Case Study: Conquering the Andes

Stringing a 500kV transmission line in High-Altitude Mountainous Terrain

The Client: A national utility contractor in South America (e.g., Peru / Chile).

The Challenge: This was a nation-building project: a new 500kV transmission line connecting a remote hydroelectric dam to the national grid. The route crossed the Andes mountains, presenting extreme challenges:

• Extreme Altitude: Operations were conducted at over 4,000 meters (13,000 ft), which saps engine power and strains hydraulic systems.

• Difficult Terrain: Many tower sites were inaccessible by road, requiring helicopter support.

• Massive Spans: The deep, rocky valleys required "super-spans" of over 1,500 meters (nearly one mile) from tower to tower.

The Solution: The contractor needed raw, reliable power. For this high-tension, large-span project, they selected our top-tier SA-YQ220 (22-ton) Heavy-Duty Hydraulic Puller. This unit was paired with our SA-YQZ220 Hydraulic OHTLstringingequipment.com/Hydraulic-Conductor-Tensioners.html target='_blank'>Tensioner to manage the bundle-OHTLstringingequipment.com/Conductor-Stringing-Equipment.html target='_blank'>conductor stringing.

• High-Power Engine: Our puller is equipped with a premium (e.g., Cummins) diesel engine, which was specially calibrated to perform reliably even in the thin, high-altitude air.

• Extreme Pulling Force: With 22 tons of pulling capacity, a single machine had the power to handle the immense weight and tension of pulling the conductor across 1,500-meter spans.

• Durable Hydraulics: The machine's closed-loop hydraulic system is designed for high-load, continuous-duty operations, preventing overheating even during the slow, hours-long pulls required for such distances.

The Execution: The project was grueling. After a drone or helicopter flew the initial pilot line, our anti-twisting steel pulling rope was pulled across. Then, the SA-YQ220 puller began its work, slowly and steadily pulling the bundle-conductors (two, three, or four cables at once) from the Tensioner site. The machine's power and stability were critical. In one of the most challenging sections, the machine operated for over 8 hours continuously to complete a single span, performing flawlessly.

The Results: Despite the extreme weather and terrain, our equipment delivered the consistent power needed to complete the project. The contractor successfully energized the line, bringing vital renewable energy from the mountains to the country's load centers. The robust performance of our machines in such a harsh environment cemented our reputation as a trusted partner for the most demanding transmission projects in South America.

Do you have a difficult terrain project? Let's equip you for the challenge.