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Fairfield Electric Cooperative (Blythewood, South Carolina) has completed the construction of 20 MVA Woodcreek Substation in Elgin, South Carolina. The project technician found that the bus and switch connectors were installed incorrectly. Contractor's use of untrained crew did not completely reduce contact with the manufacturer's advice. Some accessory connections are not completed.

Given the time constraints, Fairfield Electric consulted with AFL (Duncan, SC) to correct the problems. AFL is the only manufacturer to offer a full line of substation fittings for bolted, welded and compression applications. Fairfield Electric operates 23 substations in Fairfield, Kershaw, Richland, Chester and York counties in South Carolina. At their Lockhart Substation in Chester, SC, Fairfield Electric crews were trained by AFL engineers to install 2-inch Swage Bus Tees. Fairfield was impressed with the quality of the Swage compression connections. Equally critical was the time-savings. Swage technology installs in minutes rather than hours compared to the standard welding process.

Kevin Shull, Assistant Manager of Operations and Engineering says, “AFL immediately supplied a solution within our tight time frame and got what we needed to the job site. AND they helped us install it. Together we fixed all the incorrectly-installed fittings and completed the installation in two days to get the substation energized and operational.”

The split fitting connection being installed in the video, demonstrates the Swaging process. The unique value of a split fitting connector, using swage technology, is that a fitting can be installed over the existing bus pipe without cutting the bus and the process does not interfere with the existing bus arrangement.

Fairfield Electric is able to restore the substation project as scheduled by following AFL's Swage Compression Connection Terminal and Bus Connections. The Woodcreek substation is powered on-time to ensure reliable and robust power to meet the growing power needs of the Fairfield service area. The increased grid capacity will also allow the unloading capacity of other large Fairfield substations planned to be upgraded.

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