Increasing Productivity and Safety in Substation Maintenance Tasks

Substations are among the most congested work environments in the utility industry, demanding that workers navigate obstructions in tight spots. Unless mandated by state regulations, many utilities opt for non-insulated mobile elevated work platforms (MEWP) due to their superior maneuverability and lower cost compared to bucket trucks. 

The Challenge 

Articulated boom lifts, such as the Genie® Z-45 XC model, offer significant advantages in substation maintenance. These lifts provide 45 feet of platform height, 24 feet of up-and-over capability, a maximum platform capacity of 1,000 pounds, a 5-foot jib for precise positioning, and zero tail swing, making them ideal for navigating the tight spaces typical of substations.   

A Solution 

For many utilities, best practices have evolved over years of experience. One common practice is to bond the basket of the uninsulated boom lift as well as the chassis, to the de-energized system, creating an equipotential zone (EPZ) that protects workers. Despite this, the repetitive nature of tasks such as transformer maintenance, circuit breaker testing, and inspection of various substation components makes the process of bonding cumbersome, inefficient, prone to error, and relies on operator attentiveness. A better solution is equipment that eliminates the need to bond the basket in these situations. 

The introduction of insulated substation boom lifts, like those manufactured by Genie and upfitted by Terex Utilities, addresses these concerns. These lifts help protect operators from shock hazards due to accidental energization, induced voltages, improperly installed grounds, and violations of minimum approach distances. Historically, utilities used either insulated truck-mounted aerial lifts or custom insulated telescopic booms. While these options helped to enhance safe work practices, they significantly hampered productivity due to their operational constraints. 

Launched in 2021, the Terex Utilities Z-45 Substation Utility Boom (SUB), based on the Genie Z-45 XC model, retains the same handling and performance characteristics while incorporating a fiberglass jib section and bucket for insulation. Meeting ANSI/SAIA A92.20 and complying with ANSI/SAIA A92.2 standards for Category E insulation rating of 20 kV, the Z-45 SUB offers zero tail swing and a dual parallelogram boom structure, making it ideal for confined spaces. 

The Results 

Utility crews have reported enhanced efficiency when using the Z-45 SUB for tasks like installing bus or air switches. Previously, much time was spent repositioning insulated bucket trucks, whereas the Z-45 SUB eliminates repeated setup and bonding procedures, saving significant time. Additionally, the use of battery-powered crimpers enhances efficiency without compromising insulation. 

The Z-45 SUB’s design includes side cutouts for  visibility and a swing gate for easy access, further improving convenience. The Z-45 SUB does not replace the need for proper PPE and work practices. However, it effectively removes workers from path to ground and may provide some protection in case of human error or violation of minimum approach distances. 

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This article was drafted with the aid of AI. Additional content, edits for accuracy, and industry expertise by Jim Olson, Sr. Product Engineer and Craig Ries, Product Safety Engineer.