Welding high voltage Power Distrubution stations

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I have a little deal coming togeather I may be getting into. It will be welding aluminum on high voltage power distrubution stations.I am wondering if there is anyone on here who has done this kind of work, and if there is any advice you might offer.
Reply:Don't piss on anything that hums.  That's all I got...My name's not Jim....
Reply:I work for a Utility doing power plant maintenance work. I've welded on aluminum bus and iso-phase in the plant and in the switchyard. One of the most enjoyable jobs in my career has been welding lugs onto bus tubes on the top of a tower out of a 150ft aerial lift. Try Tigging in mid air, running a foot pedal out of a swaying bucket truck if you want a challenge! Most contractors that do this kind of work use spool guns, though. Mine was broke down at the time. The wind can be a huge factor outside, so always have a wind screen with you, and believe me, you'll have to be creative with that one! If there is anything specific you need to know, don't hesitate to ask, and good luck!
Reply:Oh, and a word of caution! ALWAYS look for yourself to make sure that the power company has protective grounds in place on the conductors that you will be working on. Don't take thier word for it...look for yourself. If it isn't grounded don't go within 20 feet of it!. High voltage can jump a looong way! If it's new construction, that's a different story, just make sure the conductors haven't been attached to the grid yet. Remember, electricity doesn't give you a second chance!
Reply:Originally Posted by welds4dI work for a Utility doing power plant maintenance work. I've welded on aluminum bus and iso-phase in the plant and in the switchyard. One of the most enjoyable jobs in my career has been welding lugs onto bus tubes on the top of a tower out of a 150ft aerial lift. Try Tigging in mid air, running a foot pedal out of a swaying bucket truck if you want a challenge! Most contractors that do this kind of work use spool guns, though. Mine was broke down at the time. The wind can be a huge factor outside, so always have a wind screen with you, and believe me, you'll have to be creative with that one! If there is anything specific you need to know, don't hesitate to ask, and good luck!
Reply:We don't have a spool gun any longer, we use the Miller MIG Runner setup with a 30 ft XR-A push pull, but I still prefer the TIG. I set a wp-18 up with about 150 ft of hoses for this use. When we get into the really heavy stuff, we have a wp-12 (500 A) torch, due to the capacity limitations of the tungsten, mainly. The 18 will only handle 5/32" and when you're pushing 300+ amps it just can't take it. Some of the bus work we have is up to 1/2" thick. I know.. why not MIG 1/2" alum.? But when the Substation Supervisor insists that it be Tigged...
Reply:Would love to see some pics of any of the setups you guys are welding on, if you have any.  I work around a lot of 480 at the ski hill but high voltage fascinates me.
Reply:+1 Pics would be awesome
Reply:Not sure that's possible, for security reasons. They get kind of funny about stuff like that. Our plant generates at 20,000 volts and is stepped up for transmission to 500,000. It will definitely stand the hair up on the back of your neck when you walk under a power line on a muggy day!
Reply:One theoretical consideration is that pure aluminum has better electrical conductivity than most or all aluminum alloys.  That would suggest 1100 alloy welding wire.  However, 1100 alloy is pretty soft.But you have to use the alloy which is specified on the job.At the high currents that others are talking about, wouldn't you need to use darker lenses in your helmet, and leathers?RichardSculptures in copper and other metalshttp://www.fergusonsculpture.comSyncrowave 200 Millermatic 211Readywelder spoolgunHypertherm 600 plasma cutterThermal Arc GMS300 Victor OA torchHomemade Blacksmith propane forge
Reply:To be honest, I don't know what the base alloy is. The specs call for 4043, so that is what we use. Never had any weld related issues at all. Yes, darker shades are required, and my Speedgas is adjustable up to shade 13. I've never used leathers, but I normally wear FR coveralls all the time. Make sure to button that top collar button or you'll end up with a nice red triangle at your neck. At the higher amps, insulated gloves, like for stick welding, are sometimes needed. I've even had to use one of those aluminized reflective hand covers.
Reply:Originally Posted by welds4dTo be honest, I don't know what the base alloy is. The specs call for 4043, so that is what we use. Never had any weld related issues at all. Yes, darker shades are required, and my Speedgas is adjustable up to shade 13. I've never used leathers, but I normally wear FR coveralls all the time. Make sure to button that top collar button or you'll end up with a nice red triangle at your neck. At the higher amps, insulated gloves, like for stick welding, are sometimes needed. I've even had to use one of those aluminized reflective hand covers.
Reply:Originally Posted by MrBeastIt sounds like I am fixing to hit quite a learning curve.
Reply:Originally Posted by welds4dBeast, I'm assuming you're already proficient at TIG and MIG of Aluminum. If you are, don't get freaked out. It's just like shop welding... except that you're hanging from your toes, upside down, while swinging from a rope....just kidding...   I forgot to mention that the super long wp18 setup that I made included a slider switch on the torch handle, to replace the foot control. After using the foot pedal out of the lift, it seemed like the logical thing to do.
Reply:Keep at it and you'll do great...patience is key when TIG welding the heavier aluminum. Let the base metal heat up a bit with a lower, non-melting amperage, til it warms up. You'll see it get 'sweaty looking' when it starts to get right. If you try to throw a huge amouny of amps into it cold, it will make for a really ugly weld. Switchyard welding is really fun, and the linemen that you might get to work with have some cool toys!
Reply:Originally Posted by welds4dKeep at it and you'll do great...patience is key when TIG welding the heavier aluminum. Let the base metal heat up a bit with a lower, non-melting amperage, til it warms up. You'll see it get 'sweaty looking' when it starts to get right. If you try to throw a huge amouny of amps into it cold, it will make for a really ugly weld. Switchyard welding is really fun, and the linemen that you might get to work with have some cool toys!
Reply:How has the switchyard work/practice been going?