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TRAINING SESSIONS ON CONSTRUCTION, PLANNING & DESIGN OF EHV TRANSMISSION LINES BY S. M.

TAKALKAR
PROPRIETOR
POWER CONSULTANTS & AGENCIES
A / 198 VISHVAMITRY TOWNSHIP, OPP: - GUJARAT TRACTORS, VADODARA - 390 011 Phone: 0265 - 2356291, Mobile: 9879599402/9925233951 Email: smtakalkar@yahoo.com

TATA POWER COMPANY LTD KALIAN

TECHNICAL SESSION – I
Power Consultants & Agencies Page 1

CONSTRUCTION OF EHV TRANSMISSION LINES
1.0 Introduction
1.1 Construction of EHV Transmission line is a very specific and specialized job. It involves lot of precision and accuracy. The transmission line is standing for many years in the open terrain and faces vagaries of nature. The construction practice should therefore ensure that the parameters, on which the design of transmission line is made, are not exceeded. 1.2 The construction mainly includes the following activities. • Survey & Alignment • Foundation Work • Erection of Super Structure • Stringing of Shield wire & Conductor • Testing & Commissioning 1.3 Each of above activity can be further divided into sub‐activities. All the erection activities are based on the design inputs as well as site situation. For example, the type of tower and foundation to be adopted will depend upon the profile & site situation, where as the span/deviation angle limitations will be based on the design factors of the tower. This part deals with the general specifications for construction of EHV lines.

2.0 Survey & Alignment
2.1 Whenever EHV transmission line is to be constructed between two subs‐stations, the ideal route length will be the direct topographical distance between the two stations. However, this will not be possible as number of obstructions in the form of villages, town important civil establishments, big ponds, rivers etc. will prevent the straight run of the line. The obstruction will result into line deviations. It will therefore be necessary to carry out survey by various means. The survey will establish the following: • The topography of the route of the line. • The important deviation points of the line. • The approximate quantity of Towers and extension. • First hand information regarding the soil strata along the route, leading to approximate estimation of foundation work quantities. • The obstructions which may result into line deviations. • Major River, Railway, Road and Power line crossings and type of structures for the same. • Information regarding availability of inputs for foundation work (cement, aggregates steel and water). • Right of way problems which are likely along the route. • Cost of transportation of material to various locations. • Tentative time frame for completing the work. 2.2 It is also usual to make trial pits or carry out soil investigation along the proposed route of the transmission line at certain fixed interval or at the points where abrupt change in soil strata is suspected. This exercise results in to the approximate estimation of the foundation types and
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excavation/concrete volumes and the re‐enforcement for the foundation work. The various stages of survey works are described in details as under. 2.3 Reconnaissance and Route Alignment Survey 2.3.1 A provisional route of transmission line is initially plotted on survey maps (topo sheets) and a reconnaissance/ walkover survey is carried out. This is essential to fix up angle tower positions tentatively, since many of the physical features on the ground may not be clearly available in the survey map due to developments that might have taken place subsequent to the preparation of the maps by department of survey of India. The topo sheets are obtained from the office of The Survey of India Deharadoon by indicating the Longitude & the Lattitude of the proposed route of the transmission line. In most of the cases more than one Topo sheets are required to cover the route of the line.
SCHEMATIC ROUTE ALIGNMENT SURVEY

ROUTE MAP
82°10' 82°15' 82°20' 82°25' 82°30' 82°35'

T-05

T-05

BAGDEWA BLOCK
AR IN G

DILWADIH BLOCK

400KV D/C KASAIPALLI TO BHARARI TRANSMISSION LINE

COA L BE

INDIA(N.T.S.)

N

N

RC

T-05

22°25'

EA AR

JAMMU & KASHMIR
HIM PR AC AD HA ES L H PUNJAB A UTTARANCHAL AN RY HA DELHI

C

22°25'

T-05

l Road Meta
CART TRACK

CAR T TRA

NEPA

RC C

DAM
8/2 8/1 8/0 7/2 7/1 7/0 6A/0 5/0 4A/0 3/0 2/3 9/0 9/1
CK

T-05

GUJARAT

MADHYA

PRADES

Nagrahi Batra Lahrapara

METAL ROAD

9/2 10/3 16/0 16/1 17/0 11/0 15/0 14/1 14/0 13/0 11/1 12/0 10/2 10/0 10/1
EX IS NG TI 40 0 KV TO

CAR T TRA

CO AL

W

ER

NE LI

6/0

BE

AR

CHAPI WATER SCHEME

EX

DUMARKACHHAR BLOCK
24/1 24/2 25/0 PROPOSED COAL EXTENSION AREA 25/1 25/2 24/3

23/0 23/1 23/2 23/3 23/4 23/5 24/0

22/4 22/2 22/3 22/0 22/1 21/5 21/4 21/3 21/2 20/4
ROAD
ck

17/1 19/0 19/1 19/2 20/0 18/3 18/2 18/1 18/0

18/6

18/5

18/4

PROPOSED 400 kV SWITCH YARD
LEGEND :DESCRIPTION
AR BE ING AR EA

START POINT

BANKI BLOCK

SRI LANKA INDIAN OCEAN

20/2

L 053

21/1 21/0

20/3
Car t Tra

20/1

TAM

IS

SYMBOL

ILN

IN G

AR EA

DAM

TI

NG

ADU

40

0

KV

C D/

NE 4/0 LI

2/2

2/1 2/0 1/0 GANTRY

SINGHALI BLOCK

MAH

ARA

RA SHT

ANDHRA PRADESH

CH HA TIS GAR H

Dhadhipara

CKBD 2 x 30 MW EXISTING POWER PLANT

RAJASTHAN

UTTAR PRADESH

L
BIHAR

BHUTAN

HAL NACSH ARUADE PR ASSAM NAGALAND
MANIPUR

CK

MEGHALAYA BANGLADESH

H

AND RKH WEST JHA BENGAL

MIZORAM

ORISSA

Proposed route with AP
Roads metalled/Asphalted road

SEA IAN ARAB

AKA NAT KAR

BAY OF BENGAL

LA KERA

DESCRIPTION
River Pond Forest Development Temple, Mosque Hutment Tree Wells lined, unlined

SYMBOL

CO

AL

SITE FOR DIPKA COLONY

Roads unmetalled Cart-track

COAL BEARIN G AREA

SARAIPALI BLOCK
PROP CO OS EXTE AL ED NS AREA ION
31/0 30/5 30/4 30/3 30/2

25/3 26/0 27/0 27/1 27/2 28/0

NO

N

CO

Railways broad gauge

AL

Railways other gauge

ZO

Canal

NE

AR

Stream

32/0 33/0
22°20'

30/1 30/0

22°20'

30/6

29/0 29/2 29/1 29/4 29/3

28/1 28/2 28/3 28/4

EA

Contours with heights Power/Telephone line Scrub Boundary state

200

Borewells Reserved/Protected forest Heights triangulated Heights point Bench-mark Post office Police station Coal Bearing Area
PO PS R.F. / PF 200 200

KARTALI BLOCK

33/1 33/2 33/3

TREE PLANT

PROPOSED 2x50 MW RATIJA 132 kV POWER STATION SWITCH YARD

Boundary district Boundary tahsil Towns or Villages

GEVRA
NARAIBODH

34/0 34/1 34/2 34/3 34/4 34/5 34/6 34/7 34/8 35/0 35/1 36/0 36/1 36/2 37/0 37/1 37/2 37/3 38/1 38/0

PROPOSED ROUTE OF SION LINE TRANSMIS

400kV

EAST OF KARTALI AREA BETWEEN KARTALI & DIPKA NUNBERA RATIJA
COA L BEA RING

Industries Coal Zone Alotment Area

DIPKA

PONRI

BHILAI
AREA

COAL BEARIN G AREA

TOTAL LENGTH STATEMENT
Sr. No.
1

DESCRIPTION
PROPOSED 400kV D/C TRANSMISSION LINE FROM KASAIPALI TO BHARARI

ROUTE

Length (Km.)
54.867

40/0 40/1 40/2 40/3 40/4 40/5 40/6 40/8 40/9 40/10 40/11 42/0 42/1 42/2 43/0 41/3 41/2 41/1 41/0
22°15'

39/4 39/3 39/2

39/1 39/0

38/3

38/2

22°15'

40/7

NO

DATE

REVISIONS

BY

CHKD

APPD PROJ.ENGR

44/2 46/0 45/2 45/1 45/0

44/1

44/0 43/3

43/2

43/1

Project:

Title:

SUB POOLING STATION

PROPOSED BHARARI

END POINT

RECONNAISSANCE SURVEY OF 400 kV D/C
SURVEYED & PREPARED BY-

POWER CONSULTANTS & AGENCIES, VADODARA
198, VISHWAMITRI TOWN SHIP, OPP. GUJARAT TRACTORS, VADODARA-390 011 www.powerconsultant.info

SCALE

DRAWING NO.

REV.

1 : 50000
82°10' 82°15' 82°20' 82°25' 82°30' 82°35'

PCA/AC/KBPL/400kV/RECCAY/RM-01

0E

2.3.2 The reconnaissance survey helps in collecting the first hand information regarding various important field data required for transmission line works. The reconnaissance survey is carried out
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by using GPS (Geographical Positioning System). The general points to be kept in view while establishing the preliminary route at the time of reconnaissance survey are as under. a) The route should be as short and as straight as possible. b) Where ever possible, attempt should be made to lay the line near to or along roadway. Alternatively, the line should be approachable to the extent possible. c) The number of angle towers should minimum and within these, the number of heavier angle towers shall be as less as possible. d) Cost of securing and clearing right of way (ROW), making access roads and time required for these works should be minimum. e) Corridor through which line is taken, should be free from Encumbrances such as non‐Agricultural land, notified area, Defense establishment, oil & gas establishment, acquired mining areas etc. f) Care is also required to be taken that the line route avoids any big planned development in the region such as, Airport, State Industrial Estate, Mega Power Projects etc. If this is not done, shifting of the line may be required later or objection to the construction may occur. g) Crossing with permanent objects, such as Railway lines and roads should be made preferably at right angles. h) In case of hilly terrain, it is necessary to conduct detailed survey and locate the tower positions suitable to the topography. Detailed survey is recommended for such terrain. i) The reconnaissance survey will also establish if we can avoid the following: • Marshy areas, low lying lands, river beds, earth slip zones etc. involving risk to stability of foundation & the tower. • Areas subjected to floods, gushing – culverts during rainy seasons, tanks, ponds, lakes, snow blizzards. • Inaccessible areas where approach roads are not possible. • Areas which will create problems of right of way and way leave. • Route involving abrupt changes in levels, too many long spans, river or power line crossings or near parallelism to telecommunication lines. • Thick forest or areas involving heavy compensatory payments for the ROW. j) The reconnaissance survey is useful for collecting the first hand information about various important field data required for transmission line construction, which are as under: • Major power line crossing details (66 KV and above) • Railway crossing details. • Major river crossing details. • Source of construction materials, viz., metal, sand water etc. along the line. • Important rail heads for the purpose of receipt of materials. • Important villages or Railway stations along the route for the purpose of selection of labor camps. • Nature of soil strata likely to be encountered along the route and the terrain. • Availability of skilled, semiskilled and un‐skilled labor, their present rate on daily basis or on contract basis. • Names of the major towns for the purpose of selection of site offices. • Likely local support or hindrance from various section of population along the route of the line.

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ground levels and the angles between the two reference points. This method needs skilled surveyors having good understanding of the use of Theodolite and basic knowledge of trigonometry. The surveyor and his team will move on an approved route and take ground levels in the field book at an interval of 20 to 30 meters.3.3.1 From the field book entries route plan and longitudinal profile.For fixing the final alignment and angle points on the ground as per the reconnaissance survey. 2. The Total Station is located at fixed point and there after the prism mounted in a stand is moved along the route of the line.2 above. The range of operation of Theodolite is much higher than the dumpy level. offset distances etc. both traversing and leveling is done by means of a tachometric Theodolite. 2.4.4. deflection angles. 2.2 The use of Total Station facilitates quick measurement of distance. The horizontal and vertical distances are computed with the help of readings of the stadia wires taken on the staff held at the reading point.2 The profile shall include the following: Power Consultants & Agencies Page 5 . The data is there after transferred to the computer.1 The method of taking level readings for preparation of longitudinal and cross section profile can be one of the following • By chain and dumpy level • By tachometric survey with Theodolite • By using Total Station and the prism First method is more useful in plain areas where chaining can be done easily with the help of semiskilled surveyors. the Total Station is the most modern equipment for surveying. commonly referred to as “route profile” or “survey chart” is prepared in the drawing office. Tachometric method offers a great advantage in hilly regions and such other inaccessible places where chaining is not possible. level differences. 2. By plotting of profiles on graphed tracing papers of mm x mm size. 2. 2. survey chains/measuring tapes etc.4 Detailed Survey 2.5.4. If the length of line is very short. preferably at an interval of 20 metres. It saves lot of time and the observations are highly accurate.4. This equipment is very expensive and needs lot of precautions in handling.5 Plotting of Profiles 2. These charts are prepared and plotted on 1mm/5mm/1cm square paper of formed drawing sheets of graphed tracing paper. 1:2000mm‐horizontal. The scale normally preferred is 1:200mm‐vertical.4.3 Field Observation Recording and Calculations 2. important objects coming within the right of way and show the landmark points/objects along the route with their distance from the alignment of line. These readings are stored in the memory of Total Station (TS).1 The main objective of carrying out detailed survey is to prepare longitudinal and cross section profiles on the approved route alignment and to prepare the route plan showing details of deviation angles. Each reading gives the distance and level difference. Work of detailed survey is normally done in two stages: 1. Theodolite can also serve the purpose. 2.4. The accuracy of the work will depend upon the quality and cost of the equipment. route alignment survey shall be carried out with the help of Theodolite and/or Total Station. In this method.2 As stated in 2. By actual field observation taking level readings and calculating distances.5.

with references to centre‐line level. the tower spotting chart or structure limitation charts are prepared. • Power Consultants & Agencies Page 6 . with zero wind condition. The sag template curves are first prepared on tracing paper and the blue print is taken out from the tracing.5 to 3 mm thick. railway lines. • Route plan giving details of all objects lying within the right of way and just along the boundary of right of way. • The cross‐section profile wherever appreciable difference in level exists. 2. railway rail top levels. • Readings should be taken and charts should show. • Angle of line deviation duly marked left (L) or right (R) as the case may be. conductor creep or snow incidences.1 The work of tower spotting is a very precise job as it has an implication on overall cost. should be marked on the route profile. Their replicas on Acrylic sheets are prepared with the itching process.7. • ‘Hot’ or ‘Maximum Sag Curve’ showing maximum sag of conductor under zero wind and maximum temperature and sag tolerances are also allowed to take care of stringing error. levels of roads. In such cases the cross‐section levels shall be taken at each 50/100m intervals. Depending upon the maximum specified permissible temperature of the conductor and zero wind condition the ground clearance is to be maintained by the line. as the river crossing is a special task in the construction process which involves special design. cart tracks etc.The longitudinal profiles along the centre‐line of the transmission line route including the bottom conductor catenaries.7 Preparation of Sag Template 2. roads. Similarly under the specified minimum temperature of the conductor surface. heights of supports/lines being crossed. important pucca roads & or rivers/canals. • It is advisable to prepare an independent route profile for Major River crossing section deploying tall special towers or normal towers on piles in the river crossing section. • Objects and their distances along the route within the right of way from centre line. • Crossing details with any other power or telecommunication lines. canals or rivers should be marked as clearly as possible. the tower tensions should be within the specified limits..6 Tower Spotting 2. • ‘Cold or Uplift Curve’‐Showing sag of conductor at specified minimum temperature and zero wind. Similarly the drawing of the sag template and its replica is prepared on Acrylic sheet. 2.2 The sag templates have the following curves itched on them.6. maximum water/flood levels. • Ground clearance Curve‐Drawn parallel to hot curve and at a distance equal to specified minimum ground clearance. all trees coming within the clearance zone. nearby villages.7. which ultimately helps in finalizing the quantity of each type of tower and their extensions (3 meter & 6 meter etc). Application of Sag Template helps to decide optimum tower position on Survey Chart.1 Sag template is a very important tool for the surveyor by the help of which Tower spotting can be done. 2. The Acrylic sheets are normally 2. canal embankments. After the tower designs are finalized.

• 2. • Besides normal ground clearance.7. null point may be outside the span. • The structure positions are marked where the tower footing curve just touches the profile. 2. other power or telecommunication lines. The ‘Cold and Hot’ Template Curves are plotted as parabola. however the sags in individual spans will vary according to their respective spans. to the same scale as the survey chart for the minimum and maximum sags for the normal span (specified in the tender specifications). • On inclined spans.. • The weight span on either side of a tower can be easily obtained by marking the low points of sags (Null Point) in two adjacent spans and then reading the distance between the two. canal embankments etc. • The acrylic sag template is applied to the ground profile by moving the same horizontally while always ensuring that the vertical axis is held vertical with reference to graphed lines of the tracing paper below. the clearances between power conductor and objects like.3 In erecting an overhead line all the spans cannot be kept equal to normal design span because of the profile of the ground and proper ground and object clearance considerations. A constant tension is calculated which will be uniform throughout the Section (from one tension tower to other tension tower).Tower footing Curve‐For normal tower drawn parallel to hot curve under ground clearance curve and separated by a distance equal to maximum sag at design span. railway tracks.8 Application of Sag Template for Tower Spotting 2. depending on which alternative is most economical. trolley wires. while the ground clearance curve is just clear and above the profile to the left or right of the centre line up to a distance equal to maximum cross area spread on either side. Power Consultants & Agencies Page 7 . roads. houses. shall be checked.8. The following are the steps to be followed for correct application of sag template. • Extra clearance can be obtained either by reducing the span or providing extension to tower body.1 The Sag Template is an important tool for correct spotting of the towers after the detailed survey work is completed.

the surveyor must know these limitations for the various types of towers Power Consultants & Agencies Page 8 • .C 75 Deg. • This is mandatory to afford better stability of the line against Transverse wind forces and to facilitate easy stringing.9. for the stability of the line it is not desirable to place a tower in such a position where it is always under permanent uplift condition.1 Since each tower is designed to withstand a definite load only. C and 32Deg. the cross‐arms of the tower subjected to up lift shall be designed to take the extra upward pull. minimum temperature and every‐day temperature under 100%. • Besides 15° angle tension tower is most economical amongst the standard angle tension towers.This indicates that the total weight of conductor is taken up by the higher tower and the lower tower is being pulled up by a force equal to the weight of conductor between lower support and the null point. minimum and every‐day temperatures are considered as 0 Deg. 2. (i. • For any easy check of whether a tower is under uplift or not. length). Normally. sections have to be provided after every 12 to 15 tangent towers. Sag and Tension charts are required to be prepared. • In case it becomes mandatory due to route compulsion. C 2.10. actual uplift will be caused and the conductor would tend to wing clear of the tower upwards. one or more line supports of the Section may be extended by inserting standard body extensions. If the conductor is required to carry large block of power.9. the maximum surface temperature of conductor can be taken up to 95Deg. • In case an individual span becomes too short on account of undulations in ground profiles. These charts indicate the values of sag and tension of conductor and the earth wire at Maximum temperature. tower which is designed to take uplift will have to be used. in plain terrain in India the maximum. • For this purpose a small angle tension tower designed for 15° should only be used.36%(66%) and 0% wind pressure. • Even if the line does not deviate for a long run. C. These values may change in the region experiencing snow or Sub‐Zero temperatures.1 Before taking up the tower design on hand. • However. the sag template curves can be plotted on the computer through a specific programme. The full scale print out of the curves is then used to prepare the Acrylic Sag Template by itching process.9 Use of computer for preparing sag template and the tower spotting 2. 3 to 4 km. • Should the upward pull of the uphill span becomes greater than downward load of the next adjacent span. 2. • If the support is under uplift and has to be extended so as to be above it and in case requisite standard body extension do not suffice for doing this. For Earth wires the maximum temperature is taken as 53Deg. • The intermediate spans shall be as near as possible to the normal design span.2 Based on the sag tension charts. C. the following method may be adopted.10 Towers Spotting Data 2. • The Template is applied horizontally until the tops of alternate supports coincide with the Cold Curve. in each of transverse.e. vertical and longitudinal directions.

REV.72 Wind Span L R 211 T 000.156 45/0 DB+3 Weight Span (Cold) L R 213. No.01 423.159 46/0 DD+0 Weight Span (Cold) L R 202. These charts are made for normal towers only.2 T 214.com Web: www.36 Wind Span L R 211 T 211 422 Loc.72 T 000.28 419.41 Weight Span (Hot) L R 205.66 T 198.powerconsultant.21 Mtr.83 T 211 416. These charts define the limits for permissible ruling span. Cold Curve 0° C Ground Clearance at 13. +3M +3M Conductor stringing point at 22.157 45/1 DA+6 Weight Span (Cold) L R 223.83 Loc.4 T 219.26 Mtr.(0265) 2343001 Fax.info TOWER SPOTTING & SAG CURVE OF 400kV D/C TRANSMISSION LINE SCALE DRAWING NO.CH:54867. These limits are given in a chart form called ‘Structure Limitation Chart or “Tower Spotting Data” which is prepared by the design department of the utility /contractor. No.99 Weight Span (Hot) L R 207.7 T 206.21 Mtr.21 Mtr.1 Weight Span (Hot) L R 220.00 207. VADODARA .(0265) 2356291 E-mail: smtakalkar@powerconsultant. weight span. No.26 Mtr. wind span. individual span and the degree of the deviation allowed on each of the standard towers.available for use on line so than he can spot an appropriate type of tower structures along the route.67m POWER CONSULTANTS & AGENCIES A / 198 VISHVAMITRY TOWNSHIP. smtakalkarpca@gmail.0m CUMULATIVE CHAINAGES(M) REDUCED LEVELS(M) AP48 . For all special crossings individual tower checking is essential by the design department.26 Mtr.00 202. 411.21 Mtr. Conductor stringing point at 22.48 Wind Span L R 205.99 T 000.CH:53612. These charts also indicate the additional angle of deviation which can be allowed in the tower by limiting the spans.26 431. Conductor stringing point at 22.06 T 201.82 Weight Span (Hot) L R 212. GUJARAT TRACTORS.16 411.16 Wind Span L R 211 T 205.46 427. No.158 45/2 DA+3 Weight Span (Cold) L R 204.info . TOWER SPOTTING Loc.390 011 Ph.02m PROPOSED SUB STATION CROSSING & INTERFERENCE DETAILS AP-45(14°48'23")R AP-46(75°43'41")L CONSULTANT: - Project: Title: CLIENT - AP49 .83 416. so that the design load limits of the tower are not exceeded.84 T 207. H:-1 : 2000 V:-1 : 200 0A Power Consultants & Agencies Page 9 .00 211 +9M +9M +6M +9M +9M +6M +3M +6M +6M +3M Conductor stringing point at 22.26 Mtr. Ground Clearance at 13. Hot Curve 85° C Ground Clearance at 13.66 422 422 Cold Curve 0° C Cold Curve 0° C Hot Curve 85° C Ground Clearance at 13.3 413. OPP. Hot Curve 85° C Ground Clearance Curve Ground Clearance Curve Ground Clearance Curve DATUM 262.83 Loc.

1 Check survey is carried out for the following. If the error is within 1% of the total section length it can be ignored and the permanent mark made during detailed survey is taken as correct and necessary correction in the line deviation angle at the starting point is made and noted in the survey chart. then closing error is judiciously distributed in all the previous temporary sections and all angle points are finally marked on ground by means of concrete pillars. traversing is done from the known fixed angle point (the starting point or any other obligatory point fixed by the purchaser) in the direction of given line deviation and up to a distance equal to the section length between the starting point and the next angle point. 2. Once the known angle point is reached. 2. Once the angle points are marked.11 Preparation of Tower Schedule 2. correct angle of deviation and section length are measured and noted on survey charts.13. If next angle point is firmly marked in field by means of a permanent peg mark (concrete burjee) then the closing error is noted both in longitudinal and transverse directions.13. following information is required from the design department: • Angle of line deviation on tower • Whether it is to be used as section tower or dead end tower • Sum of adjacent spans • Weight span on tower • Whether an immediate lower size of tower can be used in place of the actual angle tower by limiting the span. corresponding to the route profiles.1 Once each angle is fixed in field by the help of permanent concrete burjees and exact section length is known. This process is continued till an angle point is reached which is fixed in field either by a permanent burjee (pillar) or by means of identification marks given in survey charts.3 These objects only guide the surveyor in moving as closely on the correct alignment as possible. • To reconfirm the work carried out during detailed survey. Intermediate checks can also be made by measuring offsets from the line to well defined objects are shown in survey charts very accurately (but much reliance cannot be given for correct alignment based on offset distance). the surveyor proceeds to mark all intermediate tower positions on the straight line Power Consultants & Agencies Page 10 .2.2 If the second angle point reached is not marked in field by the detailed survey gang (or the mark is missing). • To locate and peg mark the tower position on ground.12 Check Survey 2. • To give direction pegs. • Whether a river can be crossed using normal tower with/without extensions or by providing special tower or by locating towers in mid stream by providing the pile foundations. 2. • Whether a hill side extension will be required. If the time span between the detailed survey and the check survey is too long.14 Spotting and Peg Marking of Tower Locations 2.1 In this operation. 2.12.13.1 In order to decide the tower type for a particular location. the angle point is tentatively fixed at the place reached as per deviation angle at starting point and first sectional length and line alignment is carried to the next deviation angle and next section length as per survey chart.11. 2. care is required to keep the proper track of the original profile bench mark and offset distances.14.13 Checking and Line Alignment 2.

• On angle towers these are rotated by an angle equal to half the angle of line deviation and then the perpendiculars are marked. Concreting.joining the two angle points spaced at distance equal to individual span length as given on survey chart and after the same is duly adjusted for the closing error. pegs are set along the centre line of route alignment and perpendicular to it.0 Foundation Work 3. • The more the number of alignment pegs the better it will be for the readings. Stub setting.2 Directional Peg Marking for Excavation Pit Marking 3. • These pegs are also very useful when main tower marking burjees are found missing at a later date (due to mischief of local people or negligence of excavation marking gang or any other reason). • In order to achieve correct alignment of all the intermediate towers between two angle points. the activity of foundation is taken on hand. 3. centre point of each leg of the tower and the periphery of pit to be excavated for each leg foundation. a number of alignment pegs are driven at the time of exact distance measurement of the section. it essential to accurately mark the centre point of the tower. • Directional pegs are essential for correct alignment of tower centre line along longitudinal and transverse directions.1 Before the activity of excavation is taken up. They are described in brief as under. Power Consultants & Agencies Page 11 .2. as instrument errors are less if similar distances are measured in one reading. This is described in brief as under. • On suspension tower. Excavation.1 After the survey work is over. 3. The foundation work mainly includes Pit marking. Back filling and Curing.

the design department/ contractor is equipped with the set of foundation design and the excavation plan for standard type of soils / rocks and their combinations. a trial pit shall be made within the base of the proposed tower width.3. Any one of the readily available foundation design for the particular type of tower which fits in to the classification of soil/rock should be adopted.2 Examination of trial pit The soil strata will be examined by EIC or an expert nominated by him who has expertise in the matter of soil classification.1 Pit marketing shall be carried out according to pit marking chart.1 Trial Pit At the location of the tower. If the strata are too strange.3. 3. clayey soil.3 Preparation/Study of Excavation Plan Suitable For the Proposed Type of Foundation 3. 3. etc. The type foundations can be used for smaller towers. sides and Power Consultants & Agencies Page 12 . Normally. including sub‐ soil water bound strata.3 Decision for type of foundation The EIC or the authorized engineer of the purchaser and the engineer of the contractor shall then decide upon the type of foundation to be adopted for that particular location.3.3. Plate type and grill type foundations are not being used these days as their reliability is low.4 Excavation 3. deformated soil. The depth of the excavation at the pit enter shall be measured with reference to the tower center level. There are many types of tower foundation which are in vogue these days. No margin is necessary in the case of undercut foundations. soft rock. The pit size in the case of open cast foundations shall be determined after allowing a margin of 150mm round. The detailed examination report of the trial pit will be made then.4. 3. The pile type & well type foundations are generally used in river crossing and crossing sections of the line. They also relate to various types of soil classification such as normal soil. hard rock. special type of foundation has to be adopted with the approval of Design department of the purchaser. The design office will furnish the survey gang with an ‘Excavation pit Marking Chart’ or ‘Excavation Plan’ which gives distance of pit centers. This shall be generally 1 x 1 x 3 m size.

Various types of foundations used for tower are shown here under.4. The excavation wall shall be vertical and the pit dimensions shall be strictly as per the excavation plan and foundation drawing. corrected and applicable excavation plan in accordance with the soil/rock classification should be obtained by the construction crew members. In case of collapsible soil. TYPES & SHAPES OF FOUNDATION Power Consultants & Agencies Page 13 .2 Actual excavation Before commencement of the excavation work. These distances are measured and each pit boundary is marked in the field by means of chalk spade or pick axe along the side of the pits. until the footing is placed. All excavation shall be protected so as to maintain a clean surface. care should be taken that earth is cut vertically/tapered/in steps as per the site requirement to avoid any mishap during the course of excavation and foundation work. While excavating. precaution should be taken by providing shuttering and supports for the safety of the crew members. 3.corners with reference to center point of the tower.

5. spade and shovel easily. 3.3. chiseling are required.1 Normal Soil: Soil which can be removed by an ordinary pick axe. there are chances of reduction of reliability of foundation against upward loads.5. shoring and shuttering. the stubs may be shortened suitably with the approval of the owner or his authorized representatives.1 Fissured Rock/Soft Rock Lime stone. The excavation shall be carried out strictly as per the excavation plan approved by the owner/customer for the particular type of structure with/without extension and the particular type of Soil Rock. However. classification of foundation will be according to the type of soil which is predominant in the footing. it shall be done with the utmost care to minimize the use of concrete for filling up the blasted area.7 Blasting Material The Contractor shall procure requisite blasting material and be responsible for the purpose of the storage and use of this material. the full volume excavated/blasted shall be filled with the structural concrete. Where the soil is of composite nature. However. the holes for tower footings shall preferably be drilled. this will not in any way entitle the material to be classified as hard rock. hard conglomerate or other soft or fissured rock which can be quarried or split with crow bars wedges or pickaxes will be classified as fissured rock/soft rock. while re‐working. but where blasting is to be resorted to as an economy measure.5 Classification of Soil 3. 3. if required. The decision of the Engineer‐in‐charge shall be final and binding with reference to classification of soil and foundation to be adopted at that particular location. 3. for which blasting. If inadvertently large quantities are excavated / blasted. the C/C distance between the two pits will be with reference to the junction of reduced chimney and footing. made out of timber planks of 30‐35mm Power Consultants & Agencies Page 14 . light blasting may be resorted to for loosening the material and hasten the excavation activity. The adoption of footing depends upon the type of Soil and the tower loadings. Necessary permission/approvals from the concerned Government department may be obtained by the contractor. In case where drilling is done. If this is not adhered to.2 Hard Rock Any rock excavation other than specified under fissured rock/soft rock above. quantum of tower loading and preference for structural arrangements of footing.3.5. 3. 3. The foundation to be adopted therefore depends upon the type of soil.5.2 Wet Soil (Submerged Soil): Where the subsoil water table is encountered within the range of foundation depth or/and where pumping or bailing out of water is required due to presence of surface water will be treated as wet soil/submerged soil. 3.8 Shoring and Shuttering If pits excavated in sandy soil or water bearing strata and particularly black cotton soil where there is every likelihood of pit collapse. However.3 Rocky Soil (Strata): 3. All necessary precautions for handling and use of blasting materials shall be taken.3.6 Hard Rock Excavation Where rock is encountered.5. laterite. drilling.

• The individual Leg Template comprises a steel channel or joist having a length more than the size of the pit. it is not possible to use the four legged stub setting template for various reasons related to design and construction. In this system a grid of pipes are laid around the area where the pits are excavated and the system is very effective in pumping water particularly in sandy soils. • Use of individual Leg Template for each stub.9 Dewatering Dewatering shall be carried out manually or by mechanical means or power driven pumps to facilitate excavation and casting of foundation. • The Stub‐setting Template comprises a light rigid square framework which holds the four stubs at the correct alignment and slope in four corners. 3. Sand bedding/stone bedding will be provided in foundation of marshy and wet black cotton foundations which will work as a sub‐grade. will be provided. 3. well point system is used for controlling water. • A chamfered cleat is welded in centre of the channel/joist to provide the slope to the stub. Stubs shall be set in the Presence of Owner’s representative available at site where required. the alignment and slope are as per the approved misfit and design so as to permit assembling of the superstructure without undue pre‐stress. There are three methods by which this is generally accomplished: • Use of combined Stub‐setting Template for all the four stubs of the tower including extension portions.10 Setting of Stubs The stubs shall be set correctly in accordance with approved method at the exact location and alignment and precisely at correct levels with the help of stub setting templates and leveling instrument. The first method is the most commonly used. • The anchors or stubs are bolted to this Template one at each corner of the Template. where Stub‐setting Template is not available. strain or distortion in any part of the structure. and are held in their proper position until the concrete is poured and gets hardened. The second method is adopted for casting the foundation locations having individual leg extensions or locations having broad base of Tower. In areas where sub‐soil water recoupment is heavy and where water cannot be controlled even by use of power driven pumps. Power Consultants & Agencies Page 15 . After commencing pumping operation the pit can be excavated avoiding risk of collapse of earth. by about 2 to 3 meters. The size of the mechanical/electrical pump will depend upon the quantum of water required to be handled per hour. • Use as a Template the lowermost tower section or extension. Dewatering is not necessary in case of bored foundations extending below water table. The pumps shall be suitable for handling muddy water. • The answer to this problem is individual leg stub‐setting template. • In such case. • The Stub‐setting Template generally of adjustable type which can suit the standard tower as well as towers with standard extensions of 3 meter & 6 meter height.thickness or steel frames of adequate strength to suit the requirement. The stubs are set in such a manner that the distance between the Stubs. • The Template is centered and leveled by sighting through transit.

• This type of Template are very useful for casting the foundations of individual leg extensions in which the foundation pits are staggered and use of either a normal Stub‐setting Template or the first section of the tower is not feasible. • Then the assembled section is lined up. • One side is held in place with props while the other side is being erected. jacking. lower section of the tower or extension is used for setting stub. Dumpy level and a measuring tape. • The other version of individual leg extension is cut corner sections of conventional stub‐setting template. • For heavy towers use of this method is not recommended.The stub is bolted to the cleat of the Template with holes as required for the slop of the stub is provided. • The assembly is lifted in such a manner that stubs are not damaged. before fixing form boxes and pouring concrete. will be very difficult. • Power Consultants & Agencies Page 16 . and the stubs are bolted to the same with correct slope and alignment. as propping. made square with line and level after the proper elevation and leveling have been done. • Thereafter the form boxes for foundations are built and the concrete is poured. • For heavy towers use of Stub‐setting Template is recommended. • The two opposite sides are then laced together with cross members and diagonals. the bolts are tightened to make the frame as rigid as is reasonably possible. • Each assembled side is then lifted clear of the ground with a gin pole and is lowered into the four pits excavated at four corners of the tower to their proper size and depth. In the third method. • The individual Leg Templates are initially set on each pit approximately to the required position with reference to the centre point of the tower and with the help of a Theodolite (or Total Station). • In this method two opposite sides of the lower section of the tower are assembled horizontally on the ground. • This is easy to fabricate and deploy at site. leveling etc.

For lean concrete. • Window on one face shall be provided for pyramid forms to facilitate concreting in the lower parts which shall be fixed after concrete in the bottom part is placed. • It shall be of right design.3. x 30cm x 39cm alternatively a cylinder of 34 cm diameter and 39 cm height shall be made ready for the proportioning. The concrete shall be transported from the place of mixing to the place of final deposit as rapidly as practicable by methods which shall prevent the segregation or loss of any ingredient or setting.1 The general requirements of form box are as under: • The form work shall conform to the shape.11 Mixing.12 Specification For From Box 3. Prepare a wooden measuring box of 35 lit capacity (i. and shall be sufficiently tight to prevent loss of liquid from concrete. The concrete shall be mixed in the mechanical mixer only.e. • The inner surface coming in contact with concrete shall be smooth and free from projections. Mixing shall be continued until there is uniform distribution of material and the mix is uniform in color and consistency. Saline water or sea water should not be used for the concrete work. the concrete may be mixed at the nearest convenient place. M 10 or 1:3:6 mix cement concrete may be used. It shall be permissible to proportionate the concrete as follows. The mix quantities according to the measuring box shall be as follows M20 (1:1. However. • Power Consultants & Agencies Page 17 .5:3) M15 (1:2:4 mix) M10 (1:3:6 mix) • Cement 1. Ordinary plain or reinforced cement concrete given in IS: 456‐1978 shall be used in overhead line foundations. The water should be free from oil/acid and any other impurities. Normally mixing shall be done close to the foundation. 3. • The form work for slabs and pyramids shall be made symmetrical about the base of the chimney to ensure interchangeable faces. Mechanical/pneumatic vibrator shall be used for obtaining homogenous concrete work and for better finish as well as avoiding honey combing. Placing and Compacting Of Concrete It is normal practice to use coarse and fine aggregates available along the line route and/of nearest locations to the route so as to have economy and better progress.0 1 Bag 1 Bag • Sand 1. and be as constructed as to the rigid during the lacing and compacting of concrete. M15 or 1:2:4 mix cement concrete shall be used.5 2 Boxes 3 Boxes • Metal 3. The properties of concrete and mix proportions shall be as given in IS: 456‐1978.12. but in no case the mixing be done for less than two minutes. but in case it is not possible. in case of difficult terrain hand mixing may be permitted at the discretion of Engineer In charge. equal to 1 bag of 50 kg of cement) with inside dimensions of 30 cm. sub basis or pads. The concrete shall be placed and compacted before setting commences. easily removable without distortions and shall be of steel or suitable materials. lines and dimensions as shown on the approval foundation design drawings. For main foundation.0 4 Boxes 6 Boxes The required quantity of water shall be used for concrete mix.

the site must be kept completely dewatered. • The surface in contact with the concrete shall be wetted and spread with the fine sand or treated with an approved compositions such as black or waste oil etc. manual compaction may be permitted at the discretion of site Engineer.4 Removal of From Box After the form work has been removed.shall be removed from the interior of the forms before the concrete is placed. Following is recommended. • At such locations where borrowed earth is required for backfilling. if any. the damage shall be repaired with rich cement and sand mortar to the satisfaction of the Owner’s representatives.12.3 Wet Location • In wet locations.12. • Backfilling shall normally be done with the excavated soil.. Power Consultants & Agencies Page 18 . the top surface should be finished smooth with a slight slope towards the outer edge. in case of difficult terrain.3. every time. both during the placing of the concrete and for 24 hours thereafter. • The concrete shall be poured in 150mm layers and consolidated well. terms and conditions laid down in the contract. 3.13 Back Filling and Removal of Stub Template 3. 3. • However. particularly chippings. to drain off any rain water falling on the coping.12.1 Process of bake filling The back filling work is very important for the stability of the foundation.13. 3. if the excavated material includes large boulders/stones. the boulders shall be broken to a maximum size of 80mm. this shall be done by the Contractor as per the rates. • There should be no disturbance to concrete by water during this period. before use. before the foundation pits are backfilled. • The mechanical vibrator shall be employed for compaction of the concrete. if the concrete surface is found to be defective.2 Clearing and Treatment of Forms • All rubbish. backfilling with the borrowed earth may not serve the purpose. • After concreting the chimney portion to the required height. so that the cement cream works up to the top and no honey‐combing is left in the concrete. • If the foundation cast is rocky type. sawdust and traces of residual concrete.

A typical example of pipe type of earthing is given. • In no case the tower footing resistance shall exceed 10 ohms. • In case the resistance exceeds the specified values.4 Earthing Earthing of tower is very important for the performance of insulators and conductor of the transmission line. multiple pipe earthing or counterpoise earthing shall be adopted in accordance with the following procedure. Power Consultants & Agencies Page 19 • . • However.1 stub leg as given in the structural drawings. • Pipe type earthing The installation of the pipe type earthing shall be in accordance with IS: 5613‐ 1985 (part II/section 2). the earth strip shall be provided on No. • The footing resistance of all towers shall be measured by the Contractor in dry weather after the erection of superstructure but before the stringing of earth wire. • After backfilling. 50mm high earthen embankment (bandh) will be made along the sides of excavation pits and sufficient water will be poured in the backfilled earth for at least 24 hours. Following may be noted. • Care shall be taken that the backfilling is started from the foundation ends of the pits.In such a case backfilling with chipped stones mixed with the cement slurry would be a better option. this would be done as per the instructions of the engineers in change. wherever required. the tower leg whish has the step bolt.3 Curing The strength of concrete work depends upon the curing provided to it. In normal circumstances. • The curing will be done from the top of the pit within the embankment area.13. • After the pits have been backfilled to full depth. earth strip shall be fixed to the stub during concreting of the chimney and taken out horizontally below the ground level. • The earth shall be deposited in maximum 200mm layers. Following requires to be noted. the stub template may be removed. towards the outer ends. the template can be removed even after 50% of backfilling of the soil. • The backfilling materials should be clean and free from organic or other foreign materials. but without interfering with the foundation concrete even though the earth strip/counterpoise lead remains exposed at the tower end. shall be done in accordance with the stipulations made in IS:3043‐1966 and IS:5613 (Part II/Section 2) 1976. • The concrete after setting for 24 hours shall be cured by keeping the concrete wet continuously for a period 10 days after lying. 3.13. 3. • No saltish or brackish water shall be utilized for curing. Normally.2 Material for bake filling The following is required to be noted for the back filling material. For this purpose. Each tower shall be earthed after the foundation has been cast. • The backfilling and grading shall be carried to an elevation of about 75mm above the finished ground level to drain out water. • The connections in such case shall be made with the existing lattice member holes on the leg just above the chimney top.13. 3. is provided with the earthing strip. • In case of urgency. leveled and wetted and tampered properly before another layer is deposited. Pipe type earthing and counterpoise type earthing.

4.0 Erection of Super Structure and Fixing Of Tower Accessories 4.1 The towers shall be erected on the foundations only after 10 days of pouring of concrete or till such time that the concrete has acquired sufficient strength. Such type of earthing is provided for hilly terrain locations where earth pit excavation to a depth of about 2. each fitted with a plug for connection to the tower leg at one end.• Counter poise type earthing Counterpoise type earthing consists of four lengths of galvanized steel stranded wires.e. Galvanized steel stranded wire preferably of the same size of the overhead ground wire may be used for this purpose. 10 ohms or less). The length of each wire is normally limited to 15 m but may be increased if the resistance requirements are not met (i. For the convenience of assembling the Power Consultants & Agencies Page 20 .5 to 3 m is not feasible and the resistivity of the earth is very high. The wires are connected to each of the legs and taken radially away from the tower and embedded horizontally 450mm below ground level. The towers are erected as per the erection drawings furnished by the manufacturers to facilitate erection.

• The four main corner leg members of the first section of the tower are first erected and guyed off. each member is marked in the factory to correspond with a number shown in the erection drawing.tower parts during erection operations. No member shall be subjected to any undue over stress. This process is continued till the complete tower is erected. 132KV.3 Build up Method This method is most commonly used in this country for the erection of 66KV. 4. for raising parts of second section. • The erection progresses from the bottom upwards. the tower is erected member by member. • Sometimes more than one continuous leg sections of each corner leg are bolted together at the ground and erected. • Cross‐arm members are assembled on the ground and raised up and fixed to the main body of the Cross‐arm members. • Tower erection activity can be done in any kind of terrain and mostly throughout the year (save difficult time of heavy rain). • The cross braces of the first section. two gin poles are placed one each on the top of diagonally opposite corner legs. • For assembling the second section of the tower. during erection. Any damage to the steel and injuring of galvanizing shall be avoided while the stringing work is in progress. • Gin poles are thus moved up as the tower grows. loading and unloading. • Availability of workmen at reasonable rates. • The tower members are kept on ground serially according to erection sequence. • The leg members and bracings of this section are then hoisted and assembled. • It does not require any heavy machinery such as cranes etc. • First section of the tower thus built and horizontal struts (belt members) if any. are bolted in position. Power Consultants & Agencies Page 21 .2 Method of Erection There are four main methods of erection of steel transmission towers which are described below: • Build‐up method or piecemeal method • Section method • Ground assembly method • Helicopter method 4. are raised one by one as a unit and bolted to the already erected corner leg angles. • These two poles are used. which are already assembled on the ground. • In this method. 220KV and 400KV transmission line towers due to the following advantages: • Tower materials can be supplied to site in knocked down condition which facilitates easier and cheaper transportation. • 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.

Power Consultants & Agencies Page 22 . a small boom is rigged on one gin pole is used instead of two gin poles. In order to maintain speed and efficiency.For heavier towers. 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.

4 Section Method • In the section method. • The gin pole then has to be properly guyed into position. • Either a mobile crane or a gin pole is used. and the assembled section is lined up. • Each assembled side is then lifted clear of the ground with the gin or derrick and is lowered into position on bolts to stubs or anchor bolts. • One side is held in place with props while the other side is being erected. made square to the line. gin pole is set on the top of the first section. • The last lift raises the top of the towers. • The two opposite sides of the section of the tower are assembled on the ground. • After completing the first section. the lacing on the other two sides is bolted up. • The gin pole used is approximately 10 m long and is held in place by means of guys by the side of the tower to be erected. • The two opposite sides are then laced together with cross members and diagonals. • To raise the second face of this section it is necessary to slide the foot of the gin on the strut of the opposite face of the tower • After the two opposite faces are raised. major sections of the tower are assembled on the ground and the same are erected as units. • The gin rests on a strut of the tower immediately below the leg joint.4. • The first face of the second section is raised. Power Consultants & Agencies Page 23 .

5 Ground Assembly Method • The complete tower is assembled in a horizontal position on an even ground. • The tower is assembled along the direction of the line to allow the cross arms to be fitted. care being taken that all bolts at every level are tightened simultaneously. • The galvanization of nuts and bolts is lost due to welding. • If during tightening process. • The welding is generally done for lowermost two sections of the tower. • For this method of erection. bolts of proper size and length are inserted and one spring washer is inserted under each nut.After the tower top is placed and all side lacings have been bolted up. a level piece of ground close to footing is chosen from the tower assembly. After the assembly is complete. each covering one leg and the face to his right. 4. a nut is found to be slipping or running over the bolt threads. • Sometimes whole one face of the tower is assembled on the ground. the bolt together with the nut shall be changed outright. • To prevent the pilferage of the tower members it is a common practice these days to tack weld the nut with the bolt in threaded portion. • All nuts shall be tightened properly using correct sized spanners. • This has to be made good by the application of zinc rich paint.1 Following are the requirements for tightening of nuts and bolts. spring washer shall be placed under the outer nut. • The opposite face is similarly assembled and hoisted and then the bracing angles connecting these two faces are fitted.6. • On slopping ground. • In case of step bolts. and non availability of good approach roads to tower locations. • The tightening shall be carried on progressively from the top downwards. • It may be better to employ four personnel (fitters). • The threads of bolts shall be projected outside the nuts by one to two threads and shall be punched at three positions on the top inner periphery of the nut and bolt to ensure that the nuts are not loosened in course of time due to the effect of the vibration. • In India. 4. it is ensured that filler washers and plates are placed in relevant gaps between members. all the guyes are thrown off except one which is used to lower the gin pole. this method is not popular because of prohibitive cost of mobile crane. however elaborate packing of the low side is essential before assembly commences. hoisted and supported in position. the tower is picked up from the ground with the help of a crane and carried to its location and set on its foundation. • Power Consultants & Agencies Page 24 .6 Tightening Of Nuts & Punching of Threads and Tack Welding of Nuts 4. • This method is not useful when the towers are large and heavy and the foundations are located in arable land where building and erecting complete towers would cause damage to large areas or in hilly terrain where the assembly of complete tower on sloping ground may not be possible and it may be difficult to get crane into position to raise the complete tower. • Before tightening.

4. like Mechanic. 4.4. It is desirable that the Designers and Users both are convinced that the tower can stand and most critical loads for which it is designed and are therefore subjected to full scale prototype test. Transverse & longitudinal deflection readings are taken by Theodolities on scales fitted at appropriate positions on the tower.3 Checking the Verticality of Erected Towers The finally erected tower shall be truly vertical and no straining is permitted to bring it in alignment. (ii) Permanent Anchors of adequate capacity to take the Transverse. In the analysis of design of these structures and their detailing a number of theoretical assumptions are made.2 Testing Requirements This full scale testing of tower is generally termed as Prototype Test and for conducting Prototype tests. the joints shall be painted with zinc rich paint on all contact surfaces during the course of erection. as far as possible simultaneously. as those that will apply to all towers during mass production. the material used shall be made to the same standards.1 Introduction Transmission line towers are highly indeterminate structures. a tower testing station is required where it is possible to measure the applied loads and deflections and observe the behavior of the tower on application of the external design loads. to take mechanical advantage and reduce load on the winch. For a Prototype test. The dials of the respective Dynamometers/Transducers indicate the load in the particular wire. fabrication and the assembly require checking. The Transverse loads are applied through pulleys positioned on the Transverse Mast (B). (iv) Electrical Winches operated by remote control from a Central Control Room used for applying loads at the different points of tower structure. 4. height and strength proposed to be tested on a test bed. Power Consultants & Agencies Page 25 .7.6.7. (iii) The arrangements for applying the combination of given loads at a specified rate of increase.7.al Spring Gauges or Electrical/Electronic Transducers/Dynamometers. if required with the help of a Multi Sheave Pulley. Longitudinal Mast(P) is a structure of adequate dimension and height.7 Tower Testing and Protomodel 4.3 Description of a Tower Testing Station A tower Testing Station shall consist of: (i) A Test Bed to withstand maximum possible compression and uplift loads and shear resulting from the external loads on a prototype tower with the highest voltage and no.2 Painting of Joints For galvanized tower in coastal or highly polluted areas. constructed at a sufficient distance from the tower bed and equipped with all Riging arrangements for applying longitudinal loads.6. The structures are mass produced and the quality of materials. which has to be subjected to testing at the Testing Station. (v) Remote control of loading mechanisms. (vi) Remote and precise reading of measuring instruments. Vertical loads are applied by means of dead weight or through anchors on the test bead. 4. Tolerance limit for vertical shall be one in 360 of the tower height. Instruments used for recording the load applied are either Mechanical Spring Gauges or Electrical/Electronic Transducers/Dynamometers.ofr circuits. Longitudinal and Vertical Pulls applied to the tower of maximum expected with.

Transverse deflection readings are taken for NO LOAD and LOADED conditions.7. 4.7. All the electrically operated machines and instruments shall be connected to and controlled from the Control Room. The choice of the test sequence shall largely depend upon simplification of the operations necessary for carrying out the test programme.1 Bolt‐Slip Test In order to eliminate as far as possible. The Tower is examined carefully to see that all the bolts and nuts are tightened properly. The differences between the two zero readings are the permanent deflections on tower. The Bolts should be tightened simultaneously on all four faces. The loads on the tower are held for 1 minute. All its members are checked for freedom from any visible defect. Calibration of the load cells is done with the use of UTM. Two graduated metallic scales are fixed at Peak and Top Cross arm level on the transverse face.6 Rigging Arrangements And Location of The Load cells To enable application of the external loads in the most representative manner and to simulate tower design conditions.7 Test Procedure The Prototype Tower is erected on the test bed and all the rigging arrangements are completed. positioned as close as possible to the test tower so that frictional losses do not cause impact on the load cells. Fitment of any member shall be easy. the readings with zero loads taken after the Bolt Slip Test taken are considered as the initial readings. Power Consultants & Agencies Page 26 .7. The loads on the tower are then reduced to zero or to as low a value as possible. Readings on these scales with reference to the plumb line are taken by Theodolite. impact of any variance in inclination of rigging wires with respect to the directions accounted for in designs is considered while preparing Rigging Chart. 4. Bolt take‐up test is done in the beginning.8.7.7.4 Calibration In order to ensure the correctness and reliability of all measuring instruments and in turn the validity of the tests the calibration of all instruments before the test is conducted. Loads are applied as per these approved rigging charts. The load cells shall be attached to the tower through the rigging wires. Under this test all the transverse and vertical loads are increased simultaneously as far as possible to 50% of the ultimate normal condition (Reliability Condition) loads. The tower is made truly plumb and square.2 Sequence of Test Loading Cases Sequence of test loading cases shall be pre‐determined. From Control Room. 4. the play between the bolts and the holes throughout the structure.7.8 Testing of Prototype Tower 4. Control room shall have the facility to have the complete view of transverse and longitudinal testing arrangements of the test tower. For subsequent test purposes. The deflection reading is once again taken for this Zero loading. 4.8. 4.5 Assembly of Prototype Tower The prototype tower. 4. the UTM shall be periodically (once in every six months) calibrated by an external third party. the tower structure is rigged suitably. the winches and the dynamometers are operated / controlled. natural and shall not be a forced one.7. fabricated as per structural drawings approved by the Purchaser shall be assembled and erected on a fixed base.(vii) Arrangement for calibration of the measuring instruments.

Longitudinal loads are then increased in steps of 50%‐75%‐90%‐95% of the ultimate loads. or as mutually agreed between the Purchaser and the Supplier. After every test the loads are brought down and deflection readings are taken for no load condition. the design will be reviewed and tower will be reinforced. Throughout the process of loading under all tests. If desired by the Purchaser. All loads are then increased to 100%. The point of failure is detected from the sudden drop of load indication in the instrument dials in the Control Room. after the final waiting period. At this final 100% loading stage. the transverse loads only are increased in steps of 5% till the failure occurs. At each step the loads are maintained for one minute and the deflections are noted. in continuation to test 2. shall be gradually brought down to zero. towe3r is observed for 2 minutes and deflections are noted. (i) Wind load from top at peak and respective cross‐arm points upto bottom cross‐arm will be simulated suitably at ground‐wire. Test 2: (Normal Condition) Reliability Condition: These loads are applied as far as possible simultaneously at all points in steps of 50‐75‐90 & 95%. The Destruction test. It is pointed out here that the tendency of bowing in bracings shall not be considered as a sign of failure even though it is during the final waiting period. The waiting period of one minute shall be maintained at each step.3 Details of Tests Test 1: (Broken wire Condition) Security and Safety Conditions as well as Anti‐cascade conditions. • Application of Loads on Test‐Tower As considered in design: Transverse longitudinal and vertical loads. • During the process of tower test. Top Cross‐arm. At all stages of loading it shall be ensured that the transverse and vertical loads are not less than the values for corresponding step of the longitudinal load. Whenever such deformation is observed the loads shall be brought down and remedial measures shall be taken. At peak and respective cross‐arm points. • Test tower shall be provided with unbraced portion of stub equivalent to distance of chimney top to the point of connection of bracing with leg. the tower shall be closely observed for any visual sign of deformation. if required. Under this condition (all conditions involving longitudinal loads in addition to the transverse and vertical loads) all the transverse and vertical loads are first increased to about 100%. • The tower which has been tested shall not be part of supply and is not to be used online. when a number of tests have been completed satisfactorily and a failure occurs as a subsequent test.8 Special Requirements • The test tower shall be black or galvanized tower as desired by Purchaser. 4. ca be discontinued beyond a certain limit on mutual agreement between the Purchaser. Power Consultants & Agencies Page 27 .4. unless the failure is of major nature. The waiting period at the final 100% loading stage shall be 2 minutes. Test 3: Destruction Test: If no Destruction Test is required by the Purchaser the loads on tower after 100% under Test‐2 above.7.7. Design & Testing Station Authority.8. however. The tower is required to withstand these loads without showing any failure. Middle cross‐arm and Bottom cross‐arm levels. which will require all the tests to be repeated. The reinforced tower will be put to test again and subjected to balance tests.

Sr. 75ºC (Amp) No/mm No/mm 1 ACSR 33/66 6/4. 66kV ‐ACSR “Dog” conductor 2. 4. if tower is able to withstand the specified ultimate loads (100% step) with no visible sign of deformation for the specified waiting period.7. depending upon the voltage class and amount of current to be handled. in quadruplicate. 400kV ‐ACSR Twin Bundle “Moose “Conductor. 4.0 Conductor & Conductor Accessories 5. Line Voltage Power Transfer capability per 3‐phase Circuit (MW) 50kM 100kM 200kM 300kM Page 28 Power Consultants & Agencies . it is a standard practice to use following conductors for different voltages.86 13316 1. loading limit and impedances are also standardized and well defined. 5.2.53 800 3.18 16250 2.7. They are based on the allowable voltage regulation on EHV/UHV lines.(ii) Wind loads on tower below bottom cross‐arm will be simulated to act at bottom cross‐arm point and test will be carried out accordingly.18 7/3. the conductor size shall be worked out on the basis of maximum system current. 220kV ‐ACSR “Zebra” Conductor 4. UTS all carrying stranding voltage weight No Conductor Kg. Thus the current loading limit and power transfer capability of various transmission lines are given in Table‐2.0 7/3.976 Panther 3 ACSR 220 54/3.10 Presentation of Test Results 5.No. TABLE ‐1 Size & Normal Over Current operating Name of Unit Sr.62 Zebra 4 ACSR 220/400 54/3.18 735 2. Thus there is an easy access for a system analyzing engineer for evaluation and assessment of power flow and optimum line loading. dia.10 9177 0. wind load on extension will be simulated on Top of Extension. The insulation is provided in accordance with the voltage.1 The standard type of conductor if used has also an advantage that the current carrying capacity. A detailed report incorporating test data and the results of complete tests along with photographs of the tower shall be prepared by the test‐ authority. 132kV ‐ACSR “Panther” conductor 3. Steel kV Kg/Mtr.1 Conductors: The different types of conductors are used on the transmission line.53 7/3.57 300 1.0 480 2.2 Insulators: 5.72 7/1.394 Dog 2 ACSR 66/132 30/3. 1.9 Acceptance of Test Results Test is considered as passed. In India. voltage. 66. capacity at Alu.02 Moose For special industrial connections at EHV. (iii) For tower with extension.2 3299 0. cm.

the conductors used in the substation buses are one size up in diameter or in bundle configuration.3 Choice of Insulators: The glazed disc type porcelain insulators have been a standard material in use for last 50 years in this country. system having 33kv line voltage with two loads of 10 and 30MW at end of 4 to 5kM long feeder may require “Zebra” conductor to be strung on it.5kV per disc up to Power Consultants & Agencies Page 29 . The insulator string consist of No. of disc unit in optimum width at about 13.6 20 67 250 5. Thus the 220kV side bus of 400kV substations may have quadruple “Moose” conductor and 66kV bus of 220kV substation may have a Twin “Zebra” or Twin “Moose” conductor (Bus). it may become mandatory to use higher size of conductor e. Of‐late it has been customary to consider 75ºC as a maximum surface temperature of the conductor.5 30 100 375 3. ii) Sag may increase bringing down the statutory clearance below the conductor to non acceptable level.2 In case of transmission line having a concentrated load and low voltage.2. i) Line losses increase with increase in temperature.g. Operating lines at high thermal limits is not advisable due to two reasons. With this in view. Similarly a lightly loaded 132kV lines can also be strung with ACSR “Dog” conductor. Since with reduction in voltage the current to be carried becomes very high and use of lower size of conductor may be hazardous. The thermal loading limits of the conductor are increasing day by day.1 2 3 4 66kV 132kV 220kV 400kV 22 120 400 1500 11 60 200 750 5. 5.

4. Power Consultants & Agencies Page 30 .3.3.1 Mid span Joint – It is used to provide joint in the conductor.1 Other insulator types in vogue these days are a solid core insulator stack and high density polymer insulator. capacitance grading. Table‐3 Length of Weight of Size of No. For AC Conductor.a voltage of 220kV. The steel tube is compressed (crimped) against the two ends of Steel which are exposed by peeling of the Aluminum Strands for half the length of steel tube strands of ACSR & the Aluminum strands. For 400kV class of line the insulator size and creep age distances are higher.3 The insulators used on the line are also governed by the basic insulation level selected in power system.3. Kg (D x H) Double Double Double mm x mm mm mm Kg No No Kg 1 66kV 1300 1000 150 75 10 5 7000 Suspensio 255 x 146 1280 1140 170 85 12 6 8180 255 x 146 n Tension 2 132kV 1716 1600 240 120 18 9 8180 Suspensio 255 x 146 2190 1790 260 130 20 10 11500 255 x 146 n Tension 3 220kV Suspensio 255 x 146 8180 14 28 130 260 2340 2640 n 255 x 146 11500 15 30 140 280 2850 3200 Tension 4 400kV 4400 4200 550 275 46 23 11500 Suspensio 255 x 146 6200 5900 1280 640 48 24 16500 255 x 146 n Tension 5. 5.of Electro insulator each Line insulators Insulator Sr. ‐mech. 5. 5. back flash over etc.4 Conductor Accessories 5. Hydraulic equipments are used for crimping. of insulators to be used are 23 for suspension and 24 for tension tower.2 The design of insulators does not only depend upon the creep age `distances but they have many intricacies such as the type of material used in the insulators. The anti‐fog type insulators are found most suitable in the polluted atmosphere. string String No Voltage insulator disc Strength per string Single Single Single . Even though the polymer long rod insulators are simpler and low weight.3.4 The choice of disc insulators to be used depend upon the terrain & the pollution level through which the transmission line has to pass and thus fog type and antifog type disc insulator are in use for different applications. and thus No. The important parameters for disc insulator string used in various voltage of transmission line are given in Table‐3. the joint comprises one small steel tube and the other bigger Aluminum tube. they are yet to be popular in this country because of very high cost. The antifog type insulators are in use for different applications. For AAAC or AAC conductor only Aluminum tube is used which is also crimped after steel tube is crimped after sliding over the crimped steel tube. thermal capability. 5.

The PA rods prevents damage and reduces fatigue on the conductor due to the relative movement of the clamp and the conductor and also helps in reducing the effect of conductor vibration on clamp & the tower cross‐ arm.4 Vibration Dampers –They are used to damp the Aeolian vibrations on the conductor. The vibration damper comprises a clamp.4.3 Pre‐formed Armor rods – This is a set of twelve helical right hand. and dead weight.4. After sliding both the parts on the conductor. Power Consultants & Agencies Page 31 .5. The length of both the parts is the same. The sleeve is manufactured in two parts longitudinally and circumferentially major part is 70% on diameter and minor part is 30% on diameter. ball ended Aluminum rods of appropriate length. the sleeve is crimped on the affected part. The set is wound on the conductor at suspension tower location and then the entire assembly along with the conductor is clamped in the suspension clamp. The dampers are clamped to the conductor near the cross arm point on both the sides at a distance of 3 to 5Mtr. The dampers can be solenoid type or 4R type. a messenger cable. 5. 5.2 Repair Sleeve – It is used when one or two strands of the outer Aluminum strands are broken.4.

two earth wires are used for better protection. The common size of earth wire used is 7/3.7 Earthwire – The earth wire is used for protecting the conductor in the mid span.15 and 7/3. They are made of Aluminum. Earth wire Accessories includes the following: 5. The earth wire passes through the suspension clamp. 5.4. two neoprene rubber jaws and two sets of armour rods (each having six rods). 5.4.4.6 Cushioned (Armour grip) spacers‐ They are used as spacers for bundle conductor with amour grip.7.1 Suspension Clamp ‐ This is used for suspending the earth wire through the earth wire peak of the transmission tower. Power Consultants & Agencies Page 32 .4. They comprise an aluminum rod. It is provided at such a height which affords an angle of shield not more than 30º with Top conductor.5 Spacer cum Dampers‐ They is used for bundle conductor spacing and for damping the vibrations.5. In case of 400kV and above. They comprise two arms with clamping device and a spacing yoke having a spring action.66. Rigid spacers are used for twin bundle conductor jumpers.

5.4.2 Tension Clamp ‐ This is used on tension locations of tower and provided in tension position on both the sides of the tension tower.3 Copper Earth bond‐ This is used for providing direct passage to the lightning surge to the tower. Power Consultants & Agencies Page 33 . The copper bond is made out of stranded copper mesh with two lugs on the ends and is about 500mm long.4.5.7. One end of this is connected to the suspension/tension clamp of earth wire and the other end is connected to the tower body.7.

4.8.4.4. They are provided in set of three from either side of the tower. 5.7. The hardware has a hook on the tower side and socket on the conductor side.5 Mid Span Joint ‐ This is used to connect the cut ends of the earth wire.4. They are nothing but a sort of parallel groove clamp. The insulator hardware commonly used is as follows:‐ 5. This is nothing but a steel tube which is crimped on the ends of the earth wire. 5.5.4 Cross bye clips (sister wire clamps) – This is used for providing better continuity to the earth wire.7.1 Single Suspension hardware – This is used on suspension locations of the tower line falling in the rural areas and also falling in the agricultural field.8 The Insulators are connected in series or in series –parallel to form a single or double string on the tower. Suitable hardware is required for securing the insulators to the tower. Power Consultants & Agencies Page 34 .

yoke on tower side and yoke.4. 5. dead end clamps on the line side.4.8.3 Single Tension hardware— This is used on tension tower locations. They have anchor and a yoke on the tower side and yoke & sockets on line side. Power Consultants & Agencies Page 35 .5.8.2 Double Suspension hardware—this is used on suspension tower locations which require a road crossing or a railway crossing & river crossing.8. This hardware has a shackle on the line side and a dead end clamp on the line side.4. They have D‐shackle.4 Double Tension hardware— This is used on tension tower location having a major road crossing. river crossing. railway crossing etc. 5. power line crossing. They also have a Suspension clamp on the line side.

6. 5. If earth wire is not provided or is missing.5. The hardware permits the conductor to swing to some extent and also restrains the conductor from over swing. Any damage to insulator will cause a short circuit on the conductor and may also lead to the break down. 5.1 Stringing is the last major item of construction activity.5.3 The hardware part of the insulator string is very important for the performance of the conductor.5 The long span of River & Creek Crossing imposes differential stresses due to variation in wind pressure and temperature along the long span. This requires much skill and technical know‐how. The stinging crew shall include skilled laborers. The length of the catenary is very long & therefore the conductor swing is also very big.5. Some salient points are described below‐ The earth wire provided on the tower provides a cover to the conductor against lightning surges. experienced fitters and supervisor. 5. The stringing activities are most important and time consuming activities in transmission line construction. b) Absorb the maximum tension of the conductor under 0ºC temperature with certain percentage of wind pressure. the life of conductor and insulator will be reduced. The variation in wind velocity over tall tower also steps up the vibration level. The stinging tools and tackles should be of good quality and in good working condition. Any loose end will result into damage to the conductor. The conductor will carry this along the line and insulators may get damaged.1 The Transmission line components described above has relation with the conductor.5. 5.4 The earthing system provides a safe passage to the fault current & lightning /switching surges.5.5.2 The insulators keep the conductor in position on suspension and tension locations & also insulate the conductor from the tower body. The transmission tower provides full support to the conductor with two extremities – a) To allow sufficient ground clearance and object clearance to the conductor under maximum temperature & still air. The earth wire accessories help in supporting the function of earth wire. if the conductor is placed within an umbrella of 30º degrees.0 Stringing of Conductor and Ground Wire 6. If earthing system is poor.5 Relation of Conductor With Transmission Line Components: 5. the conductor will be loaded by lightning and stray discharges. Power Consultants & Agencies Page 36 . Any deficiency in the tower design will lead to a catastrophe.

6. • All the insulators shall be cleaned and examined for hair cracks or any damage.2 The stringing activities are mainly consisting of the following: • Hoisting of insulators • Paying of conductor/ground wire • Rough sagging of conductor • Final sagging of conductor/ground wire • Clipping/clamping of conductor and jumpering. 6. • The security clips (R pin/W pin) should be properly placed before hoisting. 90KN. Power Consultants & Agencies Page 37 .3 Hoisting of Insulators Following may be noted for hoisting of insulators. 120KN and 160KN. • The insulators used on transmission lines are 11KV antifog type Disc insulators having capacity as 70KN. • The insulator strings shall be assembled on ground. • The suspension insulator strings shall be used on all suspension locations (tangent towers) and tension insulator strings on all tension locations (angle towers having15/30/60deg Deviation and Dead end towers). • The strings are then hoisted and fixed to the tower cross‐arm along with hardware and Arial rollers.

fencing and other obstructions which are likely to cause damage to the conductor. • Sufficient number of aluminum snatch blocks shall be used for paying out of conductor.4 Paying out of Conductor/Ground wire Following may be noted for paying of conductor. the conductors of all the phases shall be anchored near the tension location. • The mid span joints and tension hardware are compressed by using hydraulic compression machine. • Thus the tension on the wire will minimum. Further not more then one joint in a span of each conductor shall be permitted. • The conductor drums should be handled carefully at site to avoid any damage to the outer aluminum layer. • All conductors shall be stressed to their maximum working tension at the time of stringing according to the sag tension charts. • The ground wire drums should be opened and laid carefully in such a way to avoid cracks/damages. is line section). • Precautions should be taken to avoid conductor rubbing on the ground by providing adequate number of ground rollers. check for sag should also be made at intervals corresponding to the ambient temperature shown by the thermometer placed at site. • During the rough sagging. 6.6 Final Sagging of Conductor/Ground wire Following may be noted for final sagging of conductor / ground wire. no joints shall be permitted. • No joints of conductor shall be allowed within 30m from suspension/tension hardware . The ground wire running blocks are hoisted on the towers prior to taking up this operation. • Prior to taking up of conductor paying activity. • The ground wire is pulled manually or by tractor along the line. the conductor will be lifted above the ground by about 3 meters. • Dynamometers shall be used in tensioning of conductors. • Before commencing of string works. 6. • All the compression joints shall be carefully made and a record of initial and final lengths of the joints signed by the contractor’s and purchaser’s representative should be maintained. • Extra sag of 150mm should be allowed at all important tension locations of railway crossing / major road crossing/ river crossing spans.6. • It should be ensured that no joint in ground wire is within 30m from the suspension/tension clamp. • In case of railway/road crossing spans. • Normally ground wire drums are mounted on turntable near tension location. • The conductor and ground wire shall be made to sag correctly as per the approved stringing charts. Power Consultants & Agencies Page 38 . copies of sag tension charts (supplied by the design department) showing initial and final sag should be made available at site to EIC.5 Rough Sagging of Conductor • On completion of conductor paying work between two tension locations (i. • Additional rollers shall be provided for crossing thorny hedges.e. the areal rollers are fitted to the towers along with suspension strings.

• This method is applicable where it is desired to keep the conductor off the ground to minimize surface damaged or in areas where frequent crossings are encountered. • The suspension clamps of the suspension hardware should be fixed (bolted) at the centre of the preformed armour rods. • Using this method. vibrations. • The sag. before clamping. should be checked in the first and last span of the section having eight spans. 6. the conductors are kept under tension during the stringing process to keep conductor clear of the ground and obstacles which may cause conductor surface damage as well as clear of the energized circuits. the sag at intermediate spans should be verified with the help of sag board provided at suitable distances (as per the approved stringing chart and the corresponding site temperature) on the tower body of intermediate locations. splicing cart and pulling vehicle. pullers. if the section is having more than eight spans. providing of preformed armour rods. • One more important reason to use the tension stringing equipment for stringing of bundle conductor is to release. • The equipments involved in this method are reel stands. • The vibration dampers should be fitted on tension locations at an appropriate distance from the tension hardware (specified by the design department) during the rough/ final sagging of conductors. Following required for clipping / clamping: • Conductor shall be clamped within 24 hours of final sagging. the preformed armour rods shall be wrapped keeping the centre of the preformed armour rods at the centre point of the stringing sheaves. vehicles or any other reasons. tensioner. • Care should be taken to see that all the strands of the rods are fixed on the surface of the conductor without any void. payout. • During final sagging of conductor. reel winder. etc. • The conductor shall be pulled up to desired sag (final sag) and left in aerial stringing sheaves for at least one hour. • The vibration dampers on suspension locations shall be fitted at an appropriate distance on either side of the suspension hardware as specified. removal of aerial sheaves. • During the time when conductor/ground wire is on the stringing sheave (before final sagging) it shall be ensured no damage of conductor/ground wire occurs due to wind. • This will ensures equal sags of each sub‐conductor in a span and sub‐span. • At all the suspension locations. After which the sag shall be rechecked and adjusted if required.7 Clipping/Clamping of Conductor and Jumpering The clipping/clamping work includes fixing of suspension hard wares. • The stringing of bundle conductor (two or more conductor) shall be carried out by using tension stringing equipment.It should be ensured that the conductor/ ground wire after being pulled shall not be kept on stringing sheaves for more than 72 hours before being pulled to the specified sag. Power Consultants & Agencies Page 39 • . before clipping work is taken on hand. rough sag and final tensioning of all the sub‐conductors of the bundle under equal physical tension. pilot line winder. • The check should be provided at intermediate span also.

over tightening should be avoided. Care should be taken to compress the jumper cones with hydraulic compressor machine so as to have firm grip with the conductor. • The earth wire stringing is normally done before the stringing of conductor. • The tightening of bolts/nuts should be proper.9 Protection of Towers • In the hilly terrain. 6. Anti climbing devices etc as per their respective position shown on the structural drawings. Number plate. • Jumpering work is done on the earth wire tension tower. • Sister wires and clamps are provided on each tower making an additional loop on the top of the earth wire point which also ensures better conductivity & continuity. on either side of the locations. also known as sister wire clamps. • The clearance with the tower body. the foundations of the tower are susceptible to the damage due to the erosion of soil covering it. fixing of the jumper to the tension hardware on either side of the tension location etc. the suspension clamps are provided on the suspension locations and compression type dead end clamps are provided on the tension locations. • The earth wire suspension and tension clamps are connected to the main tower body using braided copper earth band. • The rough sagging and final sagging is done exactly as per the procedure described for conductor. • The bolts and nuts of cross by clips should be properly tightened. • The ground wire jumpers are also prepared using appropriate length of ground wire having compressed jumper cones on either side. after providing jumpers. • An additional ground wire piece called sister wire is fitted on the newly strung ground wire at the top of all the locations using 2 to 3 numbers of cross by clips. shall be checked as per the approved tower drawing. Sometimes the tower is spotted on the ravines or river banks and one or more of the four tower legs are subjected to soil erosion. Power Consultants & Agencies Page 40 • . • Vibration dampers are also provided on the earth wire to damp the Aeolian vibrations. • The approved stringing charts are used for stringing of earth wire. Circuit identification plate. The clamps are required to be properly tightened to ensure proper connectivity and trouble free service. • In both the above cases it is usual to provide retaining wall and or revetment. • The vibration dampers for ground wires shall be provided at appropriate distance on either side of the location as specified. • After final tensioning of the earth wire. Danger plate. • This earth bond gives direct path to the lightning discharges traveling on the earth wire to the mother earth through towers and safe guards the conductors.The jumpering work of conductor includes cutting of proper length of jumper providing of jumper cones on both the ends of jumper. • This happens because of gushing water from upstream.8 Fixing of Tower Accessories After the stringing work is done it is necessary to fix the tower accessories such as phase plate. 6. • The prepared jumpers shall be then fitted to the tension clamps on either side of the tension locations.

This barrier has to be sufficiently strong and made out of girders and channels. tackles.• • • Whenever the Transmission line is passing through a corridor having major road on both the sides or the tower line is passing very near to the major road it is necessary to provide a steel barrier around the tower up to height of 3 meters. equipments and vehicles required for the construction of EHV line of various voltage classes such as 66 KV. tackles. The transmission line construction activity generally includes:‐ • Survey and alignment • Foundation work • Erection of super structure • Stringing of shield wire and conductor • Testing and Commissioning Each of the above activity need different types of tools. 220 KV and 400 KV etc. 7. Power Consultants & Agencies Page 41 . man power etc. Tackles Equipment. Vehicles and Infrastructure Required For the Construction of The EHV Transmission Line 7. The details given here under give a broad view of the tools. • This survey work is different from the survey work required to be done for civil establishments. are given here after. • Expert surveyor assisted by helpers and suitable vehicles to carry instruments is the basic need. man power and other infra structure required in the construction of EHV transmission lines.2 Infrastructure for Survey • This is the first and foremost activity in the transmission construction. equipments. 7. The barriers have to be well founded to take the impact of the dashing vehicles. 132 KV. The activities are labor oriented and besides there are restrictions on the use of automatic machineries due to the constraint of cost and the constraint of movements in the rural and in‐accessible tower and line locations. The erection activities are spread over a long period and are mostly carried out in the rural areas and therefore appropriate infrastructure is required.1 The details of man power tool.0 Details of Manpower Tools. tackles.

The infra structure required for carrying out survey work is listed below. tables. petromax etc. In case soil collapse shoring and shuttering are required. As per requirement Transport required for Survey Gang Jeep with trailers 1 NO 7. in hilly locations we may have to blast the rock. Sometimes. dewatering has to be resorted to. Average output per gang consisting of about 85 people per month will be: Excavation 60 m³ Soft rock 150 m³ soft rock Output of hard rock will depend on situation 400 ‐500 m³ Normal soil +180 m³ normal soil Page 42 Power Consultants & Agencies . In case sub soil water is encountered during excavations. The output in hilly terrain may be substantially low. water drums camping cots.3 Foundation activity • This activity has to be carried out from location to location spread over a distance which is sometimes as large as 400 meters. Average output per month per gang consisting of about 10 crew members will be : (i) Alignment survey 15 km (ii) Detailed Survey 20 km (iii) Check Survey 20 km Wherever topographical survey is to be carried out the output will be less and will depend on the quantum of work and terrain. The surveyor should also have in‐depth knowledge of tower spotting. Tools required for Survey Gang Theodolite(or Total Station) with stand 1 NO Dumpy level with stand 1 NO Ranging rod 5 NO Leveling Staff 2 NO Engineers chain ‐30 m 1 NO Engineers chain ‐20 m 1 NO Steel Tape ‐30 m 1 NO Steel Tape ‐20 m 1 NO Survey umbrella 1 NO Chain pins 30 NO Spades. The foundation depth may vary from 1m to 5m depending upon the soil/rock and decision regarding the type of foundation has to be adopted. • The excavation plan will change accordingly. Excavation has to be carried out in various types of soils and rocks. chairs.• • • • • • • The surveyor must have the knowledge of preparing profiles and also various methods to carry out the correct survey. knives and exes for clearing the bushes and trees As per requirement Tents. The infra structure required for this activity is as below. buckets.

Stub‐setting and Concreting Gang Stub‐setting Templates Stub‐setting Jacks Form boxes/Chimneys Mixture Machine ‐Diesel engine driven Mixture Machine ‐ Hand driven Needle vibrator Dewatering pump Air compressor for drilling holes in rock High carbon drilling rods for drilling holes in rock Exploder Water tanker trailor Theodolite with stand Ranging rod Dumpy level with stand (or Total Station with Prism) Leveling staff Survey umbrella Concrete cube mould (for testing the concrete) Wooden shuttering & poles Mixing Sheets Measuring Box Metal screen (for course aggregate) ‐ 40 mm mesh Metal screen (for course aggregate) ‐ 20 mm mesh Metal screen (for course aggregate) ‐ 12.Stub‐setting & Concreting Tools and Plants required for Excavation.5 mm mesh Sand screen ‐ 4.5m length) 30 m metallic tape 30 m steel tape Engineers’ spirit level Steel piano wire/thread Crow bar Pick axe Spade Shovel Gamelas Buckets Iron rammer (4.5 Kg) Power Consultants & Agencies 60 – 70 m³ As per requirement ‐do‐ ‐do‐ 1 NO 2 NO 1 NO 2 NO 1 NO As per requirement 1 NO 1 NO 1 NO 3 NO 1 NO 1 NO 1 NO 6 NO As per requirement 12 NO 6 NO 1 NO 1 NO 1 NO 1 NO 6 NO 5 NO 1 NO 1 NO 2 NO 50 m 20 NO 12 NO 25 NO 8 NO 30 NO 12 NO 5 NO Page 43 .75 mm mesh Empty barrel (200 liters capacity) Steel/Aluminum/Wooden ladder (3.

• Tools required for Tower Erection Gang Ginpole / Derric Pole ‐ 75/100 mm dia & 8.5 – 9 m length 2 NO Polypropylene rope ‐ 25 mm dia 700 m Polypropylene rope ‐ 19 mm dia 1000 m Single sheave pulley ‐ closed type 8 NO Single sheave pulley ‐ Open type 4 NO Crow bars (25 mm dia & 1. Hook (12 mm dia). buckets. Transport required for Stub‐setting & Concreting Gang Truck (For transportation of metal and sand from Source. Slings (16 mm dia & 1 m As per length). binding wire Hammer. depending upon the type of tower. tables. Motor Cycle 1 NO 7. Poking rod (16 mm dia) ‐ 3 m length Poking rod (16 mm dia) ‐ 1. camping cots. tommy bars requirement Tents. camping Cots.5 Stringing Stringing work is almost the last activity. in the overall construction activities in the EHV transmission lines. Manila rope ‐ 12 mm dia. chairs.8 m length) 16 NO Spanners (both ring and flat).T. buckets. Tents.Masonry trowel Manila rope ‐ 38 mm dia. The infrastructure required for this activity is given under • Average output per gang considering of about 50 crew members per month will be ‐ 80 M. Hooks (12 mm dia) ‘D’ shackle. Truck 1 / 2 NO 2. As per petromax etc requirement Transport required for Tower Erection Gang 1. plumb bob (0.5 m length Blasting materials. Hammers. spanners (both ring and flat) etc. water drums. reinforcement steel and Other materials from site stores) Tractor with trailer Motor cycle 6 NO 150 m 30 m 2 NO 2 NO As per requirement As per requirement As per requirement 1 NO 1 NO 1 NO 7. While erecting it is necessary that equilibrium is maintained and damage to the tower material and accidents are avoided. cement. While stringing operations are on. load balance and rigging arrangement has to be full – proof. Tractor with trailer 1 NO 3. water drums.45 Kg).4 Tower Erection • Tower erection requires lot of precision. Besides the material has to be lifted from the ground level to various heights. save commissioning. Tables and chairs petromax etc. Tommy bar. This is really a very precise and hazardous activity.The man power deployed has to be proportional to the actual physical tension Power Consultants & Agencies Page 44 .

anchor pins (45 mm dia & 850 mm long) Hydraulic compressor machine 100 T capacity with die sets Traveling ground Dynamometer ‐ 10T 1 SET 100 NO 60 NO 2 NO 10 NO 12 NO 30/100 NO 6 NO 2 NO 4 NO 10 NO 10 NO 5 NO 4 SETS 2 NO 8 NO 12 SETS 4 NO Page 45 Power Consultants & Agencies . The infrastructure required for stringing operations is given under Average output per gang consisting of about 200 persons per month with Tension Stringing – Machine stringing method.• • • required to be given to the earth wires and conductors. Excess man power may result into over tension and less man power may result into improper stringing and accidents. For 400 KV single circuit 15 km For 400 KV double circuit 8 km For +/‐ 500 HVDC multi circuit 5 km Requirement of man power and average output per gang for carrying out various types transmission lines by manual method is furnished here under : Description of line Man power (NO) Average output / month (km) 66 KV single circuit 75 30 66 KV double circuit 75 15 132 KV single circuit 100 30 132 KV double circuit 100 15 220 KV single circuit 125 30 220 KV double circuit 125 15 400 KV single circuit 225 15 400 KV double circuit 225 8 Tools and plants required for stringing Gang for Tension/Manual Stringing TSE sets (Tensioner and Puller of 8/10 T capacity) Running block for conductor Running block for earth wire Head Board Pilot wire each of 800 m length Pilot wire joint Ground roller for Tension/Manual Stringing Wire mesh pulling grip (one end open) of required dia for conductor Wire mesh pulling grip (one end open) of required dia for earth wire Wire mesh pulling grip (double end open) of required dia for earth wire Articulated joint – Heavy duty (20T) Articulated joint – Medium duty (10T) Articulated joint – light duty (5T) Drum mounting jack for conductor drum of 10T capacity Turn table (5T capacity) Anchor plate (1.0 x 8 mm) with 15 Nos.5 m x 1.

8 m length) Nail puller Wire rope ‐ 19 mm dia Wire rope ‐ 16 mm dia Wire rope ‐ 14 mm dia Polypropylene rope ‐ 25 mm dia Polypropylene rope ‐ 19 mm dia ‘D’ – Shackle ‐ 190 mm long ‘D’ – Shackle ‐ 150 mm long Bulldog clamp ‐ 100 mm long Bulldog clamp ‐ 100 mm long Hammers. flat files. screw drivers. slings etc. 2 NO 4 NO 6 SETS 2 SETS 4 SETS 16 NO 4 SETS 4 NO 50/20 NO 15/10 NO 6 NO 6 NO 4 NO 16 NO 6 NO 6 NO 8 NO 4 NO 2 NO 6 NO 4 NO 1 NO 3 NO 1 NO 2 NO 3 NO 30 NO 10 NO 6 NO 1000 m 150 m 900 m 500 m 500 m 40 NO 125 NO 125 NO 35 NO As per requirement As per requirement Power Consultants & Agencies Page 46 . scaffolding. spanners (both flat and ring). table. etc. Tents. hacksaw frame and blades. round files. petromax. steel and metallic tapes.Dynamometer ‐ 2 T Pilot wire reel stand Four Sheave pulley with 12 mm dia 300 m length wire rope Four sheave pulley with 9 mm dia 300 m length wire rope Four sheave pulley with 12 m dia 150 m length wire rope Equalizer pulley (10 T) capacity Conductor lifting tackle Winch – motorized/ manual – 10 T capacity Come along clamp for conductor (bolted type / automatic) Come along clamp for earth wire (bolted type / automatic) Tirfor (5 T capacity) Aerial chair (For conductor) Aerial Trolley Turn Buckle ‐ 10T Turn Buckle ‐ 3 T Tension/Sag plate (for tensioning purpose) Sag Board Marking roller Mismatch roller Joint protector Walkie talkie set Theodolite with stand (or Total Station with Prism) Thermometer Survey umbrella Hydraulic wire cutter Binocular Flag (red and green) Crow bar (1. water drums. chair. buckets. cutting pliers. camping cots.

Tractor and trailors Jeep Motor Cycle 4 NO 2 NO 5 NO 2 NO 1 NO Manual Stringing 4 NO 1 NO 6 NO 2 NO 1 NO 8./45 h.2 The main activities of foundation. Proper construction practice ensures high reliability and long life of the transmission line 8. tower erection & stringing are completely diverse from each other and require different type of skill workers as well as tools tackles and equipment.0 Conclusion 8.p.p. tractor 35 h.6 Transport Required for Stringing Tension Stringing Truck 75 h. ********** Power Consultants & Agencies Page 47 .7.1 Construction of EHV transmission line is a very precise and skillful job.p.