During maintenance activities on our assets, electricians use temporary grounding clamps to ensure operational safety. AXIA Energy identified the need to improve the design of the temporary grounding clamps used for connection to the ground grid and grounded structures, incorporating insulation integrated into the conductive parts. This improvement aims to increase the level of insulation that protects the electrician in case of an error in the installation or removal sequence of the temporary grounding assemblies. 

1. Impact of the Solution on Maintenance Activities: 

Develop a temporary grounding clamp with integrated insulation for use in lines, substations, and power plants, aiming to: 

• Implement an insulation level that protects electricians from contact with live parts under induced voltage. 

• Improve the functionality and reliability of temporary grounding clamps. 

• Reduce risk exposure, protecting technicians even in cases of procedural errors or when the grounding cable falls during operation. 

2. Technical Requirements: 

• Materials with adequate dielectric properties: Use of insulating materials with high dielectric strength capable of withstanding induced voltages in extra-high voltage lines. Insulation must be equal to or greater than that of a 17 kV insulating glove. 

• Resistance to adverse environmental conditions: The insulation must withstand temperature variations, humidity, vibration, UV radiation, and chemical agents, ensuring durability and performance in harsh outdoor environments. 

• Ergonomics and handling: The insulation must allow efficient operation adapted to the human hand, preventing accidental contact with potentially energized points. 

• Installation and operation: The insulation must allow electricians to inspect the connection between the cable and clamp without the need for special tools or complex procedures. It should have a location that enables safe opening for contact inspection and secure closing. 

• Locking system: Develop a locking system for the insulated temporary grounding clamps to prevent the removal of the clamp connected to the ground side while the phase side is still connected. 

3. Recommended Tests: 

To ensure the effectiveness and safety of the developed insulation system, the following tests are suggested: 

• Dielectric Strength Test: 

Objective: Verify the insulating material’s ability to withstand electrical voltages without dielectric breakdown. 

Procedure: Apply increasing voltage until breakdown or specified value is reached, according to applicable technical standards. 

Standards: Norms for tools used in live-line maintenance, including dielectric and mechanical tests.  

Note: As a result of the project, the frequency of the dielectric strength test to be performed by the AXIA Energy maintenance teams must be defined. 

• • Insulation Resistance Test: 

Objective: Measure the electrical resistance of the insulating material to ensure no current leakage that could compromise safety. 

Procedure: Apply continuous voltage between conductive parts and insulation, measure leakage current, and calculate insulation resistance. 

Standards: Norms defining withstand voltage, dielectric strength, insulation resistance, and mechanical tests for tools used in live-line maintenance.  

• Accelerated Aging Test: 

Objective: Assess the durability of the insulating material under extreme environmental conditions simulating long-term aging. 

Procedure: Expose the material to cycles of temperature, humidity, vibration, and UV radiation, according to technical standards, to verify changes in dielectric and mechanical properties. 

Standards: Norms establishing requirements for materials used in live-line maintenance equipment, including resistance to harsh environmental conditions. 

• Mechanical Strength Test 

Objective: Ensure that insulation does not compromise the structural integrity of the clamp during installation, removal, and potential drops. 

Procedure: Apply mechanical forces simulating usage conditions to verify tensile, compression, and impact resistance. 

Standards: Norms establishing dielectric and mechanical strength requirements for tools used in live-line maintenance. 

• PPE Compatibility Test: 

Objective: Verify that the new insulation system allows the use of gloves without compromising electrician safety. 

Procedure: Perform practical tests with different classes of insulating gloves, assessing the clamp insulation’s effectiveness when used with PPE. 

Deadline:The proposal submission form will be available until 22/08/2025.  

Questions: For any questions or additional information, please send an email with the subject line identifying the title of this challenge to innovationgrid@eletrobras.com