ELECTRICAL POWER TRANSMISSION LINES

Tower Manufacturing to Construction

T.Ch.Hanuman Rao B.E.,

Dr.Majid Ali M.Tech., Ph.D, D.Sc.

A guide for the shop floor engineers / supervisors in tower

manufacturing units and for field engineers, surveyors and
supervisors in OHTL construction projects

Reference book for the Certificate Course...

"Electrical Power Transmission Line Survey and Construction"
Copy Right with the authors

First eddition: February 2011

The copies of the book can be obtained on request from

T.Ch.Hanuman Rao,
9-222/2, Plot 257, Employees colony,
Secunderabad 500 087.

Printed at:
Universal Printers
1-7-189/2, Beside Narayana Junior College,
Kamala Nagar, ECIL, HYD-62
 DEDICATION
to the staff in the shop floors and fields struggling in the agressive conditions so
that the citizens get quality power.

to those that believe that only thing constant in the change and want to be the
medium for modern technology
 Table of Contents

Table of Contents
Preface 1
Chapter 1 Electricity basics 7
1.1 Electricity 7
1.2 Alternating current 8
1.3 Transformer 9
1.4 A.C generator 10
1.5 Thermal power generation station 12
1.6 Hydel plants 13
1.7 Nuclear plants 14
1.8 Biomass power plants 16
1.9 Wind energy 17
Chapter 2 Power transmission 18
2.1 Basics of transmission lines 18
2.2 LILO arrangement 19
2.3 HVDC Transmission 20
2.4 Comparision of HVDC to AC Transmission 20
2.5 Transmission Line Planning 21
2.6 The voltages for power transmission 22
2.7 System stability 24
2.8 Environmental issues in power transmission 24
Chapter 3 Underground Power Transmission 25
3.1 General 25
3.2 Categorization by functioning under fault conditions 27
3.3 Categorization by the conductors 28
3.4 Cables based on the insulating materials 28
3.5 Cable Sheaths 29
3.6 Armouring 29
3.7 Submarine cables 30
3.8 Cable laying 30

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3.9 Joints and terminations 30

Chapter 4 Overhead Transmission Lines 32
4.1 Overhead Transmission Lines History 32
4.2 Highest Transmission line voltages in the world 36
4.3 Overhead Transmission Lines Classification by Current 38
4.4 Overhead Transmission Lines Classification by Phases 38
4.5 Overhead Transmission Lines Classification by Circuits 38
4.6 Overhead Transmission Lines Classification by Materials 39
4.7 Records in the Transmission Lines 39
Chapter 5 Power Conductors, Earthwire, Insulators and Line Hardware 42
5.1 General 42
5.2 What to look in a conductor 42
5.3 Common terms used in conductor 43
5.4 Bundle conductors 44
5.5 IACS units 45
5.6 Evolution of power conductors 46
5.7 Types of conductors 46
5.8 Copper Conductors 47
5.9 AAC (All Aluminium conductors) 47
5.10 AAAC (All Aluminium Alloy Conductor) 48
5.11 ACAR (Aluminium Conductor Alloy Reinforcement) Conductor 49
5.12 ACSR (Aluminium Conductor with Steel Reinforcement) 49
5.13 AACSR (Aluminium Alloy with Steel Reinforcement) 50
5.14 ACSS (Aluminium Conductor with Steel Support) 50
5.15 TW Conductors 51
5.16 AAC/Compact or AAC/SB (AAC/Smooth Body) 51
5.17 AAC-TW (All Aluminum Conductor Trapezoidal Shaped Conductors) 52
5.18 AAAC-TW, ACAR-TW, ACSR-TW, ACSS-TW conductors 52
5.19 ACCC (Aluminium Conductor Composite Core) conductor 53
5.20 VR conductors 54

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5.21 SD (Self Damping Conductor) (Gap Conductor) 55

5.22 MR (Motion Resistant) Conductors 55
5.23 Conductor Designation 56
5.24 Earthwire 57
5.25 OPGW (Optical Fibre Ground Wire.) 58
5.26 Insulators 59
5.27 Terms used in insulators 60
5.28 Porcelain insulators 61
5.29 Glass insulators 61
5.30 Polymer insulators 61
5.31 Comparison between the insulator types 62
5.32 Hardware fittings 62
5.33 Suspension hardware 63
5.34 Tension hardware for conductors 64
5.35 Arcing Horns and Grading Rings 66
5.36 Corona rings 66
5.37 Vibration Dampers/Spacer Dampers/Spacers 67
5.38 Armour Rods 68
Chapter 6 Transmission Line Towers Configuration, Nomenclature and
Geometry 69
6.1 What is a Tower 69
6.2 Transmission Line Tower types and shapes 69
6.3 Self Supporting Transmission Line Towers 69
6.4 Guyed towers 71
6.5 Monopole 71
6.6 Types of towers Based on cross section of tower 72
6.7 Types of Towers Based on the Type of Material Sections 73
6.8 Tower Designation 73
6.9 Suspension towers 73
6.10 Tension towers 74

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6.11 Transposition Towers 74

6.12 Special Towers 75
6.13 The factors for designing the towers 75
6.14 Tower Configuration 76
6.15 Ground Clearance for Various Voltages 76
6.16 Tower height 78
6.17 Transmission Line Tower Geometry 82
6.18 Body Extension 83
6.19 Leg Extensions 83
6.20 Stubs for conventional chimney type foundation 83
6.21 Stubs for special towers/foundations (Base shoe Assembly) 84
6.22 Nomenclature of tower parts 86
6.23 Bracing systems 89
6.24 Bolts, Nuts and Washers 92
6.25 Aviation Requirements 93
6.26 Tower Accessories 95
Chapter 7 Transmission Line Tower Manufacturing 97
7.1 Processes in the tower manufacturing unit 97
7.2 Drawings and drawing control 97
7.3 Work order processing 100
7.4 Production planning 101
7.5 Inward Material Inspection and Testing 102
7.6 Raw material handling 106
7.7 Plant layout 106
7.8 Production balancing and capacity assessment 107
7.9 Galvanizing Of Tower Parts 110
7.10 Post-Treatment 126
7.11 Testing and Inspection. 128
7.12 Defects in hot dip galvanizing 137
7.13 Fasteners 149

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7.14 Tower Accessories 150

7.15 Quality Assurance in Transmission Line Manufacturing - SMQP 151
Chapter 8 Preliminary Survey of Transmission Lines 152
8.1 Survey classification 152
8.2 UTM Zones and UTM Coordinates 153
8.3 Topo-Sheets 156
8.4 Definitions for Topo Maps 157
8.5 Survey of India Topomap Numbering 160
8.6 Survey - parts of work 161
8.7 Survey accuracy orders 162
8.8 Overhead power Transmission line surveyors 163
8.9 The Skills Required for Overhead Power Transmission Line Surveyor 165
8.10 Beeline and Routé Alignment 167
8.11 Reconnaissance Survey 168
8.12 Walkover survey 169
8.13 Preliminary survey Field Work 170
8.14 Way Leaves and Right of way 171
8.15 General Points for Route Selection 171
8.16 River crossing 172
8.17 Railway crossing 174
8.18 National highway/road crossing 177
8.19 Power line crossing 177
8.20 Communication line crossing 178
8.21 Aerodromes, Radar stations, Rifle ranges and Helipads 179
8.22 Forest crossing 180
8.23 Various instruments used in survey and their accuracies 181
8.24 Usage of New Technology for Route Alignment 188
8.25 Route Marking 189
8.26 Route Alignment Reports 189
Chapter 9 Detailed Survey of transmission lines 192

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9.1 General 192

9.2 Collection of detail survey data 193
9.3 Soil Resistivity 198
9.4 Wind Span, Weight Span, Ruling (Equivalent) Span 200
9.5 Tower Spotting Data 202
9.6 Locating the take off tower near substations 205
9.7 Sag Template 206
9.8 Sag Curve Profile 208
9.9 Manual Tower Spotting Using Sag Templates 209
9.10 Sag profiles 211
9.11 Usage of PLSCADD for Optimum Tower Spotting 213
9.12 Tower Schedules 214
9.13 Land Schedules and ROW issues 217
9.14 Line Schedules 219
9.15 Check Survey 222
9.16 Trail pits 223
9.17 Check Survey Report 223
Chapter 10 Soil Investigation 225
10.1 Objective of Soil Investigation 225
10.2 Types of Soils 225
10.3 Preliminary work 226
10.4 Standards and specifications 227
10.5 Location of soil investigation 227
10.6 Methods of investigation 228
10.7 Depth of the exploration 228
10.8 Sampling and Samplers 229
10.9 The properties and tests in the soil investigation 232
10.10 Ground Water 237
10.11 Field Investigation Rock 238
10.12 Laboratory Testing 239

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10.13 Report 240

10.14 Recommendations 241
Chapter 11 Foundation Works - Excavation & Stub-Setting 244
11.1 Loads on the foundation 244
11.2 Classification of soils 245
11.3 Selection of foundation 247
11.4 Types Of Foundations 248
11.5 PCC Pad and Chimney type foundation 251
11.6 RCC Spread Foundation 251
11.7 Block Type Foundation 252
11.8 Grouted rock anchor foundation 252
11.9 Undercut type foundation 253
11.10 Augured/under reamed foundations 254
11.11 Steel Grillage Foundation 255
11.12 Steel Plated Type 256
11.13 Precast Concrete Foundations 256
11.14 Pile Foundations 256
11.15 Well Type foundation 257
11.16 Transportation 258
11.17 Preparation of Foundation Site 258
11.18 Type of Foundation to be adopted 258
11.19 Pit Marking 258
11.20 Excavation 259
11.21 PCC 261
11.22 Stub setting by combined template 264
11.23 Checking the measurements with acuracy 265
11.24 Base shoe type stub setting 266
Chapter 12 Foundation Work 269
12.1 General 269
12.2 Aggregates 269

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12.3 Properties of proper aggregates 271

12.4 stones suitable and unsuitable for Aggregates (as per IS 383) 272
12.5 Other parameters of Aggregates 273
12.6 Grading of Aggregates 274
12.7 Sieve Analysis of Aggregates 274
12.8 Cement 276
12.9 Ordinary Portland cement (OPC) 276
12.10 Portland Pozzolana Cement 277
12.11 Portland Slag Cement 278
12.12 Cement Grades 280
12.13 Reinforcement 281
12.14 Water 284
12.15 Additives 285
12.16 Cover for RCC Work and Cover Blocks 285
12.17 Rebar/Reinforcement Binding 286
12.18 Formwork 287
12.19 Concrete grades 287
12.20 Mix Designing 287
12.21 Standard mixes 288
12.22 Correction for Bulkage of sand 289
12.23 Water Cement Ratio 289
12.24 Machine Mixing of concrete 290
12.25 For Hand Mixing 291
12.26 Ready mix concrete 291
12.27 Workability of concrete 291
12.28 Concrete Laying 293
12.29 Finishing and Coping 293
12.30 Hydration & Curing 294
12.31 Testing of concrete 294
Chapter 13 Earthing 296

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13.1 Objective of Earthing 296

13.2 The effect of lightening of the overhead power transmission lines 296
13.3 Factors that effect the earthing 297
13.4 Types of Earthing for Overhead Power Transmission Lines 297
13.5 Pipe type Earthing 298
13.6 Counterpoise Earthing 299
13.7 Spike type Earthing 299
Chapter 14 Tower Erection Works 301
14.1 Site store selection 301
14.2 Orientation of tower 302
14.3 Checking the foundation 303
14.4 Inspection 304
14.5 Pre-erection activities 305
14.6 General steps to be followed for tower erection 305
14.7 Methods of tower erection 306
14.8 Piece Meal Method (Built Up Method) 306
14.9 Section Method 307
14.10 Ground Assembly Method 308
14.11 Helicopter Method 309
14.12 Floating Pillar Method 309
14.13 Fixed Pillar Method 310
14.14 Tightening of Nuts And Punching of Threads 310
14.15 Welding and Painting 311
14.16 Check for clearing Towers erection 312
14.17 A word of Caution in Tower erection 312
14.18 Erection tools 313
Chapter 15 Stringing 314
15.1 Preparation for stringing and checks 314
15.2 Tools for stringing 315
15.3 Drum scheduling 320

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15.4 Conductor creep and creep allowance 323

15.5 Stringing Charts 324
15.6 Measuring the temperature of the conductors 326
15.7 Sag Checking Methods 327
15.8 Grounding 328
15.9 Hoisting Insulators 329
15.10 Methods of stringing 330
15.11 Stringing By Slack Method 330
15.12 Stringing By Semi-Tensioning Method: 331
15.13 Stringing By TSE Machine 331
15.14 Stringing By Helicopter 334
15.15 Final sagging 334
15.16 Precautions 335
15.17 Jointing of Earthwire 336
15.18 Jointing of Conductor 337
15.19 Repairing of conductor 338
15.20 Jointing of conductor 338
15.21 Conductor Mid-span joints 339
15.22 Clipping 340
15.23 Spacers/ Spacer-Damper/ Damper Installation 341
15.24 Jumpering 341
15.25 Transposition arrangement 342
15.26 Stringing over river crossing 343
15.27 Pre-Charging Activities 343
Chapter 16 Safety in Construction of Transmission Lines 345
16.1 General 345
16.2 Statutory Provisions 345
16.3 Punishment for noncompliance of rules 347
16.4 Requirements of an organization regarding safety 347
16.5 Generic safety precautions 348

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16.6 Safety measures during field survey work 349

16.7 Safety measures during excavation 349
16.8 Safety precautions during tower foundation works 351
16.9 Safety precautions during tower erection work 352
16.10 Safety Precaution During Tightening of Nuts 354
16.11 Safety precautions during welding of bolts and nuts 354
16.12 Safety precautions during insulator hoisting 355
16.13 Safety precautions during clearing trees 355
16.14 Safety precautions during stringing work 355
16.15 Safety precautions during clipping work 357
16.16 Safety Precautions Working Across Water Bodies 357
Chapter 17 Quality assurance in construction of transmission lines 359
17.1 Quality 359
17.2 Quality Assurance(QA) and Quality Control(QC) 359
17.3 Quality Assurance Plan(QAP) 360
17.4 Quality Documents and Quality Records 361
17.5 Measuring Tools and Instruments 363
17.6 SMQP(Standard manufacturing quality plan) 363
17.7 FQP(Field Quality Plan) 364
Chapter 18 Project Management and Coordination 366
18.1 General 366
18.2 Traits of a successful manager 366
18.3 Integrity 366
18.4 Leadership 366
18.5 Dress code 367
18.6 Time management 367
18.7 Effective Human Relations 368
18.8 Communication skills 370
18.9 Do's and Don'ts on Units 382
18.10 Project Monitoring 388

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18.11 Reading and Protection of Technical Documents 390

18.12 Field Stores and Material Handling 393
18.13 Handing funds at site 396
Annexure 1 - Quality Assurance Plan 397
Annexure 1(A). Mechanical and Chemical Properties of Structural Steels 405
Annexure 1(B). Foundation Bolts and Nuts 406
Annexure 1(C)..Hexagon Bolts For General Steel Structures 407
Annexure 1(D). Hexagon Nuts For Steel Structures 407
Annexure 1(E). High Strength Structural Bolts 408
Annexure 1(F). Step Bolts 408
Annexure 1(G) Plain Washers (IS 2016-1967 Type A) 409
Annexure 1(H). Heavy washers (IS 1367 part 8 & IS 6610) 409
Annexure 1(I). Spring washers 410
Annexure 1(J). Sampling plan tables 411
Annexure 1(K). Steel Tables - Equal Angles 412
Annexure 2…Field Quality (Assurance) Plan 420
Annexure 2A…Indian Railway Manual Extract 438
Annexure 3…BOQ Format For Transmission Line 440
Annexure 4…Survey Symbols 452
Annexure 5…Survey of India Toposheet Numbering 457
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Annexure 6…Toposheet Numbers (longitude 60 E to 72 E) 459
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Annexure 7…Toposheet Numbers (longitude 72 E to 76 E) 465
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Annexure 8…Toposheet Numbers (longitude 76 E to 80 E) 476
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Annexure 9…Toposheet Numbers (longitude 80 E to 84 E) 487
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Annexure 10…Toposheet Numbers (longitude 84 E to 88 E) 498
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Annexure 11…Toposheet Numbers (longitude 88 E to 92 E) 506
Annexure 12…Toposheet Numbers (longitude 92oE to 96oE) 512
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Annexure 13…Toposheet Numbers (longitude 96 E to 100 E) 523
Annexure 14…Indian And International Standards Relevant For TL 534
References 544

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