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

SAFETY ASPECTS OF CONDUCTOR

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

a)Mechanized Paying out of conductors and installation

Manually

b)Manual Paying out of conductor and its manual

installation.

TYPE OF RISK ASSOCIATED:

a)Fall of workmen from height

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

c)Collapse of towers, conductors and hardware

Fittings on workers and passers by

d)Electrocution due to contact of person /

Conductors with live wires

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

CONSEQUENCES OF ACCIDENTS:
a) Fatality / Injuries to workers

b) Fatality / Injuries to co-passers by

c) Loss to properties including public property

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

e) Public resentments, disgrace

f) Punishment under the relevant laws
VARIOUS STAGES OF WORK IN THE INSTALLATION OF
CONDUCTORS IN TRANSMISSION LINE

a) Insulator and aerial roller hoisting

b) Paying out of pilot wire

c) Paying out and sagging of Earth wire.

d) Paying out of conductor

e) Rough sagging

f) Final sagging

g) Clipping and fixing of line spacers

h) Fixing of jumpers

i) Stringing of river crossing reaches

j) Power line crossing

k) Stringing across Highways and other service roads

l) Transportation and stacking of conductor drums and

Hardware fittings
 HAZARDS ASSOCIATED AT VARIOUS STAGES OF WORK:

SL
ACTION REMA
NO HAZARD INVOLVED REMEDIAL MEASURES CHECK POINTS PERIODICITY
BY RK
.
INSULATOR AND ARIEAL ROLLER HOISTING
1. a) Fall of workmen from a) *Use of fall arrester must be ensured for CHECK FOR--- SITE A) REGULAR The

cross arm sitting location A) *Fall arrester. ENGINEER And for each most
making vertical movement over tower.
* Good condition / GANG insulator string hazardo
or while ascending and * Proper use of double lanyard type full body
double lanyard Safety LEADER hoisting. us
descending over tower. harness shall be ensured.
belt. aspects
b) Fall of insulator string or b) * Proper fixing of cotter pins/split pins b) * Availability of of
other tools and tackles.
mustbe ensured before hoisting insulator string. 12mm dia wire rope as b) REGULAR insulato
c) Hit by tractor in path of a lifter. And for each r
* Check the wire rope (12mm) being used for
his maneuvering. * Good condition single insulator string hoisting
insulator string hoisting for any type of visual
d) Hit Injury or crush sheave pulleys of hoisting. is when
damage.
injury while handling bearing type only. workme
* Before hoisting proper working condition both
* Additional safety c) REGULAR n uses
insulator boxes and heavy
the single sheave pulleys shall be ensured and
rope used foe securing For every road to get
aerial rollers.
also only bearing type pulleys shall be used. single sheave pulleys crossing down
* if open hook type single sheave pulleys are of open hook type. through
being used , then additional safety rope shall be * Good condition D) Regular and insulato

used for avoiding its accidental release. 16mm dia wire rope for every lot of r string

* only 16mm dia wire rope sling should be used sling. insulator boxes. for
* License and driving releasin
for securing single sheave pulleys with tower
skill of operator/ g guide
members provided , precautions has been taken
driver. rope
against sharp edges of tower members.
IMPORTANT CHECK: tied
* Check for proper connection of aerial roller 1. Before insulator with
with insulator string. hoisting tower erection bottom
3. Always avoid bending of insulator string while must be complete in all yoke

hoisting i.e. P.P rope or wire rope shall be tied regards. plate or

with 3rd or 4th insulator disc from top. Bending of 2. more importance with
shall be given to cross aerial
insulator string may lead to failure of R-clips.
arm i.e all the roller.
 c) * Only licensed and well trained driver shall connecting bolts and
tower members must be
be engaged for operating tractor, used for
in properly intact
insulator string hoisting.
condition.
* If at all any road crossing exist in maneuvering
path of tractor, presence of SIGNALMAN must
be ensured . Maneuvering path of

d) *Over height stacking of insulator boxes

shall be avoided at location.
* Wooden planks having nails shall be kept well
away from site to avoid nail prick.
*WEARING OF SAFETY HELMET AND SAFETY
SHOE IS MUST BY ALL PERSONNELS
IRRESPECTIVE OF NATURE OF JOB.
COMMAN PRACTICE: it is very common practice
of using step bolts, in D-shackles and in aerial
roller assembly , which are not meant for heavy
loading and always suspected to failure.
PAYING OUT OF PILOT WIRE
2. a) Minor cut injury to A) Periodical visual inspection of pilot wires Condition of pilot wire
Condition of P.P rope Site
fingers due to for wear and tear and other visual damages
being used Engineer
protruding wires of pilot shall be done.
Effective Use of PPEs / Gang
wire. B) Use of leather type hand gloves shall be Jhulla arrangement Leader

b) Fall of workmen from ensured to minimize the severity in case of IMPORTANT CHECK: it
is generally noticed
cross arm position/ such incident.
that local lineman uses
aerial roller (for passing C) Use of double lanyard full body hare ness
to give shutdown of
P.P rope through roller) shall be insured. 11kv and 33kv power

Or otherwise during Double arrangement for ascending over lines and fitters of
stringing gang uses to
ascending and insulator string shall be done as follows
lower the conductor
descending over tower. D)) Lanyard of safety belt shall be wrapped
after de-energizing the
c) Hit injury while around the insulator string. line. Following min.

handling pilot drum reel. E)) Jhulla arrangement made of 20mm P.P precautions must be
D) Over turning of rope, controlled from ground shall be used. ensured in such
operations---
tractor while F) Regular pep talk shall be done and
1. be perfectly sure
transporting pilot drum awareness should be created among
about distribution
reel. workmen regarding safe handling & feeder (of the

E) OTHERS: transportation of pilot drum reel. particular line) ,

installed in substation .
1.pilot wire connectors: F) Pilot wire connectors shall be checked
2. Ensures the does not
for any type of visual damages in
have any looping with
Pin and its threaded portion other line near by and

2. eye splicing in pilot Roller & U-portion then decide the point
of opening jumpers.
wire G) Visual checks shall be done for condition
( views of local people
of eye loops made in pilot wire before every
must be taken
3. Power line / road or use. regarding the rout and

highway crossing H) Obtain proper shutdown before lowering interconnection of line)

3. Before opening the
(chances of the conductors of any line crossing.
jumpers ensure the
electrocution / injury to I) Proper scaffolding capable of bearing
line is discharged
co passers. load of pilot wire and conductors shall be through bundling the
made for every P&T and road crossing. conductors by passing
a p.p rope over it.
J) Suitable warning signs with signalman
4. Ensure the use of
(equipped with walky-talky) shall be
hand gloves meant for
deployed at every road crossing irrespective working on HV/EHV
of its type and users. lines.
5. The conductors shall
be lowered and kept in
bundled condition.

PAYING OUT OF CONDUCTOR

POSITIONING OF TSE MACHINES
 Hit injury to workmen A) Proper care shall be exercised while shifting

Site Engineer / TSE operator / gang leader

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

PRE PAYING OUT CHECKS

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

SITE ENGINEER / GANG LEADER

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

connectors only in drum lifting jack. drums and TSE

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

PULLER POINT
A) Cut injury in fingers A) Proper personnel precautionary measures

SITE ENGINEER
/GANGLEADER
while handling pilot wire shall be ensured in pilot wire reel (while
reel. removing from puller machine after complete
B) hit injury/hit injury binding).
while handling --Same as above--
( loading/unloading) of
pilot wire reel.

GUYING OF DEAD-END TOWER

Failure of guy anchorage The make-up end tower shall be properly guyed IMPORTANT CHECK:

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

while working at height.

Ensure use of lifeline for making horizontal
movement over cross arm.
PAYING OUT OF CONDUCTOR
TIGHTIENING OF PILOT WIRE FROM
PULLER END
SEVERE HIT INJURY This is the most critical & hazardous IMPORTANT CHECKS:

SITE ENGINEER
SIGNALMAN WITH RED
TO WORKMEN AND activity of machine paying out operation. It
& GREEN FLAGS WITH
SIDE PASSERS, is well known that pilot wire are laid on
WHISTILES MUST BE
ANIMALS & ground through out entire section proposed PALCED IN BETWEEN

VEHICLES (ROAD for paying out. When puller starts EACH BEFORE
STRATING PILOT WIRE
CROSSING) tightening, pilot wire uses to uplift with
TIGHTIENING
high swing and speed.
OPERATION. AT LEAST
TWO SIGNAL MAN
WITH FLAG AND
WALKI-TALKI SHALL
BE POSTED ON ALL
ROAD CROSSINGS.
PULLING OF CONDUCTORS
a)SEVERE HIT A) While conductor paying out is under IMPORTANT CHECK:

SITE ENGINEER / GANG LEADER

The entire section
INJURY TO progress one supervisor (must be capable
proposed for paying
WORKMEN AND SIDE of making effective communication with
out shall be checked
PASSERS, ANIMALS & puller and tensioner operators and other
for visual hindrances
VEHICLES (ROAD intermediate personnels positioned at road
such trees, buildings &
CROSSING) / power line crossings) must have to move any other type of
B) FAILURE OF PILOT with head board. structures where
WIRE OR PILOT B) check out for free running of aerial headboard can stuck.
WIRE CONNECTOR rollers and also obstruction free passing of Branches of tress

RESULTING IN HIT head board , mid-span joints ,pilot falling in the line of

INJURY. connectors by deploying signalmans at headboard are more

dangerous, and it must
every tower . hey may tasked with keeping
be cleared without
vigil in between spans so as to keep
taking any chance.
unauthorized personnels away from
particular phase corridor.
C) Check SWL of pilot wire connector and
its physical condition and also instruct
operator (puller) slow down pulling when
connector uses to enter in bull wheal of
puller machine.

MAKE UP & ROUGH SAGGING OF

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

SITE ENGINEER/ GANGLEADER

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

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

shackles being used for holding conductors for NEALRY 6.0 FEET.
ENSURE THAT WIRE
following---
ROPE EMEREGS (FROM
A) Liner condition of came along clamp.
GROUND) AT LEAST 10.0
B) Availability of all bolts& nuts and packing 12.0 FEET AWAY FROM

washers. TOP OF PIT. FOR THAT

SLOPE CUTTING AT 45*
C) Availability of both side check nut.
SHALL BE ENSURED TO
D) Suitable capacity of D-shackle (min. 5.0 ton
AVOID DIECT UPLIFT
best suited 10.0ton capacity) LOAD ON DEADMENT
E) never replace the pin of D-shackle with any ANCHORE.

other means.
FINAL SAGGING OF CONDUCTORS

CHECK FOR SAGGING ARRANGMENT AND

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

AND TACKLES ARRANGMENT. Use articulated joint

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

loading and accordingly select tools and tied at both end of

tackles for all sections. four sheave pulley

shall be used to
GENERAL CONSEDRATION ACSR (QUAD)

Site engineer /gang leader

avoid its turning.
D/C LINE
The 12.0mm wire
A) Check the condition of sag plate and
rope lead coming
condition of welding. in. thickness of sag out from four
plate shall be of 12mm. sheave pulley set
B) Use min. 15ton capacity D-Shackle for should be routed
connecting sag plate with four-sheave pulley through close type

lifter arrangement. pulley positioned;

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

conductors in quad arrangement and one giving load.

conductor in twin conductor arrangement.

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

Site engineer /gang leader

connected directly with 15.o ton capacity D- A) Check the condition
and suitability of bolts
shackle.
being used for holding
V-sling used for holding conductors shall of
sag winch with tower
A) 18.0mm wire rope for twin conductors leg.

B) 22.0mm wire rope for quad conductors. B) proper working of

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

MARKING AND CONNECTING OF

CONDUCTORS WITH HARDWARE FITTINGS

CLIPPING ACTIVITY

JHUMPERING AND SPACERING

 Incorrect and may
lead to failure of
cross arm from
leg member and
cross-arm rafter
join position

Correct
sequence of
looping wire
rope from single
sheave pulleys ,
in insulator
hoisting.
 COMMAN CAUSES OF ACCIDENTS IN THE WORK OF INSTALLATION OF CONDUCTORS IN T/L
1. Generallackofawarenessandcommitmenttosafeworkingmethodsbyworkers,supervisors,
&siteEngineers.
2.Negligenceinusingappropriatepersonnelprotectiveequipmentsatworkplaces.
3.Lackofknowledgeandexperienceinproperuseofpersonnelprotectiveequipments.
4.Bypassing/ignoringsafetyrulesforreasonsofmisconceivedconvenienceforfaster
Executionofwork.
5.Useofaninappropriate/damagedtoolsandtackles.
6.Failureoftensionbearingmaterials/equipments.
7.Inadequateguyingoftowersorfailureoftensionbearingtools.
8.Improperorovertighteningofconductorsduringsaggingoperations.
9.Lackofgoodcommunicationandcommutingfacilities.
10.Lackofpropertrainingandcontinuingeducationtoworkers,supervisorsand
Engineersinconstructionmethods.
11.Inadequatesupervisionofworkbyqualifiedandexperiencedpersonnel.
12.Lackofdisciplineincontrollingnoncomplianceofsafetyregulations.
13.Exhaustionduetooverworkingbyworkers.
14.Scatteredworkinglocations,difficultinhavingpropercontroloverworklocations.
15.Difficultterrainsandnaturaltopography
 MEASURES AND PRECAUTIONS TO BE TAKEN IN WORK OF INSTALLTION OF CONDUCTORS IN T/L

PREPARATORY WORKS

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

operation.

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

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

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

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

accountability.

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

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

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

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

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

11. Providing temporary earth electrode for stringing equipments.

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

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

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

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

Stringing Methods & General Aspects

Methodsofstringing.
Therearebasicallytwomethodsofstringing.Theseare
i)SlackorManualmethods
ii)Tensionmethod
i)Manualmethod:
Usingthismethod,theconductorispulledalongthegroundbymeansofapullingvehicle(normally
tractor),orthedrumiscarriedalongthelineonavehicleandtheconductorisdepositedonthe
ground.Theconductordrumsarepositionedondrumstandsorjackseitherplacedonthegroundor
mountedonatransportingvehicle.Thesestandsaredesignedtosupportthedrumonanarbor,thus
permitting it to turn as the conductor is pulled out. Usually, a braking device is provided to
preventoverrunningandbacklash.Whentheconductorisdraggedpastasupportingstructure,pulling
isstoppedandtheconductorisplacedintravelersattachedtothestructurebeforeproceedingto
thenextstructure.
ii)TensionMethod:
Usingthismethod,theconductoriskeptundertensionduringthestringingprocess.Normally,this
Methodisusedtokeeptheconductorclearofthegroundandobstacles,whichmightcauseconductor
Surfacedamageandclearofenergizedcircuits.Itrequiresthepullingofalightpilotlineintothe
travelers,whichinturnisusedtopullinaheavierpullingline.Thepullinglineisthenusedto
pull in the conductors from the drum stands using specially designed tensioners and pullers. For
lighterconductors,alightweightpullinglinemaybeusedinplaceofthepilotlinetodirectlypull
intheconductor.

STRINGING PROCEDURE

Thestringingprocedureisbroadlydividedintothefollowingsteps.
i) Payingout&stringingofearthwire.
ii) Guyingarrangementoftower
iii) Insulatorandaerialrollerhoisting
iv) Payingoutofpilotwire
iv)Payingout&stringingofconductor.
v) Finalsaggingofearthwire&conductor.
vi)Clippingandfixingofaccessories.
vi) Fixingoflinespacers
viii) Fixing of jumpers

i) Payingout&stringingofearthwire:
Normallystringingofearthwireisdonemanuallysincehandlingtheearthwireiseasyanditdoes
not get damaged easily. First, earth wire rollers are provided on the earth peaks of all the
suspensiontowersinthesection.Beforehoistingofearthwirerollers,itmaybeensuredthatthe
rollersarefreefromfriction.
Alineman/fittermaybekeptoneachtowertoensurefreerunningoftherollerswithared&Green
flagandwhistle.Atthestartingendofasection,earthwirereelismountedonrollerjacksor
horizontalturntable.Theearthwireispulledfromtowertotowermanuallyorbyusingatractor.
Afterreachingthenexttowertheearthwireispassedthroughthesuspendedearthwirerollerswith
thehelpofapolypropyleneropeandpayingoutiscontinuedfurther.Afteronelengthofearthwire
reelisexhausted,thesecondlengthofwireispaidoutforthebalancesection.Midspanjointfor
earthwireiscompressedonthegroundjoiningthetwolengths.

Guyingarrangementoftower
Beforecommencementofstringing,theangletowerswherethestringingistobestartedhavetobe
Providedwithguysupportsforallthethreephases.Theguysusedgenerallyare20mmsteelwirerope.
Theguysareattachedtothetoweratthetipofthecrossarmsandcenterofthebridge,tothe
strainplateswithsuitableDshackles.Theguysareanchoredinthegroundatanangleof45
Degreesorlessfromthehorizon,attachedtodeadendanchors.Formakingdeadendanchorsinthe
Ground,pitsof1.5mx0.6m,foradepthof1.5mcanbedug.Asetofsteelbeamandchannelstiedin
thecenterwith16mmwirerope,isloweredandthepitisbackfilledwhilecompacting.Theguywire
isattachedtothedeadendanchorwirewiththehelpofturnbucklesof10tonnescapacity.
Alternately,insteadofburiedgroundanchors,adeadweightsofsag5to10tonnescanbeplacedon
thegroundandsagwireattachedtothemsecurely.Afterpullinguptheslacknessintheguy,itis
tightenedbytheturnbuckle.Excessivetighteningoftheguyshouldbeavoided.Itisadvisableto
tightentheguyprogressivelyatthetimeofroughsaggingoftheconductor.
 Insulatorandaerialrollerhoisting
TransportationofInsulators
Therequiredno.ofinsulatorsshallbetransportedtothetowerlocationswiththewoodenpacking.
Thecratesshallbeopenedatthetowerlocation.TheInsulatorhoistingisdonewellinadvanceof
Commencementofpayingoutoperation.
HOISTING:
Afteropeningofthecrates,insulatorsshallbelaidinseries,onwoodenplanksbelowthesuspension
points.Theinsulatorsshallbecleanedwithwaterandwipeddrywithcleanclothfreefromgreaseand
oil.Insulatorsshallbecheckedforanychippingorcrackandshallbereplacedwithnewoneiffound
defective.Theno.ofinsulatorsrequiredforstringshallbejoinedand`R'clipsintheclevisshall
beexpandedtoavoidslippageofthepin.
Thejointsofallinsulatorsshouldbecheckedand`R'clipsshouldbeexpanded.
The bottom insulator is joined to the moose aerial roller. The five wheels of the aerial rollers
shouldbecheckedforfreerunning.Theneoprenerubbercushionontheouterrollersshallbechecked
foranycracks/wearingoutandshallbechangedifrequired.

A single sheave pulley is fixed to the cross arm very near to the suspension hanger. A 20 mm
polypropyleneropeor12mmwireropeispassedthroughthepulleyandboththeendsarebroughttothe
ground.Oneendoftheropeisfirmlytiedbelowthe3rdor4thinsulator.Thecompletestringwith
aerialrollerisliftedupbypullingtheropethroughapulleyattachedtooneofthetowerlegsby
using tractor/manually After reaching the top the string is attached to the suspension hanger and
stringisreleasedslowlytohangfree.
INSULATORHOISTING
 Payingoutofpilotwire
Intensionstringing,apilotwireisusedtopulltheconductor.Thepilotwireisinitiallylaid
throughthecenterwheeloftheaerialroller.A22mmdiapilotwireisgenerallyusedforpulling
ofquadmooseACSRconductor.Thepilotwirecanbelaidlengthbylengthandjoinedwithpilotwire
connectors.
At power line crossings, the pilot wire is laid from both sides and free ends are joined after
obtaining the shutdown of the power line. Sound Scaffoldings shall be provided for P&T and road
crossingsbeforepayingoutofthepilotwire.AstandsignalmanshallbeensuredwithRedandgreen
flagandalsowithwalkytalkytoensureeffectivecommunicationpilotwirepullingequipment(Tractor
orPuller).

Payingout&stringingofconductor.

A)
Positionoftensionerandpuller:
Thepayingoutofconductorisdonegenerallybetweentwotensiontowers.Thepullermachinecanbe
Positionedbehindthetensiontowerononesideandthetensionerinfrontofthetensiontoweronthe
otherside.Theentryofthepilotwireintothebullwheelsofthepullermachineandrunningout
from tensioner machine should be as nearly horizontal as possible. Both the machines should be
securelyanchoredwithtwodeadendanchorsinthegroundandslacknessisremovedinthestay.
Theplacementofdrumjacksshouldbesuchthatthelateralangleofconductorapproachintothebull
wheelthroughguiderollersislowenoughtoavoidrubbingonthesidesandcreatinglooseningofthe
outerstrandsandbirdcaging.Thedistanceofthedrumsfromthetensionershallbeatleast25to30
mtrssoastodistributetheeffectofslidingofouterstrandsduetolowbacktension.Thereel
shouldbepositionedsothatitwillrotateinthesamedirectionasthebullwheels.
 Payingoutofconductor:
For passingthe conductorthrough thebull wheelsof thetensioner, a25 mmpolypropylene ropeis
initiallywoundovereachbullwheelpairinthesamewayastheconductorwillpassduringRunning.
Theropesareconnectedtotheconductors.Theconductorrunshallbefromthetopsideofthedrum.
Theropeispulledbystartingthetensioneratlowpayouttensiontopasstheconductorthroughbull
wheelsandarebroughtoutthroughtheguiderollers.Thesubconductorsareattachedtotheequalizer
pulley/runningboardbymeansofwiremesh/endsocksandswiveljoints.Thepilotwireisattachedto
theotherendoftherunningboardwithswiveljoint.Atthepullersite,thepilotwireispulledto
removeallslacknessusingthereelwinder.Thewireispassedthroughbullwheelsofthepullerand
connectedtothereelwindermachine.Thetensionercanbeinitiallysetforatensionof2to2.5
tones.CautionshouldbemadeoverthewirelesshandsettoalltheStaffwhoareatmiddlepointsand
tothetensioneroperatorthatpullingisabouttobestartedsothattheycanstayclearofpilot
wire.Thepullerisstartedtodrawupthepilotwireuntilthebullwheelsofthetensionerstart
moving.owpayingoutofBundleconductorswithtensionerandPuller.Careshouldbetakenthatthe
pilotwiredoesnotgetentangledintrees,scaffoldings,Aerialrollersetc.whilegoingupduring
tensioning.Thiscanbemonitoredbythestaffwhoarepostedinbetweenthesectionandguidingthe
pulleroperatoroverthewirelesssets.Thepullingoftheconductormaybedoneatamoderatespeed
whiletherunningboardispassingthroughtheaerialrollers.Thetensioninthetensionermustbe
adjustedsothattheconductorstravelwellovertheground.Inlongspanswhereconductorislikely
to touch the ground, ground rollers may be placed so that the conductor can pass without any
scratches.Arunninggroundshallbeconnectedtotheconductorandpilotwirebeforepayingoutnear
thetensionerandpullerwhichshallbeearthedatthenearesttower.Platformsshallbeerectedwith
sturdybellies,whereroads,rivulets,channels,telecommunicationoroverheadpowerlines,railway
lines,etc.havetobecrossedduringstringing
Operations.Itshallbeseenthatnormalservicesarenotinterruptedordamagecausedtoproperty.
Thebacktensionoftheconductorbehindthetensionerhastobemaintainedaspertherequirementof
thetensionerdeployed.Thebacktensionisadjustedbymeansofbrakesprovidedonthedrumjack.A
runninggroundshallbeconnectedtotheconductorandpilotwirebeforepayingoutnearthetensioner
andpullerwhichshallbeearthedatthenearesttower.
Thespeedofpullingoftheconductorshouldbesuchthattoachievesmoothoperation.Slowerspeeds
maycausesignificantswingingoftherunningblocksandinsulatorhardwareassemblies.Higherspeeds
cancreategreaterdamageincaseofmalfunction.Thetensionappliedduringstringinggenerallyis
abouthalfthesaggingtension.Whenlonglengthsofconductorsarestrung,thetensionatthepuller
maybehigherthanthatattensionerduetothelengthofconductorstrung,numberandperformanceof
travellers,differencesinelevationofsupportingstructuresetc.

Jointingofconductor:
Justbeforeonelengthoftheconductorpayingoutiscompletedanotherdrumhastobedeployedin
advancebesidethefirstdrum.Thepayingouthastobestoppedbybrakingthetensionerandstopping
thepullersimultaneously.Thepaidoutconductoroffirstdrumisheldwithboltedcomealongclamps
atadistanceof40to50mtrsfromthetensioner.Thecomealongclampsareattachedtotheground
anchorstays.Theconductorofthefirstdrumisheldandthefreeendiscut.Thefreeendofthe
seconddrumisalsoprepared.Thetwoendsarejoinedwithawiremeshmidspansocks.Thepayingout
is again started by releasing the come along clamps until the mid span socks emerges outside the
tensionerandpullingisstopped.Afteranchoring,theconductorisslowlydrawnoutfromthetwoend
socks.Themidspansocksisremovedandmidspancompressionjointismade.
Aftermakingmidspanjoint,thejointiscoveredwithjointprotectorsleeveswhichisdesignedto
passovertheaerialrollergrooveswithoutdamagingthemidspancompressionjoint.Thepayingoutis
continueduntiltheconductorreachesthepullerendinsufficientlengthtobeconnectedtothe
Tensionhardware.
 Roughsaggingofconductor
Beforefinalsaggingtheconductor,itisroughsaggedtoatensionslightlylessthanthefinal
Tension.Sincefinalsaggingisdonefromoneendofthesection,theconductorisinitiallyattached
tothedoubletensionstringassemblyontheotherend.Fordoingroughsagging,initiallythedouble
tensionstringassemblyisassembledwithinsulatorsandhardwareandhoistedtothecrossarms/bridge
asdoneinthecaseofsuspensiontowers.Thedeadendconesarecompressedonboththesubconductor
ends.Theconductorisheldbycomealongclampsatadistanceof5to6mtrsfromthedeadendcones
andwiththehelpofapulleyconnectedtoagroundanchor,theconductorispulledtoslackenthe
freeendofconductor(sufficientlengthtobeattachedtothehoistedinsulatorstringassembly).By
holdingtheconductorwithpulley,thedeadendconesareattachedtothetensionstring.Thepulley
isslowlyreleasedandtheconductorwillhaulupitselftothetop.Thecomealongclampsandpulley
etc.areremoved.

Finalsaggingofconductor
The sagging of the conductor shall be done using sagging winches. After being rough sagged the
conductorshallnotbeallowedtohanginthestringingblocksformorethan96hoursbeforebeing
Pulledtothespecifiedsag.Thetensioningandsaggingshallbedoneinaccordancewiththeapproved
stringing charts before the conductors are finally attached to the towers through the insulator
strings.Onlyaftertheconductorisroughsaggedontheadjacentsection,finalsaggingcanbedone
intheprecedingsectiontoavoidoverloadingoftowers.Fordoingthesaggingoperation,aspanhas
to be selected in the section to fix the sag board and check the sag. In the event of using sag
tensionchartsshowingsagsineachoftheactualspansandtensionineachsection,usualpracticeis
toplacethesagboardsinthelongestspanofthesection,andinaspanwherethedifferenceof
elevationinthetwosuspensionpointsisminimum.
Thetensioninsulatorstringsarehoistedwithallhardwareonthetower.Theconductorsareheldby
comealongclampsandattachedtoSeparatefoursheavepulleysatsufficientdistanceofsay40to50
mtrsdependinguponroughsagconditionandheightofthetower.Theotherendsofthefoursheave
pulleysareconnectedtothelinesideyokeplateofthedoubletensionstring.Thepullingwiresof
thefoursheavepulleyarepassedthroughasetofsinglesheavepulleysalongthebodyofthetower
tothegroundlevel.Theinitialpullingisdonewiththehelpoftractor/truck.Thenthe
Pullingropesareattachedtohandwinchesmountedonthelegsofthetowerorpowerwinchesduly
Anchored.Woodencrossbarsaretiedtothebodyofthefoursheavepulleyandheldbyropesina
Horizontalpositiontoavoidoverturningofthefoursheavepulleyandtwistingofthepullingwires.
Theconductorisbroughtintofinalsagpositionwiththehelpofwinchesandthesagischeckedby
sightingfarendsagboardfrombehindthenearendsagthreadbymatchingelevationtangentofthe
conductor curve. Sighting should be done keeping sufficient distance from the sag line to avoid
parallaxerror.
Afterreachingthefinalsag,thefreeendoftheconductorispickedupandpulledbyropeandpulley
attachmentalongthelineofthestring.Theconductorismarkedatthepointwherecuttingistobe
doneanddeadendconeistobepressed.Thefreeendsoftheconductorsarebroughtdownandcutnear
themarkinganddeadendconesarepressed.Thefoursheavepulleyisslightlytightenedtofacilitate
attachingthedeadendconetothetensionassembly.Afterfixing,thefoursheavepulleyisslowly
released,broughtdownandallclampsandpulleysareremoved.

Clippingofconductors:
Theclippingoftheconductorfollowssaggingoperation.Thisentailsremovingtheconductorsfrom
Therollersandplacingtheminsuspensionclampsattachedtotheinsulatorstring.Beforetaking
Upclippingoperation,theconductorisearthedproperlyonsuspensiontowers.Theconductorsare
Heldwithhooksat2mtrsawayfromtheaerialrolleronbothsides.Awireropeisconnectedto
Both the hooks passed through a pulley positioned on the cross arm tip in series with a pull
lift/ratchetleverhoist/fourortwosheavepulley.Thecenteroftheaerialrollerismarkedonthe
conductor.Theconductorisraisedbyabout75to100mmandtheaerialrollerisremovedandlowered
byropeandpulley.Thesuspensionclampandarmouredrodsarefixedwithneoprenerubbercushions
centeredoverthemarking.ThesuspensionclampisplacedoverthearmoredrodsandclampedwithU
bolts.Thesuspensionclampisconnectedtothestringandtheliftingdeviceis
Released.Theinsulatorstringwillhangfreelywiththeconductorssuspendedintheclamps.The
Verticalityofthestringmaybecheckedwithplumbbob.Careshouldbetakentopreventanydamageto
theconductorwhilebeingliftedbyhooks.Gunnybagsorrubberpadsmaybeusedaroundtheconductor
topreventdamagetotheouterstrands.

Fixingoflinespacers:
Followingtheclippingoperationsforbundledconductorlines,spacersareusuallyinstalled.Thisis
done by placing personnel on the conductors with the use of a conductor cycle normally known as
spacercycletoridefromstructuretostructure.Dependingonthelengthoflinetobespacedandthe
equipmentavailable,cyclesmaybehandpoweredordieselpowered.Caremustbeexercisedtoensure
thattheconcentratedloadoftheman,carandequipmentdoesnotincreasethesag sufficientlyto
causehazardsbyobstructions(spacers,repairsleeves,midspanjointsetc.)overwhichthecycle
will pass.The installationof thespacers onthe conductorvaries withspan length,the typeand
manufactureofthespacerandisnormallydoneinaccordancewiththemanufacturer'srecommendations
dulyapproved.Thespacercycleishoistedonthebundleatonetensionend.Incaseofenginepowered
cycles,thespacercycleisnormallyprovidedwithtravelmeter,withthehelpofwhichthespacers
are fixed at required distances as per the placement chart. In case of handpowered cycles, the
personnelpullingthecyclewithropemeasurethedistancesongroundandplacementisdoneonthe
top.Anumberofmodelsofspacersarebeingmanufacturedandthemethodofinstallationvarieswith
thedesignofthespacers.Afterreachingthenextsuspensiontower,thecycleistransferredtothe
nextspanbycrossingthesuspensionclampwiththehelpofcrossingropesprovidedinthecycle.In
caseofspanscrossingHT/LTlines,careshouldbetakenwhiledrawingthespacercyclewithrope.
Safeelectricalclearanceshouldbemaintainedtothespacercycleandrope.Forcrossingthelines,
theropeshallbedrawnuptothecycle,andbroughtdownaftercrossingtheline,keepingsufficient
clearancefromtheline.Thepersononthecyclecantravelhimselftocrossoverthesectionabove
thepowerline.

Installationofdampers:
Vibrationdampers/spacerdampersarenormallyplacedontheconductorsimmediatelyfollowingclipping
topreventanypossibledamagebecauseofvibrationstotheconductors,whichatcriticaltensionsand
windconditionscanoccurinamatterofhours.

Jumpering
Thejumpersatthesection/angletowersshallbeformedtoparabolicshapetoensureminimumclearance
requirements. Pilot suspension insulator string shall be used if found necessary (Generally where
angleofdeviationismorethan45degrees),torestrictthejumperswingstothedesignvaluesat
bothmiddleandouterphases.Clearancebetweentheconductorsandground,jumpersandthetowersteel
workshallbecheckedduringerectionandbeforecommissioningtheline.Whilejumperingismade,a
local earthing should be made to avoid any static discharge that might occur due to the voltage
inducedonthelinebyexistingpowerlinesinthevicinity.Careshouldbetakentoleavejumpersfor
oneangletowerinacontinuousstretchof25to30kms,soastopreventtransmissionofelectric
shock. These left out jumpering can be taken up during final inspections. The individual sections
jumperedshallbekeptearthedandearthshallberemovedonlybeforecommissioning.Thejumpersin
generalare10to15mtrsinlength.Henceleftoverbitsofconductorshallbeusedforjumpering.
Forinstallationofjumpers,thedistancebetweenthejumperpadsofdeadendconesismeasuredby
passingaropeintheshapeofajumperandbycheckingverticalclearancefromthecrossarmend.
Conductoriscutaftermakingadjustmentinlengthforthejumperconedimension.Theinnerandouter
conductorofthebundledjumperareofdifferentlengths,whichshallbemeasuredseparately.This
will ensure a horizontal plane of the jumper bundle when installed. After cutting the conductor,
jumper cone is pressed using hydraulic compressor. The conductors are laid out on the ground
parallellyandspacersarefixedasperthefixinginstructions.Thejumperishauledupfromboth
ends of the tension clamps and jumper cone is attached to the connector of the dead end cone.
Clearancetothetowerbodyshallbecheckedasperthedrawing.

STRINGINGSAFETY

CHECKLIST
 SAFETY ASPECTS OF TOWER ERECTION
IN
TRANSMISSION LINE

METHODS OF ERECTION
ThereareTHREEmainmethodsoferectionofsteeltransmissiontowers,whicharedescribed,asbelow

i.Builtupmethodorpiecemealmethod.
ii.Sectionmethod
iii.Groundassemblymethod.
Builtupmethod
Thismethodismostcommonlyusedinthiscountryfortheerectionof66KV,132KV,220KVand400KV
TransmissionLineTowersduetothefollowingadvantages.
i.Towermaterialscanbesuppliedtositeinknockeddownconditionwhichfacilitateeasierand
cheapertransportation.
ii.Itdoesnotrequireanyheavymachinerysuchascranesetc.
iii.Towererectionactivitycanbedoneinanykindofterrainandmostlythroughouttheyear.
iv.Availabilityofworkmenatcheaprates.Thismethodconsistsoferectingthetowers,memberby
member.Thetowermembersarekeptongroundseriallyaccordingtoerectionsequencetoavoidsearch
ortimeloss.Theerectionprogressesfromthebottomupwards,thefourmaincornerlegmembersofthe
firstsectionofthetowerarefirsterectedandguyedoff.Sometimesmorethancontinuousleg
sectionsofeachcornerlegareboltedtogetheratthegroundanderected.Thecrossbracesofthe
firstsectionwhicharealreadyassembledonthegroundareraisedonebyoneasaunitandboltedto
thealreadyerectedcornerlegangles.Firstsectionofthetowerthusbuiltandhorizontalstruts
(betmembers)ifany,areboltedinposition.Forassemblingthesecondsectionofthetowers,twogin
polesareplacedoneeachonthetopofthediagonallyoppositecornerlegs.Thesetwopolesareused
forraisingpartsofsecondsection.Thelegmembersandbracesofthis
sectionarethenhoistedandassembled.Theginpolesarethenshiftedtothecornerlegmemberson
thetopofsecondsectiontoraisethepartsofthirdsectionofthetowerinpositionforassembly.
Theginpoleisthusmovedupasthetowergrows.Thisprocessis
continuedtillthecompletetoweriserected.Crossarmmembersareassembledonthegroundandraised
upandfixedtothemainbodyofthetower.Forheaviertowers,asmallboomisriggedononeofthe
towerlegsforhoistingpurposes.Themembers/sectionsArehoistedeithermanuallyorbywinch
machinesoperatedfromtheground.Forsmallerbasetowers/verticalconfigurationtowers,oneginpole
isusedinsteadoftwoginpoles.Inordertomaintainspeedandefficiency,asmallassemblyparty
goesaheadofthemainerectionganganditspurposeistosortoutthetowermembers,keepingthe
membersincorrectpositiononthegroundandassemblingthepanelsonthegroundwhichcanbeerected
asacompleteunit.Sketchesindicatingdifferentstepsoferection
bybuiltupmethodareshownatFigure4.1toFigure4.7.

Guyingarrangement

Guyingarrangementsaretobedoneatwaistlevel/bottomcrossarmlevelaswellasinthegirder
level/topcrossarmleveldependingonSC/DCtowersanditistobeinstalledat450fromvertical.The
deadmentsforguyingarrangementsaretobeproperlymade.Asampleofdeadmentsdrawingisenclosed
atFigure4.8forreference.Guyingshouldbesteelwireorpolypropyleneropedepending
Uponrequirements.Nominaltensionistobegiveninguyingwire/ropeforholdingthetowerin
position.