Horizon Utility Supplies Ltd supply the Electricity Supply Industry with Tooling & Equipment for the maintenance of the network.

Posted by Louis Ashley – 01.01.01

Load sensors – developed for the marine industry by Cyclops, the minds at Cambridge University and INEOS TEAM UK designed the load sensors to allow sailing teams to find that extra gear again and again in all conditions, maximise speed and protect their rig – taking the guesswork out. They have found that the design and technology used in the load sensors are a great fit for many different industries, including the electrical utility sector.

Below you’ll find further information on the load sensors available and their current applications in the Electrical Utility Sector.

When a line team prepares to lift a pole, tension a conductor, or reposition heavy equipment at a substation, the stakes are high. A single misjudged pull or overloaded sling can damage assets, interrupt supply, or, worst of all, cause a life-changing accident. For Distribution Network Operators (DNOs) and utility contractors, the modern alternative to “feel”, rules of thumb, or paper logs is clear: make every lift a known, measured quantity.

This article explains why that matters, how digital load cells (like Cyclops) deliver a step change in safety and operational control, and what a practical rollout looks like for a UK utility operation.

The fundamental problem: uncertainty in the field

Many lifting and line-tensioning tasks still start with experienced crews estimating loads based on past practice. That tacit knowledge is valuable — but it’s also fallible:

- environmental conditions (wind, ice, uneven ground) change the forces on a lift;

- hidden asymmetries, snagging, or dynamic effects can create brief overloads;

- Temporary rigging configurations or unusual geometry can invalidate rules of thumb.

Those unknowns make some lifts “near misses” in waiting. Turning those unknowns into measured data reduces risk dramatically - the logic is straightforward: known load = managed load = safer outcome.

The regulatory & standards backdrop: measurement supports compliance

UK guidance and standards emphasise planning, competence, and control in lifting operations. The Health & Safety Executive (HSE) points employers to established standards and best practice for lifting operations, urging thorough planning and competent supervision of lifts. Using measurement and monitoring aligns directly with that duty of care.

British Standard BS 7121 (the accepted consensus for safe use of cranes and lifting operations) and related guidance underscore the importance of ensuring equipment is suitable for its intended load and that lifting operations are planned and controlled. Accurate, real-time load monitoring helps demonstrate that the correct equipment was used and that safety limits were respected throughout an operation - supporting both safety and auditability.

For DNOs, operational rules and asset-specific procedures (and where applicable, Network Rail or other infrastructure body requirements for joint works) demand traceable evidence that safe practices were followed. Integrating measured load data into permits, job packs, and handover records strengthens compliance and reduces ambiguity when incidents are reviewed.

What a digital load cell does — and why “digital” matters

A load cell converts force into an electronic signal. A digital load cell, such as those from Cyclops, goes further: it contains on-board signal conditioning and digitization, reducing noise, improving accuracy, and simplifying integration with displays, dataloggers, or wireless systems. Compared with analog transducers, digital load cells tend to deliver more stable readings in electrically noisy or harsh field environments - exactly where DNO work happens.

Key technical benefits of modern digital load cells for utilities:

Higher signal integrity - less susceptibility to interference from site equipment.

Built-in diagnostics - alerts for overloads, cell health, or tamper conditions.

Direct digital interfaces - simpler integration with recording systems and dashboards.

Improved repeatability & resolution - enabling better decision thresholds for crews.

Wireless capability reduces the need for trailing cables across live sites, speeds up setup, and enables multiple stakeholders - site supervisor, remote control room, or safety officer - to see the same live numbers simultaneously. That improves situational awareness and collaborative decision-making.

Operational use cases for DNOs

Below are high-impact, practical scenarios where Cyclops digital load sensors convert uncertainty into controlled outcomes:

A. Pole and gantry lifts/replacements

When replacing a wooden or composite pole, asymmetrical load transfer can momentarily spike forces on slings or winches. Real-time load measurement ensures the lift stays within rated capacities and flags unexpected load transfers immediately.

Benefits: prevents gear damage, avoids slings blowing past safety margins, reduces risk to workers on-site

B. Conductor stringing and tensioning

Stringing requires control of conductor tension; over-tensioning risks conductor damage or tower failure, and under-tensioning causes poor line behavior. Cyclops monitor units on winches or tensioners give precise, logged values for each pull.

Benefits: consistent tensioning, fewer reworks, and preserved asset life.

C. Transformer or plant handling in substations

Large piece lifts in constrained substations require absolute clarity on load direction and magnitude. A load cell in the rigging chain gives operators confidence when guiding heavy, valuable plant through tight clearances.

D. Emergency recovery and storm response

During storm recovery, crews work fast under pressure. Portable, quickly-deployable digital load cells allow responders to make safe, auditable lifts under dynamic conditions and collect log data for post-event review.

Benefits: faster, safer recoveries with traceable records for post-incident learning.

E. Continuous Monitoring for Network Insight — Long-Term Load Behaviour & Sag Trends

In situating a digital load cell, such as the Cyclops system, on a conductor, winch or tensioning assembly for extended periods, a utility can convert a once-off measurement device into a continuous data platform. Over days, weeks or seasons, the load cell remains in situ and streams live load and force data to remote supervisors or asset-management systems.

This continuous feed enables engineers to correlate load/tension fluctuations with ambient conditions — for example: conductor sag changes with temperature, wind, ice or seasonal load; tension peaks during surge or maintenance events; or gradual drift indicating rope or rigging wear. For overhead transmission lines, research shows that tensile-load variation from seasonal conditions strongly influences sag and safe clearance margins — making ongoing monitoring of sag and load a significant maintenance enabler.

Benefits: By integrating the Cyclops load cell’s time-stamped data into the network’s asset-management framework, a DNO gains: Real-time alerts when loads exceed predetermined thresholds; Trending insight into how environmental conditions affect operations (e.g., higher tension in cold winter than in the summer warmth). Predictive maintenance triggers when repeated anomalies or drift appear.Audit-ready records of all load events for compliance and post-event review.

This use case turns a lifting/tensioning tool into a network-resilience sensor, supporting smarter decision-making across the field and control rooms.

Addressing common concerns

“Won’t the sensors get damaged or complicate work?”

Cyclops-class devices are designed for tough sites; choose models with appropriate IP rating and overload protection, and use simple mounting fixtures to minimise setup time. Regular training and maintenance checks keep complexity low.

“How do we know the data is trustworthy?”

Digital load cells with on-board diagnostics and signed data logs reduce tampering risk. Routine calibration and documented maintenance further prove data integrity. HSE and BS guidance both emphasise the value of demonstrable records in managing lifting risk.

“Is wireless safe in electrically noisy substation environments?”

Modern wireless load systems are engineered with robust protocols and shielding for industrial sites; in addition, a dual display (local and remote) helps guard against single-link failures. Always test the chosen system in representative sites before full rollout.

Beyond safety: operational efficiency and asset lifecycle benefits

• Measured lifts deliver more than accident prevention:
• Fewer reworks and reduced asset damage. Correct lifts first time, save the costs and network interruptions caused by damaged poles, conductors or plant.
• Faster decision-making in the field. When supervisors can see live load numbers, they can approve or pause operations immediately rather than relying on subjective judgment.
• Better maintenance planning. Load data can reveal repeated overload events or trends that suggest rigging or lifting equipment needs servicing.
• Data for continuous improvement. Logged lift records feed into post-job analysis and training, helping to institutionalise safer procedures.
• These benefits map directly to DNO priorities: reducing unplanned outages, improving safety KPIs, and lowering lifecycle costs of assets.

Conclusion — making every lift measurable is making every lift safer

For DNOs, the case is simple: lifting operations are a persistent source of risk and cost. The move from subjective estimation to objective measurement reduces risk, creates auditable proof, improves operations, and supports a culture of continuous improvement.

Cyclops digital load cells give field crews the visibility they need, safety teams the evidence they require, and network operators the operational confidence they demand. In short: when every lift is a known quantity, the whole network is stronger.

Download our full guide: "Making Lifting Measurable"

Horizon Utility Supplies Ltd. stock a large range of Material Handling equipment

Cable Installation & Pole Handling | Slings, Stockings & Swivels | Hoists, Pullers & Dynamometers | Cable Jacks & Drum Rollers | Cable Grips

Contact us with enquiries

contactus@hor-i-zon.com

+44 (0) 1275 342 700