Larger wire can also deliver more amps. Overall, this means when a power line is upgraded, future demand on that line must be considered so the correct size wires are mounted on poles that meet expected loading.
The grid is a balance of cost and function. The high cost of building and updating transmission lines might cause undersizing. The resulting shortages might be mitigated by local generation from solar panels, batteries etc (microgrids). But a fragmented grid means some people would not have power, or only receive power a few hours per day as experienced in some countries.

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Substations have voltage regulators (often built into transformer). So if transmission lines deliver voltage above or below standard voltage, the regulator will correct outgoing distribution voltage so local area will not suffer voltage irregularities.
3-phase high voltage Power transformer at local substation
69K-125K subtransmission lines supply power to local substations.
Local substations use power transformers to convert the high voltage subtransmission into 12,470 volts or 3 lines of 7200 volts for distribution that travel to local homes and businesses.

The large cylindrical tank mounted on left side contains oil for cooling the transformer.
The upright insulators located on top of transformer are called bushings.
While voltage remains relatively unchanged throughout the day, amperage (or number of electrons flowing along the line) rises and falls depending on the load, with more amps flowing when more loads are turned on.
During high consumption periods, or peaks, the voltage is pushing massive numbers of electrons across wires and through the transformers.
The increased flow of electrons encounters increasing resistance which acts like friction, causing heat across the whole grid. Transformers are rated by their KVA (power) capacity, and how much heat they can withstand, and how fast they recover (cool) after a high-heat or peak event.

Resource
Recommended-losses for-power-transformers.pdf
Large-Power-Transformers-and-the-Grid.pdf
"The function of a substation is to transform voltage to a lower or higher level of voltage, and to provide the ties, transformation, switching, and protection for the transmission and distribution systems.
Substations contain transformers in order to convert voltage levels, as well as circuit breakers, and a large amount of protection and control equipment. Substations can vary in size, depending on the amount of voltage being transferred and the number of lines terminating at or originating from the substation. There are various types and classifications assigned to different substations, based on the amount of voltage, transformation desired, and equipment on site. Substations can be manned or unmanned.''
Volts and amps are inversely proportional. When volts are increased by transformer, then amps are reduced. Higher volts and lower amps means more force (volt) is pushing fewer electrons (amps) through the matrix (atomic structure) of the conductor (wire). As a result the wire offers less resistance, meaning there is less heat loss (energy loss), which means electricity can be transmitted longer distance using relatively small wires that can be supported by poles and towers that are spaced further apart ... thus saving money and energy. The use of transformers makes electric power possible for the masses.
Power lines leave substation
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3-phase distribution
Many poles leave substation transformers, traveling to each business and neighborhood
Wires leaving a local substation branch off many directions on wooden poles, sending power to local homes and businesses. This is the source of 7200 volt distribution.


Follow power lines using google earth to reveal complexity of transmission and distribution networks.
Poles leaving substation carry groups of 3-wires, always accompanied by Neutral.
Poles are generally wood, but can be steel or concrete.

Each pole has ground wire running down pole and into the ground
"Distribution substations contain many components, a few of which are power transformers, circuit breakers, and voltage regulators. The power transformers step down sub-transmission voltages (69 kV to 125 kV) to distribution voltages (2.4 kV to 19.92 kV). Circuit breakers, that shut down power during overloads on the line, are placed between the distribution circuits and low-voltage bus for substation protection during fault or surge conditions. Voltage regulators are installed on each distribution circuit if the power transformers are not equipped with automatic tap changing capabilities that enable bus voltage regulation.'' Source P13 
Voltages generally stay the same across the incoming high voltage lines, but momentary surges can occur. Voltage regulators and tap changers automatically react to anomalies so that distribution voltage going to local homes and businesses remains stable, and doesn't experience the same surge.
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Newly installed 3-phase 7200 volt distribution lines
Air is the insulation.
This newly installed overhead distribution line is made of 7/8" diameter bare aluminum-alloy wire. Overhead wires are bare and have no insulation.

Wooden poles have good insulating properties, and generally last 25 years before they are rotted beneath the ground and need replacement.

To ensure power does not arc to ground or other structures, high voltage wires are suspended in the air, using the air as insulator. The higher the voltage, the higher the wires are suspended to ensure safety.

The pin type insulators on each pole keep bare wires away from poles and other wires. Insulators must have high mechanical strength to withstand loads such as wind and have high electrical resistance. 'Porcelain is most common material for insulators, but glass, steatite and other composite materials are used. Pin type insulators are used up to 11 kV (11,000 volts)'

'Bare overhead wires are cheaper to install but don't last as long as insulated underground cables.
Underground transformer vaults can be susceptible to flooding and water damage. Hubbell-underground-vaults.pdf

The grid is a balance of cost and function. "Overhead line construction is less expensive (3x to 10x less expensive) than underground cabling for the same kVA (power) load. In rural or semi-rural areas, the sheer cost of underground cabling would make it impossible for customers to afford cost of supply.
The downside is that overhead lines operate under continual mechanical stress with exposure to varying climatic conditions (wind, heat, ice, lightning etc).
This results in progressive deterioration in time as a result of corrosion, mechanical wear and fatigue, timber rot, etc. All components must be periodically inspected and replaced" However overhead lines are easier to inspect for damage, and are rarely damaged by short-term overloads and catastrophic failures are rare.

"Overhead systems are rarely as reliable as underground ones. The greater spacing of overhead line conductors generally results in higher system inductance (resistance over time) than for a cable system. This means an overhead line has a greater voltage drop than an underground cable of equal current-carrying capacity and hence cannot supply power over as long a distance as the underground equivalent. However the capacity of an overhead feeder can be readily increased by replacing it with larger conductors and/or increasing the voltage insulation/operating level.
This flexibility is one big advantage of overhead systems." Source P18    Wood-distribution-pole-Design.pdf   www.woodpoles.org
Let's suppose, if all homes in a neighborhood install solar panels. In Hawaii, it was determined that just 50% of homes feeding PV-generated power back to the grid on a good day posed problems that required updating distribution lines and substation transformers. IF a neighborhood has underground distribution lines, then updating might be more expensive than above-ground distribution. In any case, the cost of distribution improvements should be included when calculating the value of rooftop solar. Microgrid experiments in Austrailia are installing pole-mounted batteries that are charged during day and help supply power to 3000 homes at night.

Line sag. 'Bare overhead conductors are able to withstand a lot of pressure and high temperatures,' but lines will sag if they are carrying too many amps (current of electrons), even if lines are thermally rated to handle emergency loading. Lines usually have "thermal time constraints that allow temporary overloading (5-20 minutes)," but if the problem is not cleared quickly, then sagging lines can come into contact with trees or with each other, causing outages. High currents can also cause conductors "to anneal, which increases chance of a break happening."
Tree clearing by power companies is a tradeoff. It's often unsightly, and seems opposite of 'going green,' but will protect grid reliability and could produce fuel for biomass generators if possible or located nearby. Image
power plant to house electricity
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Power plant switchyard    
to   3-phase 500,000 volt Transmission  
to   3-phase 69,000 volt Subtransmission  
to   3-phase 12,470 volt Distribution/ Hot to Hot    
to   single phase 7200 volt Distribution/ Hot to Neutral
to   single-phase 120-240 volt Home


Power plant to house electricity
In a simplified version of events, the illustration shows grid transmission from power plant to substation, subtransmission from substation to substation, and distribution from local substation local homes and businesses.

Homes and businesses require high-amp, low-volt power. Except high amperage causes heat loss during long-distance transmission. To solve the problem, transformers located at substations can raise and lower amps by raising and lowering voltage.
Voltage and amperage are inversely proportional.
Volts x amps = watts.
When volts are reduced at at substation transformer, amps are increased.
The result is low-amp 500,000 volt electricity is used for long-distance transmission. Higher amp, 69,000 volt subtransmission lines are used for shorter distances. And higher amp 12,000 volt is used for local distribution lines.

For example, transformers at local substation reduce 69,000 volt subtransmission lines into safer 12,000 volts so it can be distributed along wires that are suspended nearer to ground and can pass close to trees.

Residential single phase is achieved by taking one 7200 volt Hot wire (measured Hot to neutral) and a Neutral off the 3-phase 12,000 volt (measured hot to hot) distribution line to create 7200 volt single phase. The single 7200 volt Hot wire and Neutral are then connected to each of the residential transformers in the same neighborhood.

Converting 7200 volt 3-phase into 7200 volt single phase ... pulling 1 Hot and a Neutral off 3-phase distribution line.
 Once the 7200 volt Hot and Neutral wire reach each home, the residential transformer will reduce the 7200 volt single phase into usable 120-240 volt single phase, ensuring that households receive safe, low volt, high amp power.

Numerous homes will draw amperage off the same 7200 volt power line without overtaxing the line. That's because a 250 amp 120-240 volt residential service that is running at full capacity will pull a maximum 8 amps off the 7200 volt distribution line. At any given time, very few home will be running at maximum amperage. Most will draw just a couple amps off the power line.
Resources See calculation  Ampacities of power lines

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Low volt, high-amp power works nicely because household 120-240 volt single-phase can be safely controlled by small switches, relays, cell phone chargers etc contained within steel and plastic enclosures, while the amperage (and heat) is controlled by circuit breakers (overcurrent protection) and then distributed to outlets, switches, clothes dryer etc using correctly sized wire to match amp rating of breaker.

Resources:
Line-post-insulators-Insulators.pdf
What is 3-phase
See inside residential main breaker box
Basic household electric
Troubleshoot household electric
Identify transformer wiring
Difference between single-phase and 3-phase
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Grounding 3-phase distribution
"Standard 142-1991 lists several reasons for limiting the ground fault current by resistance grounding:
1. To reduce burning and melting effects in faulted electrical equipment, such as switchgear,transformers, cables, and rotating
To reduce burning and melting effects in faulted electrical equipment, such as switchgear, transformers, cables, and rotating machines.
2. To reduce mechanical stresses in circuits and apparatus carrying fault currents.
3. To reduce electrical-shock hazard to personnel caused by stray ground fault currents in the ground return path.
4. To reduce the arc blast or flash hazard to personnel who may have accidentally caused or who happen to be in close proximity to the ground fault.
5. To reduce the momentary line voltage dip occasioned by the occurrence and clearing of a ground fault.
6. To secure control of transient over-voltages while at the same time avoiding the shutdown of a faulty circuit on the occurrence of the first ground fault (high-resistance grounding)."
By Larry A. Pryor, P.E., GE Senior Specification Engineer.

"... lightning activity can be characterized by lightning ground flash density, expressed in terms of number of lightning flashes to ground per square mile per year. The line itself tends to be a somewhat focused collector of lightning and will attract flashes which would otherwise strike the ground over a swath whose width is approximately four times the average height of the uppermost conductor or shield wire" ... the Neutral or static wire found atop transmission, subtransmission, and distribution poles.

If a pole has the 3 Hot wires at the top and Neutral traveling lower on pole, then the line is considered unshielded from lightning. In this case "lightning to unshielded lines involves a strike to one of the phase conductors (hot wires), resulting in line outage.
"For properly designed lines, having well located shield wires (as shown in photo), most lightning strikes to the line will terminate on the shield wire. The surge of current will travel along the shield wire until it reaches a structure (pole) where it will be conducted down into the ground'"
Transmission surge arrestors .pdf
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3-phase and Single-phase 12,000+ volt distribution
Typical 3-phase distribution line follows alongside a road or street, and supplies both 3-phase and single-phase for all end users located along the road or street.

A three phase distribution line has 3 out-of-phase Hot wires accompanied by the Neutral.

Normally, a 3-phase service has 3 transformers, and takes 3 Hot wires and sometimes the Neutral, while single-phase service has 1 transformer, requiring 1 Hot and the Neutral.

The same distribution line can supply power to multiple neighborhoods with each neighborhood pulling off a separate Hot wire in effort to keep the 3-wire 3-phase distribution lines 'balanced.'
Balanced mean all 3 hot wires on the 3-phase distribution line will supply the same amount of power, and that one hot wire does not do more work than other two hot wires.
www.woodpoles.org
Lightning and Shield wire
Refer to photo above
: Note the nearest pole has a 4x4 extension at top of pole to hold the Neutral wire ... also called the static wire, static line, shield wire .., and sometimes called the ground. The Neutral at top of pole is always bonded to the ground rod  or grounding located at bottom of each pole.

When the shield wire is at top of pole as shown, it will protect the 3 hot wires from lightning. It will also protect the communication and internet cables located lower on pole.

Older distribution lines often have 3 Hot wires at top of pole with the Neutral traveling below. If there are taller subtransmission lines nearby or taller structures, there is minimal risk. If not, then a line without shield wire is more susceptible to damage from lightning. A damaged phase conductor will run hotter and with less efficiency, sometimes requiring splice repair or line replacement between two poles.

Power companies can change older installation by adding a 4x4 and moving Neutral wire to top. Another option is to install a taller pole. The 4x4 technique allows new and old installations to connect at minimum cost ... or keep older pole in service more years.
Connect transformer to wire 7200 volt distribution
Hot clamps are often used to connect smaller lines to a larger conductor or distribution line. When the conductor arrives at home or business, then a hot clamp is used to connet the transformer to the distribution lines.

Hot clamps are also used to pull a 7200 volt distribution line off the three phase distribution to supply single phase to a neighborhood.

This type clamp is used on 7200 volt distribution lines, but not on high-voltage transmission and subtransmission lines.


Resource:
Line post-insulator.pdf
Hot clamps pdf
Single-phase 7200 volt distribution
Hot clamps
For connecting transformers and other wires to a 7200 volt distribution line
Note that parts require a man or men to install and tighten bolts.
Resource:
Hot clamps pdf

Electricity arrives from the pole
See Larger
Neutral connects to transformer. Ground wire connects to Neutral wire.
Ground wire is smaller diameter than Neutral. Ground and Neutral work together for household safety, stability of grid, and to help absorb overvoltages and shorts caused by lightning, equipment failure, surges from inductive loads etc.
Single-phase 7200 volt distribution line arrives at home
Power poles carry high-volt, low-amp electricity
-High-volt low-amp lets power company transmit electricity long-distance without heat loss caused by high amperage.

Before entering house, electricity is converted to lower volts and higher amps at distribution transformer.
Different transformers are used for different voltages. -Residential transformers receive 4500-7200 volts from 1 high voltage line and a neutral. The transformer reduces voltage to 240Volts and splits the voltage into two 'out-of-phase' 120Volt Hot wires that enter home. The two out of phase Hot wires offer 240Volt potential used to power water heaters, air conditioner etc. While 120 volts using 1 Hot and 1 Neutrals used for outlets and lights.

-Note: 3 wires enter home <> 2 hot wires and 1 neutral wire <> the neutral also connects to ground wire at bottom of service pole. The ground wire is bonded (connected) to the ground rod that is driven into the soil and is used for safety and to stabilize the grid.
Resources:
Where power comes from: What is 3 phase
Difference between household and commercial electricity
Read about electric power from power plant
Why you need ground wire
Underground residential electric service Single-phase 7200 volt distribution line arrives at home
Underground residential electric service is same as above-ground service
-It's easier to photograph above-ground electric service.
-All electric services, above and below ground, follow same pattern from power line => to transformer => to meter box => through the meter => to main breaker box.

-Meter and meter box for underground service is the same as above ground, except wires arrive in underground conduit pipe instead of dropping down from a pole.
-Transformers for underground service are inside ground-level boxes or underground vaults, and perform exactly same function as above- ground, except offer more protection, reliability and longer lifespan.
Resource:
Underground electrical vaults .pdf
parts on electric poleLarger image
Single-phase 7200 volt distribution line arrives at home

7200 volt Hot and Neutral wire arrive at home.
The Neutral is at top of pole, and Hot wire is suspended lower on pole.

The residential transformer converts 7200 volt distribution line into safe 120-240 volt for use inside household.
This transformer supplies power to a single home.

Power is pulled off the Hot line using a Hot Clamp attached to the Hot line.
The fuse protects against overloads and fault currents (amperage).
The surge arrestor protects against overvoltage.
Both work together to protect the installation.
'Transformers have no moving parts, ensuring a long trouble-free life under normal conditions.'

Power leaves the transformer via triplex wire that is attached to side of transformer. Triplex is a 3-wire bundle made up of two insulated Hot wires and a grounded bare aluminum neutral wire that are strong enough to be suspended overhead until they enter a service mast and drop down into the meter box before entering the household main breaker box.

2 Insulated Hot wires and bare aluminum Neutral wire
Resources:
Read more about residential transformer
Surge arresters .pdf
See inside household electricity
Basic home electricity
Figure volts amps watts
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Single-phase 7200 volt distribution line arrives at home

Same as above: 7200 volt Hot and Neutral wire arrive at home.
The Neutral is at top of pole, and Hot wire is suspended lower on pole.

The Neutral atop the pole serves as a shield wire to catch lightning strikes and safely redirect the excess voltage to ground so it will not damage the electric grid.
High-strength steel wire for long spans that carry few amps.
Resources
Overhead grounding standards
Grounding code
Dead end clamps


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Fuse on power pole
Fuse
Full image
Tripped fuse
Tripped or open fuse
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Single-phase 7200 volt distribution line
Fuse cutout located on power pole
-High voltage distribution wires carry 4500-7200 volt that must pass through a fuse before connecting to transformer.
-Fuse will trip when heat exceeds fuse rating, protecting transformer from surge caused by lightning, overload, malfunctions etc.
-Electric company resets fuse using long fiberglass pole.

-Far left image shows high voltage line terminating on a porcelain dead end strain insulator located on last pole at end of street.
Resource
cutout-fuse-instructions.pdf
dropout fuse
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7200 volt distribution line
Dropout fuse
''The primary function of the drop out expulsion type fuse is to protect equipment connected to distribution overhead lines from overloads and fault currents within its rating.''
This type fuse is used on 7200 volt distribution lines, but never on high-voltage transmission and subtransmission lines.
Note that resetting a fuse requires a skilled man and a truck.
Resources
Cutout-fuse-instructions.pdf
Hot sticks and power line tools pdf
Fiberglass Hot sticks
arc-flash-clothing.pdf
power-line-tools.pdf
techline-lineman-tool-catalog.pdf
Klein-lineman-Tools-Utility-Catalog.pdf
Lineman resetting fuse
Lineman resets fuse at night
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The lineman must wear protective clothing and insulated boots.
Resetting fuse can result in flash explosion.
Static belt serves as continuous ground/ protection when working close to energized lines
Conductive suit, hot suit, conductive Boots, socks, gloves / clothing is bonded to the conductor so lineman can use hands on live conductor
Rubber insulating gloves must operate within voltage class, must be in good condition for work on hot lines
Protective Ground Grid / ground blanket/  for a lineworker to stand on during energized and de-energized work
Temporary conductor support fiberglass is used to hold energized distribution conductors during replacement of poles or repair or replacement of pole top and stand-off insulators
Temporary Conductor Support: Nylon binder strap ratchet assembly hold energized distribution conductors during replacement of poles or repair
Grounding set with grounding clamp each end
Resources
Hubbell
Performed energy
Spun concrete poles
Lineman slang dictionary
Performance-Evaluation-Overhead-Power-Line-Proximity-Warning-Devices pdf
Aerial-tools-and-equipment.pdf
Distribution repair manual

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Another image
Single-phase 120-240 volt residential service
Resource:
See inside household electricity


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Single-phase distribution transformer
-After 7200 volt distribution Hot wire travels through the fuse, it drops down to the lightning or surge arrestor, and then connects to the primary bushings located top of the transformer. Note the Neutral wire connects  the other bushing on top of transformer, and also connects to ground wire.
-The ground wire is bonded to the shell of the transformer, and to any metal that is attached to pole before traveling down length of pole into soil at base. Across the grid, all poles, transformers, and electrical services are grounded, with all grounds bonded to the Neutral, forming a giant array of grounding that stabilizes the grid against overvoltages, lightning and insulation failures etc.
-The transformer photo shown above supplies electric service to two homes instead of more typical single home. Disadvantage of serving two homes is lights flicker when heavy amp loads turn on, such as air conditioner.
-Electricity leaves the transformer and travels through 3-wire bundles called triplex that contains 2 Hots and 1 Neutral.
Distribution transformers .pdf

Why are transformers used?
"Three-phase transformer banks are used in three-phase AC power circuits for the same reasons as single-phase power transformers in single-phase ac circuits, i.e., to step-up or step-down the voltages in the circuit and to provide electrical isolation (separation) between the primary windings (coils) and the secondary windings."

Transmission and distribution lines from the power plant are high voltage, low amperage to reduce heat loss. Heat occurs when voltage pushes amperage (current of electrons) against the matrix, or atomic structure, of the conductor. Using high voltage and low amperage means more force is pushing fewer electrons against the conductor matrix, which means less resistance from the conductor and less heat.
Resource
Ampacities of power lines
By reducing heat loss, electricity can be transmitted longer distance without losing power.

To prevent electricity from jumping (arcing) to other wires, or to the transmission tower, or to the earth, high voltage conductors (wires) are suspended high above the ground and spaced far apart, utilizing air as an insulator. The higher the voltage, the more space is needed to keep the voltage under control.
High voltage also requires large and expensive switchgear, and is extremely dangerous, making it impractical and hazardous for residential and commercial use.
To solve the problem, transformers are used throughout the grid to step up or step down voltage. Since amps and volts are inversely proportional, when volts are stepped down by the transformer at local home or business, amps are stepped up. The lower voltage can be controlled at home and business using small switches contained inside metal or plastic enclosures while amps are controlled with properly sized circuit breaker and wire.

3-phase arrives at building
3-phase 7200 volt distribution line arrives at commercial building
Typical 3-phase service has 3 transformers, while single-phase service has 1 transformer.

 The same distribution lines that supply 7200 volt to neighborhoods and individual homes also supply power to businesses and buildings that require 3-phase service.

Single phase power delivered to homes requires one transformer, while a 3-phase service to buildings requires 3 transformers (which are sometimes installed as a single transformer that contains 3 transformers).

A service is the voltage and amount of KVa or power that is delivered from the grid to the building.
A residential service is 120-240 volt single-phase, while a commercial 3-phase service can be a variety of voltages including 120-208-240-277-480-347-600 volt etc.

''When a building is not of sufficient height, a service riser will be necessary to achieve the proper service drop clearance.
When field conditions do not permit the use of a riser, a service pole may be substituted.''

Resources
JEA-Overhead-Grounding.pdf

Difference between single-phase and 3-phase
What is 208 volt
What is 277 volt
Electric pole parts3-phase 7200 volt distribution lines arrive at building service
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Rosenberg Texas
3 phase service at local Walgreen
Image shows Delta Primary and 4-wire WYE Secondary.

The primary is Delta: How do we know? Each 7200 volt hot wire from the distribution line connects to two different transformers.... so the three transformers are wired in series or Delta on the primary (or distribution side).
The System neutral connects to Neutral and ground, but not to the bushings on top of transformers.

The secondary is WYE. There are 4 wires, 3 hots and 1 Neutral. The Neutral connects to all three transformers. Each of the 3 Hot wires connect to a different transformer ... so the three transformers are wired in parallel or WYE on the secondary (or customer side).

Delta primary, WYE secondary is 'most common type of wiring' because Delta has lower amps/ meaning less heat, so insulation on primary coil on each transformer is less expensive.

Transformers can be wired different ways depending on the incoming electric supply and end user need.
Two key factors for the grid are economic performance and reliability.
Reliability is necessary because electricity must run clean without high-voltage spikes and low-voltage brownouts. Unreliable power means motors and HVAC equipment will have shorter lifespan.

Resources:
Transformer configurations pdf
Index of transformer manuals
Identify more illustrations of transformer wirings
Power line surge protectors pdf
Read more about 3-phase service
Insulated wires attach to secondary side (customer side) of commercial transformer

Each installation on the grid requires tools, trucks and men.
Each man is trained for a specific voltage range. So a man working on 7200 volt distribution will not work on 79,000 volt subtransmission.
Higher voltages use different trucks, techniques and safety equipment.

Most line work is done with live power, so knowing and following exact technique is necessary for survival, but also longevity of installation.
As general rule, linemen are large, strong men who must perform each action and install each part exactly, with bolts tightened to specification so the installation lasts decades without problem.

Note how wire size exactly matches the point of attachment on the transformer.
High leg deltaLarger image
3-phase 7200 volt distribution lines arrive at building service
High leg delta service at local business

7200 volt distribution power comes from across the street on 3 Hot lines and 1 Neutral
The Neutral can be at the top if there is higher risk of lightning.
The Neutral will redirect a lightning strike into the ground wire at each pole. Otherwise, the Neutral is installed below the Hot lines as shown in Fig-2. If lightning or surge impacts the Hot wires, the lightning arrestor and fuse will protect transformers. If surge on the Hot wires exceeds rating of wire and grounding, the breaker at substation will trip and protect the distribution and transmission systems.

While wires on the secondary side going to the customer service panel are always insulated, the distribution Hot wires in this picture are bare, stranded aluminum or aluminum alloy, approximately .8-.9" in diameter.
Wire size and material used for the grid are a balance of cost and performance.
For example, copper offers less resistance and less expansion and contraction than aluminum ... and steel is very strong and resistant to heat ... but aluminum and aluminum alloys are the choice for most overhead electrical conductors.

Copper is best choice for interior wiring inside business and home. Inside home or business, aluminum wire will expand and connections come loose with high-amp loads, creating high risk of fire unless properly installed with special AL-rated compression fittings.

Resources:
Types of electric cable pdf
What is high leg delta
parts on electric pole
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Original image
Rosenberg Texas near fairgrounds
3-phase 7200 volt distribution lines arrive at service
3 phase service at county fuel depot

With 3-phase service, there are several different standard voltages and transformer configurations depending on end user need.
In this case, the 3 transformers on Primary side are connected in parallel (WYE) since the Neutral wire connects to the Neutral bushing on each transformer. Likewise, the Secondary or customer side is wired in parallel, so this is a 208-120 volt, 480-277 or 600-347 volt WYE-WYE service.

Note that the Neutral wire is below the 3 Hot wires. This means the Neutral cannot function as a shield against lightning strike.

Since the location had no other tall structures nearby, an unshielded service is more prone to damage since lightning will energize the Hot wire(s), causing potential outage and damage.

The fuses and lightning arrestor located on each Hot line and transformer will minimize damage.

Resources:
What is 3-phase


Same service drop as the image below.

Resource:
Drop-wire service ends
parts on electric pole
Rosenberg Texas near fairgrounds
3 phase service drop

The image in table above shows the primary and transformers
The image to left shows the service drop for the image above.


Drop-wire-service-ends.pdf
Preformed clamps (also called wiggle wires) are used to secure insulated conductors, guy wires, neutral wires etc.
Preformed clamps come in specific lengths, diameters, strengths etc ... so some are longer and have more wires, some shorter, but each has a specific use.
After leaving service pole and transformers, 4 insulated wires drop down to commercial building and are secured using preformed clamps.
To avoid contact with trucks, people etc, a service drop must meet standards for height above ground.
This service drop has a riser to meet height requirements.

The power enters each service mast via insulated wires that enter the weatherhead and travel to the meter first, and then though a service cut-off, before entering building.

Each business served by this installation has a separate meter, and each metered line must have an easily accessible safety cut off or safety switch with pull-down handle to de-energize power in case of emergency, repairs etc.

The steel riser, weatherheads, conduit, meter boxes, safety switches etc are grounded for safety.

The drop wires, riser, weatherhead, conduit, meter box, safety shutoff etc require skilled workers to install. The work is labor intensive and requires certified electricians, electrical engineers, inspectors, high-quality parts, etc ... but once completed, will last decades.

power pole switch
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Overhead switch/ Sectionalizer
3-phase 7200 volt distribution lines
>"Sectionalizers are one of the most used for distribution system protection.
The sectionalizer opens and isolates the faulty section of line. This permits the power company to re-establish supply to those areas free of faults. If the fault is temporary, the operating mechanism of the sectionalizer is reset."
Overhead switch lets power company de-energize lines for repair and emergency
A metal pole with a manual switch lever is located at bottom of pole
When switch is open the line on one side or the other is de-energized.

Resource:
4 Factors To Consider When Selecting a Sectionalizer
Overhead switch    Overhead switch/ Sectionalizer
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>Rosenberg Texas
Overhead switch   Overhead switch/ Sectionalizer
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Rosenberg Texas
Sectionalizers are used to shut off power to a local distribution line, usually for line repairs etc.
Note sectionalizers are manually operated.

Each power plant is interconnected with other power plants. If a local plant is shut down for repairs, updates, emergency etc, then local customers still receive uninterrupted power from the interconnected grid.

The grid is designed to hold voltage stable so it does not rise and fall too much over time. Each power plant can only energize a certain distance or area, so if several power plants shut down during a time of heavy usage such as heat wave or cold spell, then voltage can drop.
If voltage drops, the local power plant is at risk of automatic shut down to avoid damaging the plant.

If the power plant experiences a shut down, it might take days to restart ... typically requiring a large amount of electricity from other power plants. To avoid plant shut-down, the local grid operator must turn off power to some customers, known as blackouts. Blackouts help the power plant stay operational while supplying power for key facilities such as sewage treatment and hospitals.

If the local grid is not mapped out at the customer or distribution level, then it might be difficult to engage in rolling blackouts because the power company doesn't know which circuits go to which areas. A circuit might be switched on to a large area that would cause a sudden voltage drop that would risk a power plant shut-down.
Switching during a power blackout or rolling blackout can be done at local substation, but if the distribution area is not mapped, then shut-offs require using manual overhead switches and guesswork. Unmapped distribution get complicated since some areas receive power from a single line while others receive power from two lines etc.
http://waterheatertimer.org/Pulling-electric-wire.html

Pole-mounted capacitor bankPole-mounted capacitor bank
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Capacitor banks are used to improve power factor (PF), improve voltage, and reduce line losses.
Capacitor banks shall have voltage and current sensing capability.
Capacitor banks shall be connected grounded wye.

Resource:
What-is-power-factor.pdf
Pole-mounted-three-phase-capacitor-bank
pole-mounted-three-phase-capacitor-bank55.pdf
3 phase surge suppressionCapacitor bank on 3-phase distribution line
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Includes an overhead switch or sectionalizer, located on right side of pole, that can be used to by-pass the capacitor.
This 3-phase line is 7200 volts and supplies power to multiple neighborhoods, including my neighborhood
These lines also supply power to several businesses that use motors
With several motors or inductive loads on the line, it will reduce power factor on the line.
Transformers without load also create reduced power factor.

Inductive loads such as motors, contactor coils, relays.... consume large amounts of amperage before voltage during start up ... causing voltage to lag behind amperage.
Resistive loads such as lights and heaters...  consume voltage and amperage at same time, without lag.
Capacitor banks help solve problems caused by voltage lag.

This protects motors of all kinds from surge, including the motors at local businesses, and homeowner appliances and HVAC unit.

Neutral wire at top of pole not shown.

Resource
Read about surge suppression for residential and


Effective operation of down-line distribution capacitors optimizes
the feeder voltage profile and minimizes var flow.

Voltage Regulators and Controls
Capacitors and regulators are used to flatten the feeder voltage profile. The capacitor acts as both a voltage and power factor device to deliver the
optimal feeder voltage profile.

Power factor correction is a crucial element in improving energy efficiency and reducing losses. Capacitors are used to correct the distribution feeder var flow.
VAR control is only required when both current and voltage are out of phase within an electrical circuit.
Open Rack Layouts

Distribution control system
Capacitors-on-Rural-Electric-Systems.pdf
, Power Factor equals kW divided by kVA

usda.gov/publications/regulations-guidelines/bulletins/electric
pole mounted capacitor-bank
Voltage regulator Larger image
"Voltage regulators are devices that maintain distribution voltage within a specified range of values.
They are used by power companies to minimize voltage
drop and to ensure that the proper voltage is supplied to customers."
Voltage regulator can level average voltage across the 3 Hot wires, often resulting in energy savings.

"A line voltage regulator automatically adjusts the voltage to a regular level, makes the distribution grids “smarter”, and allows the infeed of higher amounts of renewable power."

"New distributed energy resources, such as solar, combined with the growth of sophisticated loads creates voltage challenges on distribution network systems.
Existing voltage control devices cannot maintain a consistent voltage profile, especially when trying to manage the intermittency of these new resources and loads. These new loads and intermittent resources tend to drive the voltage regulation beyond its designed capability, and reduce the typical voltage regulator life expectancy and increase the ongoing maintenance cost for reliable operation."

"Voltage regulators are cost effective solutions to regulate voltage without compromising quality and reliability...".
Voltage-Regulators.pdf


More overhead wiring Resources:
Sectionalizer
Hoist stick pdf
Jumpers etc pdf
Jumper clamps pdf
Line construction tools
Web ratchet puller pdf
Pulling-electric-wire
What-is-3-phase-electric

Web strap ratchet lever hoists
lineman’s puller

hot stick
hoist options
Tension Puller
pullers and tensioners
Compression clamps
Jumper clamps
Power line tools/ pdf
Arc protective clothing pdf
Compression Splices
After wires are pulled together by tensioner, a compression splice or sleeve is added to securely connect both sections of wire.

The conductor is cleaned and inhibitor applied to both surfaces, and then spliced is applied.

"There shall not be more than 1 splice per conductor in any span, and preferably not in adjacent spans."

Resource:
Hubbell-splices-and-sleeves.pdf
Splice repair
Splices-en.pdf
Inhibitor .pdf
Lineman's utility cart carries rolls of smaller wire used for neutral, grounding and guy wires, and triplex drop wire for residential service.

Each lineman is trained for specific voltage range because protective equipment, parts, materials, safety-equipment and other factors vary by voltage.

Conductor sizes range from 12 mm˛ (#6 American wire gauge) to 750 mm˛ (1,590,000 circular mils area), with varying resistance and current-carrying capacity.
Thicker wires would lead to a relatively small increase in capacity due to the skin effect, that causes most of the current to flow close to the surface of the wire.
Electric supply trailer
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Rosenberg Texas
Electric supply trailer
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Fig-A shows freshly cut 37 strand 'concentric round' aluminum bare overhead Distribution conductor with strands of wire splayed apart.
Fig-A is called 'concentric round' since each strand is identical, each is round, and cable is round. Diameter 0.795." or .455 square inches.
This wire was laying on the ground as part of the installation of new Distribution lines along the freeway.

Note: "each layer in a conductor is wound in the opposite direction"

Fig-B shows 28 strand bare overhead Subtransmission conductor with 7 strands of high strength steel surrounded by 21 strands of trapezoidal-shaped aluminum wire.
''Air space between strands can be reduced by compacting the aluminum conductor into trapezoidal shape for a more compact wire size."
Wire in Fig-B was laying on the ground as part of the installation of new Subtransmission lines along a local highway.

"Overhead wire can have 70-127 strands and be 2.3" or more in diameter, and made from a variety of aluminum alloys. 12mm˛ to 750 mm˛."
Household wire can be 7-19 strands and less than 1/4" across
Wire sizes are given in kcmil.  Example wire is 954 Circular Mils (kcmil) = 483.4 square mm ... since 1000 square mm = 1.55" ... 500 square mm = .75 square inches. 954 kcmil = .7493 square inches of area = diameter .97"
Zinc coated and aluminum coated steel wire are used where temperatures exceed 200° F.
Resource pdf:
Ampacities-of-overhead-conductor
Amp-rating-power-lines.pdf
Overhead-Installation-Guide
4_overhead_conductors
Mechanical-Design-of-Overhead-Lines
Advanced-Conductors-for-Overhead-Transmission
Design-overhead-distribution
Overhead Conductor Installation .pdf
Overhead-aluminum-conductor
Wire & Cable Technical Handbook.pdf
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Size comparison steel core 28-strand Subtransmission wire with compressed trapezoidal shape
 vs 37-strand concentric round aluminum Distribution wire.

Trapezoid design eliminates much of the air space between strands, allowing higher-voltage wires to have more compact diameter.
Each layer in a conductor is wound the opposite direction
Conductor examples

 Conductor examples
Different conductors are chosen for different applications
Illustration is general  depiction of materials and not exact numbers of strands or types of cores or shapes of wire configuration.

Choice of conductor is always a balance of electrical need, efficiency and cost of materials

Galvanized steel wire surrounded by aluminum wire is used for long spans. ACSR ACAR
Steel wire is strong, but a poor conductor. The aluminum wire carries most of the electricity.
The 'skin effect' causes most of the current to flow close to the surface of the wire

For shorter spans, up to 50 meters, with high load demand, all-aluminum wire is used. AAC AAAC

For rural areas with few customers, price of conductor becomes main issue. Galvanized wire is used.
Galvanized steel is a poor choice of conductor for areas with high load

Overhead conductors can last at least 40 years
Resources:
Overhead conductors pdf
Amp rating of power lines
Ampacities-of-overhead-conductor.pdf
Utility-Wire-and-Cable.pdf
Overhead-wire-types.pdf
Wire types pdf
Overhead aluminum conductors
General cable/ overhead conductors
]General cable/ overhead line solutions
Battery-powered, hydraulic cutting tool
Each tool has different rating. The one in photo is rated to cut 1/2" steel re-bar up to 1.5" aluminum conductor, etc.

Various types of battery-powered tools are important for line work, for crimping, cutting wire, tightening bolts to correct torque etc.

Resource:
Huskie-lineman-tool-Catalog

Resource: Spun-Concrete-Poles-Valmont-Utility.pdf
For subtransmission and distribution

Note the ground wire traveling down full length of pole
RCC reinforced concrete pole/ High-voltage Subtransmission tower/ with local distribution lines located bottom right corner of photo.
Vertical bundling for twin conductor suspension, Vertical Bundle Assembly Suspension Clamps/ located in Rosenberg Texas
Resource:
UEP_Bulletin_1724E-2044.pdf
Hot wires connect on pole
Distribution line
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Rosenberg Texas
3-phase 7200 volt distribution lines
Hot from North side of freeway attaches to South side
Suspension clamp is tightened against wire using 4 bolts.
Wire is bent downward.
The bend in wire adds a mechanical resistance to slippage of wire
The bend also pulls the Hot wire away from the insulator.
The Hot wire is connected to Hot wire on pole.

Suspension clamp is connected to insulator.
Insulator is bolted to steel pole

Long suspension spans use aluminum-coated steel wire or steel cored aluminum ACSR
Aluminum wire will sag more than steel wire over long spans.
Steel coated aluminum wire is used.
The steel carries mechanical strength while aluminum strands carry bulk of current
Poor conductivity of steel makes it a poor choice for long distance transmission of high voltage.
Galvanized steel is used in rural areas with few customers on the line because it is less expensive.
Resources:
Spun concrete poles
Spun-Concrete-Poles-Valmont-Utility.pdf
prestressed-concrete-poles.pdf
Dead end clamps pdf
Compression hot clamp
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Compression hot clamp
Color difference added for clarity
Distribution hot line connected to another distribution hot line.
Used for higher amperage application compared with hot clamp used for home.
Wires shown are 3/4" diameter, 37 strand aluminum

Resource:
Overhead-primary-clamps.pdf
Hot clamps Hot clamps
For connecting wire to distribution line
Resource:
Hot clamps pdf

suspension clamp
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7900 volt distribution
Suspension clamp and silicone strain or dead end insulator
Suspension clamp has 4 bolts that are tightened against wire.
The clamp holds wire and keeps it from slipping.
Used when suspending wire across long distance or at pole located at corner

Strain insulator vrs suspension insulator vs dead end insulator: Horizontal vs vertical vs horizontal end of line, they are the same except used different ways.
Resources:
Mechanical design overhead lines
Transmission power pole parts.pdf
Overhead-primary-clamps.pdf
Dead end clamps pdf
Suspension jumper support
Composite insulators are two metal ends connected by a 'fiberglass' rod that is both flexible and non-conductive.

The fiberglass rod is covered with silicone sheathing that includes a number of semi-rigid fins called sheds.
Hot wires connect on pole
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Original non-photoshopped photo
7900 volt distribution
Strain clamp and silicone strain insulator

Power company installed new poles for freeway construction.
When new poles were wired and energized, the old poles were taken down.
Hardware was removed from old poles.
This assembly was left along freeway overnight .... I picked it up from the ditch, photographed it, then returned it to the ditch 2 days later. It was about 36" long.
Surprising was that the fins on the insulator were rubber (silicone) material, as was the coating around the insulator.
The fins are for dissipating heat and preventing flashover.
Resources:
Composite-insulators.pdf
suspension clamp
220,000-240,000 volt Transmission assembly
Resource:
Hubbell-Power-Systems-Deadend.pdf

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Subtransmission installation
Quadrant Strain Clamp
Quadrant style deadends or strain clamp
Let the wire make 45% bend


Resource:
Hubbell-strain-clamp.pdf
Anderson-dead-end-clamps.pdf

230,000-324,000 volt Transmission assembly
(Insulator shortened for illustration)

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Strain clamp and porcelain strain insulator
This older installation used porcelain strain insulators and wood pole. The function was to bring 3 Hot wires and a neutral across the freeway and connect onto the 3-phase distribution line that runs parallel to freeway.
The pole and wiring were updated when new freeway construction required poles pushed back farther away from road.
The wood pole was replaced with a 26,000 lb spun concrete pole, all new wire and hardware installed and the porcelain strain insulators were replaced with new style silicon insulators. Pin type porcelain insulators were still used with the new installation.
Resource:
Hubbell-Tee-and-jumper.pdf
Hubbell-dead-end-strain clamps.pdf
Anderson-dead-end-clamps.pdf

Compression Tees are used  when there is no pulling stress on the conductor
Strain clamps, shown above, are designed to hold the conductor by force without splaying apart the conductor and interfering with conductivity ... while compression Tees, splices, and line repairs must be concerned with conductivity between two different surfaces.
"There are three general connector functions; to tap, to terminate, and to splice conductors." This is accomplished various ways, but always two conductive surfaces coming together.
"Two conductor surfaces (e.g. connector and cable) can never be perfectly matched. On a microscopic level, each surface resembles rough terrain with peaks and valleys. When the two surfaces come together, the peaks from one will randomly match up with peaks on the other surface, forming what are called A-spots.
A-spots are ideal because they theoretically have zero voltage drop.
In actuality, however, there may be very few A-spots. So when voltage is applied, the current will flow, but only through the A -spots. The restriction of current flow to these few points constitutes the contact resistance.
For an electrical connector to achieve its objective, it must develop as many true A-spots or electrical contact areas as possible.
There are two ways to increase A-spots. 1) Pressure-applied connectors (mechanical and compression technologies where surfaces are flattened, broadened, and increased in quantity), or 2) fusion connections (soldering, brazing and welding technologies where the application of heat and the introduction of a joining medium create an alloyed boundary).
The goal is to increase the connection quality, by lowering contact resistance ... which will be determined by the electrical contact area (A-spots) established at the time of installation. Thus, a connection's long term performance is directly related to the quality of the original installation. However, not only must the connector’s true electrical contact area be maximized during installation; it must also be maintained over the intended life of the connection."
Factors working against a good connection include surface contaminants or corrosion at time of installation, thermal fatigue from amp flow and direct sun, mechanical stress from wind and ice, long term corrosion from moisture, salt and age etc. Source
neutral connection
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Rosenberg Texas
3-phase 7200 volt distribution lines
Neutral connection at top of pole
:Neutral from pole north of freeway, tied to Neutral line on south pole using 2 compression fittings
Neutral connected to top cap insulator using side tie
Compression connection is accomplished with hand tool that looks similar to bolt cutter

Resource:
Grounding steel poles
Crimping tools

neutral connection
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Aluminum distribution clamp

Before installation, both conductors are cleaned with wire brush and coated with inhibitor

Resource:
Crimping tool pdf
Cutters pdf
Distribution pole
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Distribution pole assembled on ground
Poles are delivered without hardware, and dropped in location where each will be set.
Linemen install hardware that is assembled to specification.
For example the polymer riser (insulator) must be set at specific distance from bottom of pole, and from each other etc.

Wood poles are used for spans up to 50 meters.
Wood poles rot underground after 20-25 years
Cannot be used for voltages higher than 20 Kv

Resource:
Mechanical design of overhead power
Power pole tool
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Power pole tool: Cant Hook
Linemen use ordinary tools: drill, wrench, stapler
They also use specialized tools such as the tool shown (cant hook) that is made specifically to roll the pole, or keep it from rolling.
They use climbing spikes and safety belt when ascending and descending pole.
power pole tool- cnnt hook
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Cant Hook
Neutral compression connection to ground wire
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Distribution pole assembled on ground

top of power pole
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Top of power pole
A shackle insulator has been added to pole.
This is a type of strain insulator that lets linemen install a short line to another pole for local service
Standoff for ground wire
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Standoff is for holding the neutral wire that will drop down to the transformer, or to the ground wire, and ground rod.
Extra length of neutral wire looped back in toward the pole will be attached to Neutral wire at top of pole.

Shackle or spool insulators can be made of ceramic, glass, polymers etc and are used to hold the triplex drop line going to a home.

The fiberglass guy strain insulator is attached to pole at one end and guy wire at other end. The purpose is to insulate the guy wire from any possible contact with live voltage from the pole.

Resource:
Guy strain insulator .pdf
Standoff for ground wire
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Standoff for neutral wire
Each wooden pole on the distribution grid has a Neutral-ground wire that travels down the side of pole.
Standoffs are used to keep the neutral wire away from hot wires ... And help prevent possible arcing from the hot to metal parts on the pole and then to ground.
Once the neutral is below the height of the hot wires, the ground wire is attached directly to pole.
The neutral also connects to Neutral going to business or home
At the transformer, a ground wire is connected to neutral and to each transformer
Bottom of pole, the ground wire enters the soil at a depth specified by local code to meet proper ground for the type of soil conditions

Resources:
3-phase electric
Household electric service
Why you need ground
Formulas-for-Ohms-law
Standoff for ground wire
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Standoff for Neutral wire with Neutral wire attached
Extra wire will be connected to Neutral wire at top of pole
Neutral compression connection to ground wire
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Neutral compression connection found where neutral wires are connected together at top of pole, or connected to ground wire.
Hand crimped connection using crimp tool, Every pole has a Neutral-ground wire.
The ground wire going into the soil at base of each pole always connects to Neutral
The Neutral wire runs down side of pole to the soil when a ground connection is made
Each ground is connection is determined by type-of-power plus location, type of soil etc

Neutral wire runs from pole to pole across the entire grid.
Ground wire is connected to each neutral across the grid to stabilize and protect grid from overvoltages, surge etc.

Before installation, both conductors are cleaned with wire brush and coated with inhibitor
Neutral compression connection to ground wire
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Copper ground wire at bottom of power pole: Butt coil
Depth of pole into ground is determined by engineers during planning stage
Once the pole is set in the soil, the weight of pole helps the ground make contact with soil
Using a coil of wire on the the bottom or butt of the pole is common technique.
Using a butt plate is another method.

A butt coil is made from the #6 copper wire that is stapled to side of pole.
The copper wire is coiled on the bottom, and pieces cross each other to maximize contact.
In addition to the coil, a ground rod is also driven into the soil to depth that is specified by engineer.
Depth of ground rod is based on resistivity and dampness of soil.
The ground must reach soil that is permanently damp... and below the frost line
This installation is done in a damp Texas coastal region with clay soil.
Dense soil such as clay has less resistance to ground than dry rocky soil.
The best soils are dense, non-frozen, clay. The worse soils are loosely compacted gravel with a permafrost.
Grounding specifications vary by soil, type of pole, voltage, etc.

Resource:
Why you need ground
Overhead grounding standards pdf
Standoff for ground wire
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Ground wire, ground rod, butt coil, guy wires etc are pre-installed on pole before pole is set in hole.

"Connections in a ground network are subject to severe corrosion, high mechanical stress due to electromagnetic forces, and rapid thermal heating due to high current magnitudes during fault conditions."
In addition to the physical strain, ground connections must also withstand high thermal shock due to the passing of fault current. Depending on how the ground system electrodes were sized and the duration of the fault, conductor temperatures may reach 250°C (maximum for copper in tension applications) to well in excess of 600°C (copper melts at 1085°C). The connector must be capable of handling these extreme temperatures without loss of integrity."
Source
Neutral wire runs full length of pole to the point where the ground wire connects.
Here is the connection point between the copper ground wire and the aluminum-coated steel wire that runs to top of pole
On some poles, the copper wire is used for full length of ground.
In this instance, the aluminum-coated steel or aluminum wire is used since it is cheaper.
The bare copper wire is #4.
Copper can never be installed above the aluminum to prevent copper salts from washing down on aluminum.
The Neutral wire on each pole or tower, no matter if pole is wood, steel or concrete, or used for transmission, subtransmission or distribution, is bonded (connected) to a ground (earthing) located at bottom of pole.

The massive array of grounding protects the grid from overvoltages, lightning strikes etc and carries throughout the grid, all connected together by the Neutral wire continuously from power plant to end user.
Guy wire connection
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Guy strain insulator connects to pole.
Guy wires cannot be energized with electricity. To solve problem, guy strain insulators are attached to pole at one end and then attached to guy wire lower down. The guy wire is then attached to anchor that is driven into ground.

Resources
Performed-Guy-Strain-catalog.pdf
Preformed_Guy_Strain_Insulator.pdf
Guy wire anchor
The load resistance of an anchor is based on soil conditions.

Resource:
Hubbell anchors

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Assembly of parts before installing guy wire for new pole

Resource:
Guy markers
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Tripleye® Guy Adapter with a Pulling Eye is made for attaching 3 guy wires to a single anchor.
Other guy adapters are made for 1 or 2 guy wires.
Load capacities vary by type of soil and are determined by installation torque.
Each guy wire has a Guy Grip that wraps around the guy wire and attaches it to the guy anchor.
Guy wires do not carry voltage and are safe as long as attached to the guy anchor. In Houston, a boy was electrocuted when a loose guy wire was being used as a 'grapevine' for swinging back and forth. Guy wire came into contact with live power up at the transformer.

Guy markers are important for safety. Without the yellow guy marker, it would be easy to walk into a guy wire and trip or injure oneself easily.

Resource:
Hubbell anchors
Hubbell anchor tools
Guy grips
Steel guy wire is stronger and less expensive than alternative metals

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Guy wire

''Down guy travels downward at angle and is attached to guy wire made of 7-strand galvanized wire. Diameter of wire and number of guys vary by load requirement.
The guy wire is attached to the anchor. Parts include the lead section, and extensions.
The anchor lead section and extension are screwed into the soil to the correct depth based on soil and load. A soil probe is used test the soil, and results compared with charts that give correct soil classification. Extensions are used to increase depth.
The guy wire connects to an extension which is connected to the anchor. The entire guy assembly is connected together and to the pole using hardware such as anchor rods, thimble eye, couplings, eyebolt, eyenuts, shakel, clevis, wrap guy, guy lock, guy grip.

The down guy is covered with a shield at the bottom, called a guy marker. The purpose is to make guy wires visible to the eye and avoid collisions and encounters with people, animals etc that might get hurt or damage the guy.''
Resources:
Guy markers
Guy anchors
Aluminum conduit standoff
Deadend-guy-en.pdf
wire and wire ties
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Rosenberg Texas
Formed Wire:
Deadends for Guy Wires, laying on ground next to 7/8" diameter distribution conductor (wire).

In lineman slang, wire ties are called wiggle wires.
Wire ties are used to attach the conductor to the insulator at each pole, and attach guy wire to anchor etc.

Wire ties are prefabricated for each wire size

When viewing electric repair trucks and supply trailers on the road, you can see the pre-fabricated ties hanging on back of vehicle



Resource pdfs
Lineman slang
Hubble
Brenco
Formed-wire
Connect electric wire to insulator
Electric supply trailer
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Top cap
Top cap is one type of insulator used to keep wire away from pole.
Wire can be attached to top of cap, or on side
Top cap is type of insulator used to keep wire from touching the pole

Insulators are required to withstand mechanical and electrical stress.
Electrical stress is caused by line voltage... failure is caused by a crack or puncture and flashover.

Higher voltage/ the greater the cost of insulator
Over 33Kv, a suspension insulator is used instead of a pin type insulator


Resource:
Mechanical design of overhead power
Electric supply trailer
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Preformed Tension Clamp
Preformed Wraplock Tie
Top cap and side tie
Top cap sitting on disturbed soil near freeway construction.
Prefabricated tie partially om the cap
Tie has rubber insulator to hold wire away from insulator

Electric supply trailer
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Wire, side tie, top cap.
Same image as above, photoshopped. with photo of Neutral wire
Electric supply trailer
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Simulation of connection using photoshop.
The tie wire is wrapped 1 turn around cap
Rubber insulator on side tie forms a barrier between wire and cap
Tie is twisted around the wire.



Connection at top of pin insulator
Resource:
Preformed Wraplock tie
Types-of-insulators.pdf


Pulling new subtransmission wire
sheavesLarger image

Pulling new subtransmission wire requires specific size sheaves depending on size of wire etc.
The power company set this metal crate at base of each pole.
Each sheave has 3 separate wheels so power company can run 1,2 or 3 wires.
See image

Next they raised each sheave, one at time, up to the correct height where two men in a bucket truck attached the sheaves to the 3 line post insulators.
sheave
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Line post insulator is made from hydrophobic silicone polymer, or silicone rubber compound.
Bottom Fitting is an aluminum Gain Base.
The live end fitting on this one is called a Tear Drop Blade. Other types include Horizontal Clamptop. Source Hubbell

The power line was designed for two conductors (wires).
Each wire was pulled separately.

Resource:
Line-post-Insulators.pdf

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There are 3 large spools of wire at one end of the pull that are held in a machine called a tensioner, and at other end is a machine called a puller.

First they run 3 steel cables from the puller that is strung through each sheave and goes to the tensioner.
The 3 pull cables are attached to the 3 conductors at the tensioner. See image

The puller pulls the wire through the sheaves to the end point, while the tensioner reels out the cable, ensuring the wire is not pulled so hard that it splays apart the strands. The wire must maintain it's structural shape and design to function correctly.
Damaged wire can overheat, causing inefficiency and point of failure.

 Double String Dead End
Polymer Assembly


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