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PROJECT:-765KV S/C RAIGARH-CHAMPA TL.

SAFETY ASPECTS OF CONDUCTOR INSTALLATIONS


IN
TRANSMISSION LINE
METHODS ADOPTED FOR CONDUCTOR INSTALLATIONS IN 765 KV T/L

a) Mechanized Paying out of conductors and installation

Manually

b) Manual Paying out of conductor and its manual installation.

TYPE OF RISK ASSOCIATED:

a) Fall of workmen from height

b) Fall of objects from height, on workers and co-passers –by

c) Collapse of towers, conductors and hardware

Fittings on workers and passers –by

d) Electrocution due to contact of person /

Conductors with live wires

e) Hit by Vehicles (Workmen and co passers-by)

CONSEQUENCES OF ACCIDENTS:
a) Fatality / Injuries to workers

b) Fatality / Injuries to co-passers by

c) Loss to properties including public property

d) Lost of man-hours resulting in time and cost overruns

e) Public resentments, disgrace

f) Punishment under the relevant laws


VARIOUS STAGES OF WORK IN THE INSTALLATION OF
CONDUCTORS IN TRANSMISSION LINE

a)Insulator and aerial roller hoisting

b) Paying out of pilot wire

c) Paying out and sagging of Earth wire.

d) Paying out of conductor

e) Rough sagging

f) Final sagging

g) Clipping and fixing of line spacers

h) Fixing of jumpers

i) Stringing of river crossing reaches

j) Power line crossing

k) Stringing across Highways and other service roads

l) Transportation and stacking of conductor drums and


Hardware fittings
HAZARDS ASSOCIATED AT VARIOUS STAGES OF WORK:

SL
ACTION PERIODICI
NO HAZARD INVOLVED REMEDIAL MEASURES CHECK POINTS REMARK
BY TY
.

INSULATOR AND ARIEAL ROLLER HOISTING


1. a) Fall of workmen from a) *Use of fall arrester must be ensured for CHECK FOR--- A) REGULAR The most

cross arm sitting location A) *Fall arrester. And for each hazardous
making vertical movement over tower.
* Good condition double insulator aspects of
or while ascending and * Proper use of double lanyard type full body
lanyard Safety belt. string insulator
descending over tower. harness shall be ensured.
b) * Availability of 12mm dia hoisting. hoisting is
b) Fall of insulator string
b) * Proper fixing of cotter pins/split pins wire rope as a lifter. when
or other tools and tackles.
must be ensured before hoisting insulator * Good condition single workmen
c) Hit by tractor in path of sheave pulleys of bearing b) REGULAR uses to get
string.
his maneuvering. type only. And for each down
* Check the wire rope (12mm) being used for
d) Hit Injury or crush * Additional safety rope insulator through
insulator string hoisting for any type of visual
injury while handling used foe securing single string insulator
damage.
sheave pulleys of open hook hoisting. string for
insulator boxes and heavy
* Before hoisting proper working condition type. SITE releasing
aerial rollers. ENGINEER
both the single sheave pulleys shall be * Good condition 16mm dia c) REGULAR guide rope
/ GANG
ensured and also only bearing type pulleys wire rope sling. For every road tied with
* License and driving skill of LEADER crossing bottom yoke
shall be used.
operator/ driver. plate or with
* if open hook type single sheave pulleys are
IMPORTANT CHECK: D) Regular aerial roller.
being used , then additional safety rope shall
1. Before insulator hoisting and for every
be used for avoiding its accidental release.
tower erection must be lot of insulator
* only 16mm dia wire rope sling should be complete in all regards. boxes.
used for securing single sheave pulleys with 2. more importance shall be
tower members provided , precautions has given to cross arm i.e all the
been taken against sharp edges of tower connecting bolts and tower

members. members must be in properly


intact condition.
* Check for proper connection of aerial roller
with insulator string.
3. Always avoid bending of insulator string  M

while hoisting i.e. P.P rope or wire rope shall a


n
be tied with 3rd or 4th insulator disc from top.
e
Bending of insulator string may lead to failure
u
of R-clips.
v
c) * Only licensed and well trained driver e

shall be engaged for operating tractor, used r


i
for insulator string hoisting.
n
* If at all any road crossing exist in
g
maneuvering path of tractor, presence of ‘
p
SIGNALMAN’ must be ensured .
a
d) *Over height stacking of insulator boxes t
h
shall be avoided at location.
o
* Wooden planks having nails shall be kept
f
well away from site to avoid nail prick.
t
*WEARING OF SAFETY HELMET AND SAFETY
r
SHOE IS MUST BY ALL PERSONNELS a
IRRESPECTIVE OF NATURE OF JOB. c
COMMAN PRACTICE: it is very common practice t

of using step bolts, in D-shackles and in aerial o


r
roller assembly , which are not meant for heavy
.
loading and always suspected to failure.

PAYING OUT OF PILOT WIRE


2. a) Minor cut injury to A) Periodical visual inspection of pilot Condition of pilot wire
Condition of P.P rope being Site
fingers due to wires for wear and tear and other visual
used Engineer
protruding wires of damages shall be done.
Effective Use of PPE’s / Gang
pilot wire. B) Use of leather type hand gloves shall Jhulla arrangement Leader

b) Fall of workmen be ensured to minimize the severity in IMPORTANT CHECK: it is


generally noticed that local
from cross arm case of such incident.
lineman uses to give
position/ aerial roller
shutdown of 11kv and 33kv
(for passing P.P rope C) Use of double lanyard full body hare power lines and fitters of
stringing gang uses to lower
through roller) Or ness shall be insured.
the conductor after de-
otherwise during Double arrangement for ascending over
energizing the line.
ascending and insulator string shall be done as follows— Following min. precautions

descending over tower. D)) Lanyard of safety belt shall be must be ensured in such
operations---
c) Hit injury while wrapped around the insulator string.
1. be perfectly sure about
handling pilot drum E)) Jhulla arrangement made of 20mm
distribution feeder (of the
reel. P.P rope, controlled from ground shall be particular line) , installed in

D) Over turning of used. substation .


2. Ensures the does not have
tractor while F) Regular pep talk shall be done and
any looping with other line
transporting pilot awareness should be created among
near by and then decide the
drum workmen regarding safe handling & point of opening jumpers.(

reel. transportation of pilot drum reel. views of local people must


be taken regarding the rout
E) OTHERS: F) Pilot wire connectors shall be checked
and interconnection of line)
1.pilot wire for any type of visual damages in –
3. Before opening the
connectors: Pin and its threaded portion jumpers ensure the line is

Roller & U-portion discharged through bundling


the conductors by passing a
G) Visual checks shall be done for
p.p rope over it.
2. eye splicing in pilot condition of eye loops made in pilot wire
4. Ensure the use of hand
wire before every use. gloves meant for working on

H) Obtain proper shutdown before HV/EHV lines.


5. The conductors shall be
3. Power line / road or lowering the conductors of any line
lowered and kept in bundled
highway crossing crossing.
condition.
(chances of I) Proper scaffolding capable of bearing
electrocution / injury load of pilot wire and conductors shall be
to co passers. made for every P&T and road crossing.
J) Suitable warning signs with signalman
(equipped with walky-talky) shall be
deployed at every road crossing
irrespective of its type and users.

PAYING OUT OF CONDUCTOR


POSITIONING OF TSE MACHINES
Hit injury to A) Proper care shall be exercised while shifting
3. workmen— machine to a long distance.

Site Engineer / TSE operator / gang leader


Toppling of machine B) Check air pressure and find out the suitable
while approach road for shifting.
shifting/placing C) While shifting no workmen shall be allowed
ride over it.
D) Well-experienced tractor driver shall be
taken for the task.
E) TSE machines shall be properly anchored
with dead-end anchors in the ground. The
preferable angle with ground should be 45* or
less.
F) The puller shall be placed at a distance
(from Ist normal tower), not less than three
times the tower height.

PRE PAYING OUT CHECKS

4. A) DRUM POINT
A) Cut injury in fingers A) Hand gloves shall be used while handling IMPORTANTCHECK: A) place

while placing two ends wire meshed single/ double end shocks. the conductor drums at least
30 M back to the tensioner
and single ends B) Watch out for protruding wires, and
machine.
shocks. removes the same by cutting plier and if the
B) Check weather the
B) Hit injury or cut wire mesh is severely damaged replaces it
conductor release from drum
injury while placing with new one.
and entry into machine is
drum lifting jack or C) Place the drum-lifting jack on firm and level smooth and free from
conductor drums. ground to avoid is toppling. obstruction.
C) Failure at D) Never replace drum-mounting shaft with C) The area between drums
headboard assembles any other inferior means such M.S or tor steel and TSE machine must be

point. used for reinforcement work. Use only kept barricaded to avoid
unauthorized entry.
recommended connectors only in drum lifting

SITE ENGINEER / GANG LEADER


jack.
E) Check the Physical condition and load
bearing capacity (from test certificate of
supplier) of swivel joints (articulated joints)
provided behind Headboard.
F) Check the condition of wire rope and single
end wire meshed shocks before applying the
load.
G) place suitable capacity D-Shackles at each
joint.

PULLER POINT
A) Cut injury in fingers A) Proper personnel precautionary measures
while handling pilot shall be ensured in pilot wire reel (while
wire reel. removing from puller machine after complete

SITE ENGINEER
B) hit injury/hit injury binding).

/GANGLEADER
while handling ( --Same as above--
loading/unloading) of
pilot wire reel.

GUYING OF DEAD-END
TOWER
Failure of guy The make-up end tower shall be properly IMPORTANT CHECK: angle of

anchorage or guy rope guyed before with the help of 18mm dia wire turn shall be maintained for
guy rope according to the
itself resulting in rope and deadment anchor. The tightening of
turn of line . angle of guy
damage of tower turnbuckles shall be done carefully to avoid
rope shall not be more than
(cross-arm) extra loading on cross arm. Pit for dead ment,
45* with cross arm.
Fall of person from standards of logwood shall be maintained as
Ensure effective tying of wire
height while mentioned above. rope with cross arm.
Ensure use of fall arrester for ascending and
descending over tower.
Ensure use of double lanyard full body harness
while working at height.
Ensure use of lifeline for making horizontal
movement over cross arm.

PAYING OUT OF CONDUCTOR


TIGHTIENING OF PILOT WIRE FROM
PULLER END
SEVERE HIT INJURY This is the most critical & hazardous IMPORTANT CHECKS:
SIGNALMAN WITH RED &
TO WORKMEN AND activity of machine paying out operation.
GREEN FLAGS WITH
SIDE PASSERS, It is well known that pilot wire are laid on
WHISTILES MUST BE PALCED
ANIMALS & ground through out entire section IN BETWEEN EACH BEFORE

SITE ENGINEER
VEHICLES (ROAD proposed for paying out. When puller STRATING PILOT WIRE
TIGHTIENING OPERATION.
CROSSING) starts tightening, pilot wire uses to uplift
AT LEAST TWO SIGNAL MAN
with high swing and speed.
WITH FLAG AND WALKI-
TALKI SHALL BE POSTED ON
ALL ROAD CROSSINGS.

PULLING OF CONDUCTORS
a)SEVERE HIT A) While conductor paying out is under IMPORTANT CHECK:
The entire section proposed
INJURY TO progress one supervisor (must be capable
for paying out shall be
WORKMEN AND of making effective communication with
checked for visual
SIDE PASSERS, puller and tensioner operators and other
hindrances such trees,
ANIMALS & intermediate personnel’s positioned at
buildings & any other type of
VEHICLES (ROAD road / power line crossings) must have to structures where headboard
CROSSING) move with head board. can stuck.
B) FAILURE OF B) check out for free running of aerial Branches of tress falling in
PILOT WIRE OR rollers and also obstruction free passing the line of headboard are

PILOT WIRE of head board , mid-span joints ,pilot more dangerous, and it must
be cleared without taking
CONNECTOR connectors by deploying signalman’s at
any chance.

SITE ENGINEER / GANG LEADER


RESULTING IN HIT every tower . hey may tasked with
INJURY. keeping vigil in between spans so as to
keep unauthorized personnel’s away from
particular phase corridor.
C) Check SWL of pilot wire connector and
its physical condition and also instruct
operator (puller) slow down pulling when
connector uses to enter in bull wheal of
puller machine.

MAKE UP & ROUGH SAGGING OF


CONDUCTORS
FAILURE OF Ensure the effective depth for deadment IMPORTANT CHECK:

DEADMENT ANCHOR (depth not less than 6.0feet) and also condition
10.0-12.0 FEET
/ FAILURE OF CAME of wood log(length not less than 6.0 feet and
ALONG CLAMP. dia. 10-14inches)or steel beam of suitable 6.O’’

section shall be ensured.


Use of 18mm or 20mm steel wire rope in good
condition shall be used for holding conductors.
ENSURE THE EFFECTIVE DEPTH
Check the condition of came along clamps& D- OF DEADMENT NEALRY 6.0

shackles being used for holding conductors for FEET.

SITE ENGINEER/ GANGLEADER


ENSURE THAT WIRE ROPE
following---
EMEREGS (FROM GROUND) AT
A) Liner condition of came along clamp.
LEAST 10.0 –12.0 FEET AWAY
B) Availability of all bolts& nuts and packing FROM TOP OF PIT. FOR THAT

washers. SLOPE CUTTING AT 45* SHALL


BE ENSURED TO AVOID DIECT
C) Availability of both side check nut.
UPLIFT LOAD ON DEADMENT
D) Suitable capacity of D-shackle (min. 5.0 ton
ANCHORE.
best suited 10.0ton capacity)
E) never replace the pin of D-shackle with any
other means.

FINAL SAGGING OF CONDUCTORS

CHECK FOR SAGGING ARRANGMENT AND


TOOLS & TACKLES
FAILURE OF TOOLS CHECK POINTS IN FINAL SAGGING IMPORTANT CHECK:

AND TACKLES ARRANGMENT. Use articulated joint of


capacity not less 3.0 ton
RESULTING IN We must note final sagging is the most
with 12.0 mm wire rope
critical activity of stringing which involves
used in between four-
application of very have load and failure of
sheave pulley
any kind can disastrous. Such as fall of
arrangement to avoid
towers injuries to workmen. kinking or twist in wire
Before finalizing the tools and tackles we rope.
must give attention over sag chart and P.P rope shall be tied at
select the section that requires heaviest both end of four sheave

Site engineer /gang leader


loading and accordingly select tools and pulley shall be used to
avoid its turning.
tackles for all sections.
The 12.0mm wire rope
GENERAL CONSEDRATION ACSR (QUAD)
lead coming out from four
D/C LINE
sheave pulley set should
A) Check the condition of sag plate and
be routed through close
condition of welding. in. thickness of sag type pulley positioned;
plate shall be of 12mm. A) Near tip of the cross
B) Use min. 15ton capacity D-Shackle for arm.
connecting sag plate with four-sheave pulley &

lifter arrangement. B) Near bottom rafter of


cross arm with tower leg.
B) Use good condition 12.0mm dia. Wire rope
A min. of 10.0 ton
for making lifter arrangement with two four
capacity sag winch shall
sheave pulley sets. Both four sheave pulley
be used for giving load.
shall be separated a min. length 50.0-60.0M
wire rope of 12.0mm dia. length of lifter
arrangement should be sufficient enough so as
to ensure tightening of conductor.
C)one set of lifter arrangement uses to lift two
conductors in quad arrangement and one
conductor in twin conductor arrangement.

Accordingly select the suitable capacity of four- Always avoid sudden loading
during final sagging
sheave pulley block (SWL of min. 10.0Ton for
operation.
quad and 5.o ton for twin).

Site engineer /gang leader


Check point for sag winch:
Equalizer pulley and four-sheave pulley shall be A) Check the condition and

connected directly with 15.o ton capacity D- suitability of bolts being used
for holding sag winch with
shackle.
tower leg.
V-sling used for holding conductors shall of—
B) proper working of locking
A) 18.0mm wire rope for twin conductors arrangement.

B) 22.0mm wire rope for quad conductors. Three bolt earth wire clamp
or automatic clamp shall only
Use twin came along clamps for holding single
be used for providing extra
conductor.
safety lock to wire rope after
giving final load from sag
winch.

MARKING AND CONNECTING OF


CONDUCTORS WITH HARDWARE
FITTINGS

CLIPPING ACTIVITY
JHUMPERING AND SPACERING
Incorrect and may
lead to failure of
cross –arm from
leg member and
cross-arm rafter
join position

Correct
sequence of
looping wire
rope from single
sheave pulleys ,
in insulator
hoisting.
COMMAN CAUSES OF ACCIDENTS IN THE WORK OF INSTALLATION OF CONDUCTORS IN T/L
1. General lack of awareness and commitment to safe working methods by workers, supervisors,
& site Engineers.
2. Negligence in using appropriate personnel protective equipments at work places.
3. Lack of knowledge and experience in proper use of personnel protective equipments.
4. By passing / ignoring safety rules for reasons of misconceived convenience for faster
Execution of work.
5. Use of an inappropriate / damaged tools and tackles.
6. Failure of tension bearing materials/ equipments.
7. Inadequate guying of towers or failure of tension bearing tools.
8. Improper or over tightening of conductors during sagging operations.
9. Lack of good communication and commuting facilities.
10. Lack of proper training and continuing education to workers, supervisors and
Engineers in construction methods.
11. In adequate supervision of work by qualified and experienced personnel.
12. Lack of discipline in controlling non-compliance of safety regulations.
13. Exhaustion due to over working by workers.
14. Scattered working locations, difficult in having proper control over work locations.
15. Difficult terrains and natural topography
MEASURES AND PRECAUTIONS TO BE TAKEN IN WORK OF INSTALLTION OF CONDUCTORS IN T/L

PREPARATORY WORKS

1. Preparation of towers – tower shall be complete in all regards before starting stringing

operation.

2. Guying arrangement of towers shall be done as per given work procedure

3. Inspection and testing of tools and tackles ( follow checklist)

4. Inspection of personnel protective equipments for adequacy and workability.

5. Pre-task briefing to workmen and gang leaders before starting the job and fixing of

accountability.

6. Information and caution to general public through caution boards and sign boards.

7. Identification of nearby hospital /medical center as a emergency preparedness.

8. Removal of tress and other visual obstructions in line corridor.

9. Identification of existence, source and listing power lines in section where the work is set out.

10. Arrangements for road or highways crossing coming in pathway of line corridor.

11. Providing temporary earth electrode for stringing equipments.

12. Adequate no. of First –Aid kit shall be made available at all work places.

13. Any restrictions on patter n of loading of towers shall be ascertained from designer.

14. Ascertaining for restrictions on placement of pulleys and application of tension for hoisting and

sagging operation.
COURSE OF WORK
1. checking of all the towers immediately before commencement of insulator hoisting, for tightening
punching, tack welding and availability of all members.
2. Positioning of pulleys for hoisting of insulators and other materials and equipment to be done
correctly to avoid improper pull on the cross arms and towers. (Refer insulator hoisting
Methodology)
2. Clear path for maneuvering tractors puling the hoisting slings for lifting material /
Tensioning.
4. Availability of gang leader to co-ordinate pulling and lifting operation.
5. Proper counter weight anchors or log anchors to be installed for guying the towers, tension and
puller equipments and for holding conductors under rough sag.
6. Turn buckles used for stay wires should be tightened periodically.
7. All workers working at height above 2.0M heights shall have to wear safety belt.
8. Effective and clear communication system shall be made available
METHODOLOGY OF STRINGING

Stringing Methods & General Aspects


Methods of stringing.
There are basically two methods of stringing. These are
i) Slack or Manual methods
ii) Tension method
i) Manual method:
Using this method, the conductor is pulled along the ground by means of a pulling vehicle (normally
tractor),or the drum is carried along the line on a vehicle and the conductor is deposited on the
ground. The conductor drums are positioned on drum stands or jacks either placed on the ground or
mounted on a transporting vehicle. These stands are designed to support the drum on an arbor, thus
permitting it to turn as the conductor is pulled out. Usually, a braking device is provided to prevent
overrunning and backlash. When the conductor is dragged past a supporting structure, pulling is stopped
and the conductor is placed in travelers attached to the structure before proceeding to the next
structure.
ii) Tension Method:
Using this method, the conductor is kept under tension during the stringing process. Normally, this
Method is used to keep the conductor clear of the ground and obstacles, which might cause conductor
Surface damage and clear of energized circuits. It requires the pulling of a light pilot line into the
travelers, which in turn is used to pull in a heavier pulling line. The pulling line is then used to
pull in the conductors from the drum stands using specially designed tensioners and pullers. For lighter
conductors, a lightweight pulling line may be used in place of the pilot line to directly pull in the
conductor.
STRINGING PROCEDURE

The stringing procedure is broadly divided into the following steps.


i) Paying out & stringing of earth wire.
ii) Guying arrangement of tower
iii) Insulator and aerial roller hoisting
iv) Paying out of pilot wire
iv) Paying out & stringing of conductor.
v) Final sagging of earth wire & conductor.
vi) Clipping and fixing of accessories.
vi) Fixing of line spacers
viii) Fixing of jumpers

i) Paying out & stringing of earth wire:


Normally stringing of earth wire is done manually since handling the earth wire is easy and it does not
get damaged easily. First, earth wire rollers are provided on the earth peaks of all the suspension
towers in the section. Before hoisting of earth wire rollers, it may be ensured that the rollers are
free from friction.
A lineman/ fitter may be kept on each tower to ensure free running of the rollers with a red & Green
flag and whistle. At the starting end of a section, earth wire reel is mounted on roller jacks or
horizontal turntable. The earth wire is pulled from tower to tower manually or by using a tractor. After
reaching the next tower the earth wire is passed through the suspended earth wire rollers with the help
of a polypropylene rope and paying out is continued further. After one length of earth wire reel is
exhausted, the second length of wire is paid out for the balance section. Mid span joint for earth wire
is compressed on the ground joining the two lengths.
Guying arrangement of tower
Before commencement of stringing, the angle towers where the stringing is to be started have to be
Provided with guy supports for all the three phases. The guys used generally are 20mm steel wire rope.
The guys are attached to the tower at the tip of the cross arms and center of the bridge, to the strain
plates with suitable D shackles. The guys are anchored in the ground at an angle of 45
Degrees or less from the horizon, attached to dead end anchors. For making dead end anchors in the
Ground, pits of 1.5mx0.6m, for a depth of 1.5m can be dug. A set of steel beam and channels tied in the
center with 16mm wire rope, is lowered and the pit is back filled while compacting. The guy wire is
attached to the dead end anchor wire with the help of turnbuckles of 10 tonnes capacity.
Alternately, instead of buried ground anchors, a dead weights of sag 5 to 10 tonnes can be placed on
the ground and sag wire attached to them securely. After pulling up the slackness in the guy, it is
tightened by the turnbuckle. Excessive tightening of the guy should be avoided. It is advisable to
tighten the guy progressively at the time of rough sagging of the conductor.
Insulator and aerial roller hoisting
Transportation of Insulators
The required no. of insulators shall be transported to the tower locations with the wooden packing.
The crates shall be opened at the tower location. The Insulator hoisting is done well in advance of
Commencement of paying out operation.
HOISTING:
After opening of the crates, insulators shall be laid in series, on wooden planks below the suspension
points. The insulators shall be cleaned with water and wiped dry with clean cloth free from grease and
oil. Insulators shall be checked for any chipping or crack and shall be replaced with new one if found
defective. The no. of insulators required for string shall be joined and `R' clips in the clevis shall
be expanded to avoid slippage of the pin.
The joints of all insulators should be checked and `R' clips should be expanded.
The bottom insulator is joined to the moose aerial roller. The five wheels of the aerial rollers should
be checked for free running. The neoprene rubber cushion on the outer rollers shall be checked for any
cracks/wearing out and shall be changed if required.

A single sheave pulley is fixed to the cross arm very near to the suspension hanger. A 20 mm polypropylene
rope or 12mm wire rope is passed through the pulley and both the ends are brought to the ground. One
end of the rope is firmly tied below the 3rd or 4th insulator. The complete string with aerial roller
is lifted up by pulling the rope through a pulley attached to one of the tower legs by using
tractor/manually After reaching the top the string is attached to the suspension hanger and string is
released slowly to hang free.
INSULATOR HOISTING
Paying out of pilot wire
In tension stringing, a pilot wire is used to pull the conductor. The pilot wire is initially laid
through the center wheel of the aerial roller. A 22 mm dia pilot wire is generally used for pulling
of quad moose ACSR conductor. The pilot wire can be laid length by length and joined with pilot wire
connectors.
At power line crossings, the pilot wire is laid from both sides and free ends are joined after obtaining
the shutdown of the power line. Sound Scaffoldings shall be provided for P&T and road crossings before
paying out of the pilot wire. A stand signalman shall be ensured with Red and green flag and also with
walky-talky to ensure effective communication pilot wire pulling equipment (Tractor or Puller).
Paying out & stringing of conductor.
A) Position of tensioner and puller:
The paying out of conductor is done generally between two tension towers. The puller machine can be
Positioned behind the tension tower on one side and the tensioner in front of the tension tower on the
other side. The entry of the pilot wire into the bull wheels of the puller machine and running out from
tensioner machine should be as nearly horizontal as possible. Both the machines should be securely
anchored with two dead end anchors in the ground and slackness is removed in the stay.
The placement of drum jacks should be such that the lateral angle of conductor approach into the bull
wheel through guide rollers is low enough to avoid rubbing on the sides and creating loosening of the
outer strands and bird caging. The distance of the drums from the tensioner shall be at least 25 to 30
mtrs so as to distribute the effect of sliding of outer strands due to low back tension. The reel should
be positioned so that it will rotate in the same direction as the bull wheels.
Paying out of conductor:
For passing the conductor through the bull wheels of the tensioner, a 25 mm polypropylene rope is
initially wound over each bull wheel pair in the same way as the conductor will pass during Running.
The ropes are connected to the conductors. The conductor run shall be from the topside of the drum. The
rope is pulled by starting the tensioner at low pay out tension to pass the conductor through bull
wheels and are brought out through the guide rollers. The sub conductors are attached to the equalizer
pulley/running board by means of wire mesh/end socks and swivel joints. The pilot wire is attached to
the other end of the running board with swivel joint. At the puller site, the pilot wire is pulled to
remove all slackness using the reel winder. The wire is passed through bull wheels of the puller and
connected to the reel winder machine. The tensioner can be initially set for a tension of 2 to 2.5
tones. Caution should be made over the wireless hand set to all the Staff who are at middle points and
to the tensioner operator that pulling is about to be started so that they can stay clear of pilot wire.
The puller is started to draw up the pilot wire until the bull wheels of the tensioner start moving.ow
paying out of Bundle conductors with tensioner and Puller. Care should be taken that the pilot wire does
not get entangled in trees, scaffoldings, Aerial rollers etc. while going up during tensioning. This
can be monitored by the staff who are posted in between the section and guiding the puller operator over
the wireless sets. The pulling of the conductor may be done at a moderate speed while the running board
is passing through the aerial rollers.The tension in the tensioner must be adjusted so that the conductors
travel well over the ground. In long spans where conductor is likely to touch the ground, ground rollers
may be placed so that the conductor can pass without any scratches. A running ground shall be connected
to the conductor and pilot wire before paying out near the tensioner and puller which shall be earthed
at the nearest tower. Platforms shall be erected with sturdy bellies, where roads, rivulets, channels,
telecommunication or overhead power lines, railway lines, etc. have to be crossed during stringing
Operations. It shall be seen that normal services are not interrupted or damage caused to property.
The back tension of the conductor behind the tensioner has to be maintained as per the requirement of
the tensioner deployed. The back tension is adjusted by means of brakes provided on the drum jack. A
running ground shall be connected to the conductor and pilot wire before paying out near the tensioner
and puller which shall be earthed at the nearest tower.
The speed of pulling of the conductor should be such that to achieve smooth operation. Slower speeds
may cause significant swinging of the running blocks and insulator hardware assemblies. Higher speeds
can create greater damage in case of malfunction. The tension applied during stringing generally is
about half the sagging tension. When long lengths of conductors are strung, the tension at the puller
may be higher than that at tensioner due to the length of conductor strung, number and performance of
travellers, differences in elevation of supporting structures etc.

Jointing of conductor:
Just before one length of the conductor paying out is completed another drum has to be deployed in
advance beside the first drum. The paying out has to be stopped by braking the tensioner and stopping
the puller simultaneously. The paid out conductor of first drum is held with bolted come-along clamps
at a distance of 40 to 50 mtrs from the tensioner. The come- along clamps are attached to the ground
anchor stays. The conductor of the first drum is held and the free end is cut. The free end of the
second drum is also prepared. The two ends are joined with a wire mesh mid span socks. The paying out
is again started by releasing the come along clamps until the mid span socks emerges outside the
tensioner and pulling is stopped. After anchoring, the conductor is slowly drawn out from the two end
socks. The mid span socks is removed and mid span compression joint is made.
After making mid span joint, the joint is covered with joint protector sleeves which is designed to pass
over the aerial roller grooves without damaging the mid span compression joint. The paying out is
continued until the conductor reaches the puller end in sufficient length to be connected to the
Tension hardware.
Rough sagging of conductor
Before final sagging the conductor, it is rough sagged to a tension slightly less than the final
Tension. Since final sagging is done from one end of the section, the conductor is initially attached
to the double tension string assembly on the other end. For doing rough sagging, initially the double
tension string assembly is assembled with insulators and hardware and hoisted to the cross arms/bridge
as done in the case of suspension towers. The dead end cones are compressed on both the sub conductor
ends. The conductor is held by come along clamps at a distance of 5 to 6 mtrs from the dead end cones
and with the help of a pulley connected to a ground anchor, the conductor is pulled to slacken the free
end of conductor (sufficient length to be attached to the hoisted insulator string assembly).By holding
the conductor with pulley, the dead end cones are attached to the tension string. The pulley is slowly
released and the conductor will haul-up itself to the top. The come along clamps and pulley etc. are
removed.
Final sagging of conductor
The sagging of the conductor shall be done using sagging winches. After being rough sagged the conductor
shall not be allowed to hang in the stringing blocks for more than 96 hours before being
Pulled to the specified sag. The tensioning and sagging shall be done in accordance with the approved
stringing charts before the conductors are finally attached to the towers through the insulator strings.
Only after the conductor is rough sagged on the adjacent section, final sagging can be done in the
preceding section to avoid overloading of towers. For doing the sagging operation, a span has to be
selected in the section to fix the sag board and check the sag. In the event of using sag tension charts
showing sags in each of the actual spans and tension in each section, usual practice is to place the
sag boards in the longest span of the section, and in a span where the difference of elevation in the
two suspension points is minimum.
The tension insulator strings are hoisted with all hardware on the tower. The conductors are held by
come-along clamps and attached to Separate four sheave pulleys at sufficient distance of say 40 to 50
mtrs depending upon rough sag condition and height of the tower. The other ends of the four-sheave
pulleys are connected to the line side yoke plate of the double tension string. The pulling wires of
the four-sheave pulley are passed through a set of single sheave pulleys along the body of the tower to
the ground level. The initial pulling is done with the help of tractor/truck. Then the
Pulling ropes are attached to hand winches mounted on the legs of the tower or power winches duly
Anchored. Wooden cross bars are tied to the body of the four sheave pulley and held by ropes in a
Horizontal position to avoid over turning of the four-sheave pulley and twisting of the pulling wires.
The conductor is brought into final sag position with the help of winches and the sag is checked by
sighting far end sag board from behind the near end sag thread by matching elevation tangent of the
conductor curve. Sighting should be done keeping sufficient distance from the sag line to avoid parallax
error.
After reaching the final sag, the free end of the conductor is picked up and pulled by rope and pulley
attachment along the line of the string. The conductor is marked at the point where cutting is to be
done and dead-end cone is to be pressed. The free ends of the conductors are brought down and cut near
the marking and dead end cones are pressed. The four-sheave pulley is slightly tightened to facilitate
attaching the dead end cone to the tension assembly. After fixing, the four-sheave pulley is slowly
released, brought down and all clamps and pulleys are removed.
Clipping of conductors:
The clipping of the conductor follows sagging operation. This entails removing the conductors from
The rollers and placing them in suspension clamps attached to the insulator string. Before taking
Up clipping operation, the conductor is earthed properly on suspension towers. The conductors are
Held with hooks at 2 mtrs away from the aerial roller on both sides. A wire rope is connected to
Both the hooks passed through a pulley positioned on the cross arm tip in series with a pull-lift/ratchet
lever hoist/four or two-sheave pulley. The center of the aerial roller is marked on the conductor. The
conductor is raised by about 75 to 100 mm and the aerial roller is removed and lowered by rope and
pulley. The suspension clamp and armoured rods are fixed with neoprene rubber cushions centered over
the marking. The suspension clamp is placed over the armored rods and clamped with U bolts. The suspension
clamp is connected to the string and the lifting device is
Released. The insulator string will hang freely with the conductors suspended in the clamps. The
Verticality of the string may be checked with plumb bob. Care should be taken to prevent any damage to
the conductor while being lifted by hooks. Gunny bags or rubber pads may be used around the conductor
to prevent damage to the outer strands.
Fixing of line spacers :
Following the clipping operations for bundled conductor lines, spacers are usually installed. This is
done by placing personnel on the conductors with the use of a conductor cycle normally known as spacer-
cycle to ride from structure to structure. Depending on the length of line to be spaced and the equipment
available, cycles may be hand powered or diesel powered. Care must be exercised to ensure that the
concentrated load of the man, car and equipment does not increase the sag sufficiently to cause hazards
by obstructions (spacers, repair sleeves, mid span joints etc.) over which the cycle will pass. The
installation of the spacers on the conductor varies with span length, the type and manufacture of the
spacer and is normally done in accordance with the manufacturer's recommendations duly approved. The
spacer cycle is hoisted on the bundle at one tension end. In case of engine-powered cycles, the spacer
cycle is normally provided with travel meter, with the help of which the spacers are fixed at required
distances as per the placement chart. In case of hand-powered cycles, the personnel pulling the cycle
with rope measure the distances on ground and placement is done on the top. A number of models of spacers
are being manufactured and the method of installation varies with the design of the spacers. After
reaching the next suspension tower, the cycle is transferred to the next span by crossing the suspension
clamp with the help of crossing ropes provided in the cycle. In case of spans crossing HT/LT lines, care
should be taken while drawing the spacer cycle with rope. Safe electrical clearance should be maintained
to the spacer cycle and rope. For crossing the lines, the rope shall be drawn up to the cycle, and
brought down after crossing the line, keeping sufficient clearance from the line. The person on the
cycle can travel himself to cross over the section above the power line.

Installation of dampers:
Vibration dampers/spacer dampers are normally placed on the conductors immediately following clipping
to prevent any possible damage because of vibrations to the conductors, which at critical tensions and
wind conditions can occur in a matter of hours.

Jumpering
The jumpers at the section/angle towers shall be formed to parabolic shape to ensure minimum clearance
requirements. Pilot suspension insulator string shall be used if found necessary (Generally where angle
of deviation is more than 45 degrees), to restrict the jumper swings to the design values at both middle
and outer phases. Clearance between the conductors and ground, jumpers and the tower steel work shall
be checked during erection and before commissioning the line. While jumpering is made, a local earthing
should be made to avoid any static discharge that might occur due to the voltage induced on the line by
existing power lines in the vicinity. Care should be taken to leave jumpers for one angle tower in a
continuous stretch of 25 to 30 kms, so as to prevent transmission of electric shock. These left out
jumpering can be taken up during final inspections. The individual sections jumpered shall be kept
earthed and earth shall be removed only before commissioning. The jumpers in general are 10 to 15 mtrs
in length. Hence left over bits of conductor shall be used for jumpering. For installation of jumpers,
the distance between the jumper pads of dead end cones is measured by passing a rope in the shape of a
jumper and by checking vertical clearance from the cross arm end. Conductor is cut after making adjustment
in length for the jumper cone dimension. The inner and outer conductor of the bundled jumper are of
different lengths, which shall be measured separately. This will ensure a horizontal plane of the jumper
bundle when installed. After cutting the conductor, jumper cone is pressed using hydraulic compressor.
The conductors are laid out on the ground parallelly and spacers are fixed as per the fixing instructions.
The jumper is hauled up from both ends of the tension clamps and jumper cone is attached to the connector
of the dead end cone. Clearance to the tower body shall be checked as per the drawing.
STRINGING SAFETY CHECK LIST
SAFETY ASPECTS OF TOWER ERECTION
IN
TRANSMISSION LINE

METHODS OF ERECTION
There are THREE main methods of erection of steel transmission towers, which are described, as below

i. Built-up method or piecemeal method.


ii. Section method
iii. Ground assembly method.
Built up method
This method is most commonly used in this country for the erection of 66 KV, 132 KV, 220 KV and 400 KV
Transmission Line Towers due to the following advantages.
i. Tower materials can be supplied to site in knocked down condition which facilitate easier and
cheaper transportation.
ii. It does not require any heavy machinery such as cranes etc.
iii. Tower erection activity can be done in any kind of terrain and mostly through out the year.
iv. Availability of workmen at cheap rates.This method consists of erecting the towers, member by
member. The tower members are kept on ground serially according to erection sequence to avoid search
or time loss. The erection progresses from the bottom upwards, the four main corner leg members of the
first section of the tower are first erected and guyed off. Sometimes more than continuous leg
sections of each corner leg are bolted together at the ground and erected.The cross braces of the
first section which are already assembled on the ground are raised one by one as a unit and bolted to
the already erected corner leg angles. First section of the tower thus built and horizontal struts
(bet members) if any, are bolted in position. For assembling the second section of the towers,two gin
poles are placed one each on the top of the diagonally opposite corner legs. These two poles are used
for raising parts of second section. The leg members and braces of this
section are then hoisted and assembled. The gin poles are then shifted to the corner leg members on
the top of second section to raise the parts of third section of the tower in position for assembly.
The gin pole is thus moved up as the tower grows. This process is
continued till the complete tower is erected.Cross-arm members are assembled on the ground and raised
up and fixed to the main body of the tower. For heavier towers, a small boom is rigged on one of the
tower legs for hoisting purposes. The members/sections Are hoisted either manually or by winch
machines operated from the ground. For smaller base towers/vertical configuration towers, one gin pole
is used instead of two gin poles. In order to maintain speed and efficiency, a small assembly party
goes ahead of the main erection gang and its purpose is to sort out the tower members, keeping the
members in correct position on the ground and assembling the panels on the ground which can be erected
as a complete unit. Sketches indicating different steps of erection
by built up method are shown at Figure 4.1 to Figure 4.7.
Guying arrangement

Guying arrangements are to be done at waist level/bottom cross-arm level as well as in the girder
level/top cross-arm level depending on SC/DC towers and it is to be installed at 450 from vertical. The
deadments for guying arrangements are to be properly made. A sample of deadments drawing is enclosed
at Figure 4.8 for reference. Guying should be steel wire or polypropylene rope depending
Upon requirements. Nominal tension is to be given in guying wire/rope for holding the tower in
position.

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