Rethinking Automatic Splices:
Challenging Routine Work Practices and a Call for Change in the Electric Utility Industry
Written by: Ken Lulow
The use of automatic splices in the electric utility industry has become a widely accepted practice, primarily due to their ease of use and time-saving qualities. Line workers appreciate their simplicity, and utilities often favor them for their speed in restoring power during emergencies. However, their frequent and routine use raises critical concerns about their long-term impact on grid reliability, safety, and efficiency.
A deeper examination of automatic splices reveals serious limitations and risks that utilities, engineers, and line workers must confront. The findings from a pivotal BC Hydro study, conducted after identifying significant automatic splice failures, underscore the importance of this discussion.
Lessons from BC Hydro: A Case Study
BC Hydro undertook a comprehensive study after experiencing a high volume of automatic splice failures. The investigation revealed that 46% of the automatic splices surveyed were at risk of failure, an alarming statistic that prompted action. This realization became a critical issue as the utility prepared for the 2010 Winter Olympics, where ensuring uninterrupted power was paramount.
BC Hydro decided to systematically replace automatic splices with compression splices across its grid. The result? A notable improvement in reliability, reduced failure rates, and fewer service interruptions. Their proactive stance set a precedent that other utilities should carefully consider.
Unpacking the Risks of Automatic Splices
1. Structural and Electrical Weakness
Automatic splices rely on gripping the outer strands of aluminum conductors but do not connect to the steel core of ACSR conductors, which provide the integral strength of ACSR conductors. This design introduces vulnerabilities, particularly under mechanical stress or extreme weather conditions such as high winds, rain, or saltwater fog.
Environmental Impacts: Rain and saltwater fog corrode the internal components of the splice, degrading the connection over time. Poor compression of the splice sleeves leads to compromised electrical conductivity, increasing resistance and causing hot spots.
Mechanical Integrity: Without anchoring to the steel core, the splice becomes the weak link in the conductor's strength, especially during heavy loading conditions or ice storms.
2. Impact on Ampacity and Efficiency
Automatic splices reduce the ampacity of the conductors they are installed on. As society transitions toward greater electrification, every inefficiency matters. Studies have shown that automatic splices create higher electrical resistance, leading to energy losses and reduced power factor. Over time, this waste translates to real financial losses for utilities and their customers.
3. Installation Errors
The success of automatic splices depends heavily on proper installation. Conductors must be:
Cleanly cut, free of damage or defects.
Thoroughly cleaned and brushed to ensure a rough, abrasive surface for a better connection.
Unfortunately, improper preparation and rushed installations are common in the field, further increasing the likelihood of failure.
4. Undocumented Failures
Most automatic splice failures go untracked or are misattributed to other causes like vegetation or general equipment failure. This lack of documentation prevents utilities from identifying weak links in their grid and addressing them proactively.
Compression Splices: A Better Alternative
Compression splices address many of the shortcomings of automatic splices:
Stronger Mechanical Connection: Some Compression splices bond directly to the steel core of ACSR conductors, ensuring greater tensile strength.
Improved Electrical Conductivity: The compression process creates a tighter connection, reducing resistance and minimizing energy losses.
Enhanced Durability: Compression splices are less susceptible to environmental degradation, making them a better choice for areas with extreme weather conditions.
The data from BC Hydro and other utilities demonstrates that switching to compression splices leads to fewer failures, greater reliability, and long-term cost savings.
The Role of Line Workers and Utilities
Utilities and line workers play a pivotal role in ensuring the integrity of the grid:
Routine Maintenance: Utilities should adopt policies to remove automatic splices during routine maintenance, particularly in critical areas like roadway crossings, wildfire-prone zones, and saltwater environments.
Emergency Use Only: Automatic splices should be reserved for emergency repairs where speed is paramount. Once the immediate crisis is resolved, these splices should be replaced with more reliable alternatives.
Training and Awareness: Line workers need comprehensive training on proper installation techniques and the risks associated with automatic splices.
A Call to Action
The utility industry must challenge the normalization of automatic splices. Engineers, planners, and line workers should prioritize grid resilience and efficiency over convenience. The evidence is clear: replacing automatic splices with compression splices reduces failures, saves energy, and improves public safety.
Recommendations:
Establish a Maximum Number of Splices: Utilities should limit the number of splices allowed in a single span of wire. Beyond a certain threshold, the entire span should be replaced.
Document Failures: Create systems to track and analyze splice failures, identifying patterns and addressing weaknesses in the grid.
Invest in Quality Repairs: While automatic splices have a place in emergency restorations, they should never be a long-term solution.
Moving Toward a More Reliable Future
As the push for electrification continues, the demands on the electrical grid will only grow. Addressing weak links like automatic splices is critical to meeting these challenges. Utilities that take proactive steps to phase out automatic splices in favor of compression splices will not only improve reliability but also position themselves as leaders in safety, efficiency, and innovation.
The question remains: Will we continue to accept the risks of automatic splices, or will we take decisive action to build a stronger, safer, and more efficient grid? The choice is clear—now is the time for change.
