SOP-220kV Transmission Line PDF

ADANI GREEN ENERGY LIMITED
Document No. Issue No/Date Revision No/Date

AGEL/CM/SOP/
Title: CONSTRUCTION PROCEDURE OF TRANSMISSION LINES
STANDARD OPERATING PROCEDURE

(TRANSMISSION LINE)
DEPARTMENT : CONSTRUCTION MANAGEMENT

AGEL/CM/SOP/
1. INTRODUCTION
➢ PURPOSE:
This document describes the step wise work procedure to carry out the Foundation work of 11-132 / 220 /
400/ 765 KV Transmission Line work in planned and controlled manner with reference to the drawings,
technical specification and standards.
➢ SCOPE:
It includes survey, shifting of materials to work locations, setting to work, erection, testing & commissioning of
Transmission lines.
➢ SAFETY ASPECTS:
➢ STANDARD SPECIFICATIONS:
Materials should be supplied & Standards to be complied with erection of the lines:
▪ IS:8112 of 1989 (Ordinary port land cement of grade 43
▪ IS: 1786 Tor steel of reinforcement
▪ IS:383-1970 (Specifications of coarse & fine aggregates from natural source for concrete)
▪ IS:456-2000 (Plain & reinforced concrete code of practice)
▪ IS:516-1959 (Method of test for strength of concrete)
▪ IS:10262-2009 (Concrete mix proportioning)
▪ IS: 4082-1986 (Storage of construction material at site)
▪ IS : 5613 (Part 2 / Section 2) – 1985
▪ IS : 5613 (Part 3 / Section 2) – 1989 (Installation of lines)
▪ IS: 7861 (Part1)-1975 (Hot weather concreting)
▪ IS: 7861 (Part2)-1981 (Cold weather concreting)
▪ IS: 4091-1979 (Code of practice for design & construction of foundations for transmission line towers & poles)
▪ IS: 5613 (Part-11)-Danger boards, phase plates, bird guards & number plates
▪ IS: 3043 (Earthing).
➢ RESPONSIBILITY:
Responsibility of implementation of this procedure rest with below mentioned officials:
PRIMARY: Site-In charge, Site Engineer, Site Supervisor, Quality Assurance Engineer (QA) & Safety
Engineer.
SECONDARY: Project Manager & Site Head.
2. PREREQUISITE:
▪ Approved Drawings
▪ Generic Contract Documents (as applicable)
▪ Standard Field Quality Plan (SFQP) & Protocol check lists
▪ Availability of tested handling equipment’s, tools, and tackles
▪ Availability of skilled manpower.
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PROCESS FLOWCHART FOR CONSTRUCTION OF TRANSMISSION LINES:
3. CONSTRUCTION OF TRANSMISSION LINE:

▪ Concrete work will be done in a manner as per approved design & drawing. Sequence for same is as
under: -
➢ MATERIAL FOR CONCRETE & IT’S STORAGE:
▪ All the materials such as fine and coarse aggregates, water & cement required source should be AGEL
approved lists and design mix test should be conduct in approved third party NABL approved
laboratories.
▪ Joint Inspection of fine and coarse aggregates, water & cement should be done at site in presence of
site QA representative.
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➢ CEMENT:
▪ Cement shall be adequately protected from moisture or contamination during transportation and
storage at site.
▪ All bags of cement shall be stored on site in a correct and proper manner such that, those shall be
protected from rain and surface water. Storage of Cement in bags shall be limited within a heap of 10
bags at site.
▪ Cement should be stored on Wooden / Plastic Pallets with Tarpaulin
▪ Cement grade and type (OPC or PPC) to be pre-approved AGEL.
▪ Initially MTC (Material test certificate) must be submitted and test on cement to be conducted,
results must be verified and approved before consumption at site
▪ Week number mentioned on the cement bag must not exceed beyond expiry limit that is of 12 weeks.
➢ COARSE AGGREGATES
▪ Aggregates shall conform to specifications for coarse and fine aggregates from natural sources for
concrete as per IS: 383.
▪ The aggregates shall be of clean, broken hard granite or other stone specified or approved by the
client.
▪ It shall be of hard, closed-grained quality. It shall also be as far as possible cube like, preferably
angular, but not flaky & elongated, perfectly clean and free from earth, organic or other deleterious
matters.
▪ Aggregates will pass through a sieve (mesh size should be as per aggregate size) measured in the
clear.
▪ Aggregates shall be stored in a manner, which prevents contamination by dust, clay, water or any
harmful material as per IS 4082-1986.
▪ The coarse aggregates stack shall be kept physically separated depending upon the sizes of coarse
aggregates as per IS 4082-1986.
▪ If the coarse aggregate contains any foreign material (mud excess fines, etc.) they shall be washed
prior to use.
➢ FINE AGGREGATES
▪ The sand used for the concrete shall be composed of hard siliceous materials.
▪ It shall be clean and of a sharp angular grit type and free from earthy or organic matter and
deleterious salts.
▪ Fine aggregates found to contain foreign material shall be rejected.
▪ The sand shall conform to Zone 1 Grade to IS: 383, which is the coarse variety with maximum size of
4.75 mm. Zone II Grade of fine aggregates may also be used or as per requirement.
➢ WATER
▪ The water used for mixing concrete shall be fresh clean and free from oil, acid and alkali organic
materials or other deleterious substances.
▪ Potable water is generally satisfactory.
▪ The PH value of water shall not be less than 6.
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➢ EQUIPMENTS REQUIRED FOR CONCRETING:

▪ Form Boxes.
▪ Mixer Machine (In case where mixing of construction material is done mechanically).
▪ Needle Vibrator.
▪ Dewatering Pump (In case there is need to pump out water from excavated pits).
▪ Dumpy Level / Water pipe level.
▪ Concrete cube moulds.
▪ Wooden / Steel Shuttering (In case of side collapse).
▪ Mixing sheets.
▪ Measuring Box.
▪ Metal Sieve.
▪ Sand Sieve.
▪ Empty Barrel.
▪ Plumb Bobs.
▪ Water Tanker.
▪ Spade.
▪ Shovel.
▪ Receptacle.
▪ Buckets.
▪ Poking / Ramming Rod (Vibrator).
▪ Spanner (Ring & Flat).
▪ Steel Tape.
▪ Drop Hammer/Single or Double acting Hammer/Hydraulic Hammer
▪ Kent ledge
▪ Pile Rig
➢ LEAN CONCRETE (PCC)

The methods used for the preparation of concrete, and all its properties regarding its strength under
Compression, tension, shears, punching and bending etc., as well as workmanship shall conform to
IS: 456.
➢ MEASUREMENT OF CONCRETE PRIOR TO MIX

▪ For Lean concrete sub-bases or pads, mix cement concrete ought to be as per approved mix design. The
properties of concrete and mix proportions to be as given in IS 456- 1978.
▪ Weigh batching shall be adopted for mixing the ingredients of Concrete by using weigh-batcher initially
and conversion of the weighed materials in equivalent volume shall be done in Batch Box. For actual
execution of work, equivalent volume batching shall be adopted by marked batch boxes.
▪ It shall be permissible to proportionate the concrete as follows:
▪ Prepare a wooden measuring box of 35 liters capacity (that is, equal to 1 bag or 50 kg of cement) with
inside dimensions not exceeding 30X30X38 cm alternatively 34 cm diameter and 39 cm height.
▪ Measurement of water may be made with separate water-tight drums of the above size with 1 or 2 liter
mugs.
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➢ BATCHING & MIXING OF CONCRETE:

▪ All material aggregate, cement and reinforcement will be checked, prior to commencement of
concreting.
▪ Prior to commencement of concreting activities the following shall be available on site :-
▪ Mixer in good condition
▪ Vibrator
▪ Water (required quantity)
▪ Fine Aggregate (required quantity)
▪ Coarse Aggregate (required quantity)
▪ Cement (required quantity) and protection for the same
▪ Aggregate measuring boxes
▪ Concrete chutes / Slides / Elephant Trunks
▪ De-watering pumps (if necessary for site)
▪ Cube Moulds (As per Owner / Client Requirements)
▪ Slump Cone.
▪ The equipment shall be constantly maintained in first-class workable condition during the working
period.
▪ The concrete mixing shall be proper and inspected at suitable intervals in the presence of the
Project/Site QA Engineer.
▪ Each time the work stops, the mixer shall be cleaned out.
▪ The concrete mixer shall be placed in a location so that the transport distance of the concrete to the
foundation is minimized.
▪ The measuring equipment shall be maintained and operated as required to accurately determine and
control the amount of each separate ingredient entering the concrete.
▪ The boxes shall not be overfilled. After filling the box the contents shall be flush with the top edges of
the box sides to ensure the correct quantity in each box.
▪ The mix quantities / ratio shall at all times be strictly in accordance with the approved design mix
quantities as per foundation drawing.
▪ The minimum cement content, the water cement ratio, the slump and all other characteristics of
concrete shall be demonstrated to conform to the relevant Indian Standards & same to be filled in Slump
Test Report.
▪ Mixing shall be continued until there is uniform distribution of material and the mix is uniform in colour
and consistency but in no case the mixing is done for less than 2 minutes.
▪ When a homogeneous mix has been obtained the water then shall be added after which the mixing shall
continue for not less than 1 minute.
▪ The mixer shall be rotated at the speed recommended by the manufacturer and thereafter mixing shall
be continued for at least 2 minutes and at least forty (40) revolutions after all materials are in the drum.
▪ For batches larger than 0.75 cum., mixing time shall be increased by 15 seconds for each additional
0.75 cum. or fraction thereof.
▪ All concrete shall be discharged within 3 minutes after the introduction of mixing water to the cement
and aggregates.
▪ Mixer Machine should be cover by Gunny Bags in Summer time / Hot atmosphere.
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▪ On the approval of client, ready mixed concrete may be used in foundation if the journey to site is in
excess of 45 minutes with proper proportion of admixture content.
➢ PLACEMENT & COMPACTION OF LEAN CONCRETE (CASTING)

▪ The excavated foundation level shall be free from loose material.
▪ The site engineer will ensure the line level, dimensions and surface to receive the concrete according to
drawings & specifications.
▪ Grade of concrete shall be checked as per requirement. Concreting can start only after getting Pour card
clearance.
▪ Site Engineer will inform AGEL quality engineer the timing of concrete well in advance.
▪ Pour the lean concrete on the surface and level it using hand tools to the required finish.
▪ Water curing of finished concrete surface shall be done for 7 day for OPC Cement & 14 days for PPC
(min.) with water wetting, before backfilling. When shuttering and reinforcement is being placed / tied,
then water sprinkling shall be done.
▪ ACCEPTANCE CRITERIA:
▪ Conformity of All dimensions as per design & drawing
▪ Conformity of Mix Design
▪ Conformity of Slump
▪ Conformity of Cube Strength.
➢ RECORDS:
▪ Foundation Material Checklist

▪ Checklist for PCC
▪ Pour Card
▪ Joint Measurement Certificate – Foundation.
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4. METHOD OF STATEMENT:
➢ SURVEY FOR TOWERS:
▪ Check survey shall be conducted to locate and peg mark the tower positions on ground conforming to the approved
profile and tower schedule using GPS, Total Station, and Digital Theodolites etc.
▪ In the process, it is necessary to have the pit centres marked according to the excavation marking charts.
▪ The levels, up or down of each pit centre with respect to the centre of the tower location shall be recorded at
intervals of 2 metre using Total station/GPS/ Digital Theodolites and digitized contour plans shall be made and
recorded for determining the amount of earthwork required to meet the approved design parameters.
▪ Changes in the preliminary tower schedule after detailed survey, if required, shall be carried out by the contractor and
he shall thereafter submit a final tower schedule for the approval of AGEL.
▪ The tower schedule shall show position of all towers, type of towers, span length, type of foundation for each towers
and the deviation at all angles as set out with other details.
▪ Initial route proposal marked on Google Earth Map along with type of Poles proposed (as per customer
requirement / specification), Conductor & Span Length will be provided by AGEL-Engineering Team.
Sample line routing on Google Earth Map shown below.
➢ During line survey the following points shall be considered by the contractor.
▪ Survey team shall carry a GPS device and record all CP (angle / straight) coordinates.
▪ Line route shall be selected to minimise the RoW problems as far as possible.
▪ All approach roads for carrying out the line works shall be identified and choose the route in such way to
minimise creating additional approaches and RoW for approach.
▪ The survey route should be following the initial route proposal sent by AGEL/ engineering team closely.
However, deviations as may be required due to field conditions shall be brought to notice with alternate
option, for review and approval.
▪ Road Crossings, Power Line Crossings, Railway Crossings, Cultivation Lands, public and private premises,
ponds, tanks, lakes, gardens, and plantations are to be avoided as far as possible.
▪ Religious Places, Forest, Defense installations, Aerodromes etc., crossings must be avoided under all
circumstances.
▪ The necessary clearance availability (using the poles / structures proposed per initial route proposal) for all
crossings shall be checked adopting Indian Electricity Rules.
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➢ RIGHTS OF WAY (ROW):

▪ Rights of Way to lay the poles / structures as required for the proposed line, from :
o Land owners
o Concerned Authorities
o Other departments, if any, shall be obtained, in advance, by AGEL/Contractor.
▪ All necessary approvals shall be obtained by the contractor in the name of AGEL. All the documents
required for application to the statutory authorities must be prepared by the contractor &
submitted to the AGEL.
▪ Trimming or cutting of tree branches in line corridor (i.e, minimum 2m and maximum 3m from
center of the line on both sides) during erection / survey is within the scope of the contractor &
contractor shall arrange for necessary way-leave and compensation in this regard.
▪ During erection of the line, compensation for tree cutting, damage caused to crops, actual cutting
and felling of trees including way-leave permission for such route clearance shall be arranged by the
contractor.
The transmission line requires a right of way along its route to keep minimum clearances from earthed objects. All objects
within this zone are to be cleared. Normal power transfer capacities and right of way requirements of transmission lines of
various system voltages is shown in the table below.
➢ MINIMUM ROW CLEARANCE:
Sl.No. System Voltage ROW requirement

1 11 to 33 kV AC 18 m
2 132 kV AC 27 m
43 220 kV AC 35 m
4 400 kV AC 46-52m
➢ MINIMUM ELECTRICAL CLEARANCE:
Sl.No. System Voltage Phase to Earth in mm Phase to Phase in mm

1 11 kV AC 177.8 228.6
2 33 kV AC 381 431.8
3 66 kV AC 658.8 787.4
4 110 kV AC 863.3 990.6
5 132 kV AC 1068.8 1219.2
6 220 kV AC 1778 2057.4

AGEL/CM/SOP/
➢ MINIMUM CLEARANCE BETWEEN LINE CROSSING EACH OTHER:
Sl.No. System Voltage 132 KV 220 KV 400 KV

1 11-66 kV AC 3.05 4.58 5.49
2 132 kV AC 3.05 4.58 5.49
3 220 kV AC 4.58 4.58 5.49
4 400 kV AC 5.49 5.49 5.49
➢ MARKING OF TOWER PITS:

▪ The cut point poles locations are identified using GPS, as per the coordinates in the approved survey
report and marked.
▪ For plain lands Straight poles between the two cut points are identified / marked using men stationed
at pole locations (as per the span length between two adjacent locations) by line of sight method
through the cut point pole locations.
▪ The pole locations shall be marked with pegs (or) lime powder (or) white paint. While marking pole
locations, ensure that the pole pits are in alignment.
➢ EXCAVATION OF TOWER PITS:

▪ Pole pit center shall be marked for the poles. Excavation of pits for pole foundation shall be carried
out by augers & Boring.
▪ Pole pits shall be augured/bored as per the dimensions indicated in the project specific drawings.
▪ The depth of the pole pit shall not be less than 1/6th of the pole height.
▪ The pits for the supports (stay or stud) shall be excavated in the direction of the line, as this will
facilitate greater lateral stability.
▪ While digging the pit it should be dug straight. After pit digging , base of the pole shall be brought
near to the pits.
▪ Pit shall be free from loose soil.
▪ Excavations for tower foundations shall be carried to an adequate depth below the bottom of structural concrete and
then be brought to the required level by sand filling and/or placing lean concrete of 1:4:8/1:3:6 mix with aggregate of
40 mm nominal size.
▪ Loose, soft, in sand or in loose strata encountered in excavation at the required depth shall on Engineer-in-charge’s
instructions be excavated to a firm bed and the difference made up to the required level by filling with lean concrete
PCC (1:4:8) conforming to IS: 456-2000. No foundation shall rest on filled up soil.
➢ PCC CONCRETE PADDING FOR POLE PIT:

▪ Due to the weight of the fittings, pole/stubs may shrink in soft soil. Hence base padding is
necessary which distributes the total weight in the pit.
▪ PCC for 50mm with the ratio of cement: Sand: Coarse Aggregate has 1:2:4 ratio shall be poured as
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leveled before erection of the pole/stubs.

▪ Curing time for Minimum 12 Hrs shall be allowed for proper setting of PCC for erection of
poles/stubs.
➢ EQUIPMENTS REQUIRED FOR TOWER ERECTION:
▪ Derrick Pole
▪ Poly Propylene Ropes - 12 to 32 mm dia. (Depending on the requirement)
▪ Winch
▪ Tirfor
▪ Chain blocks
▪ Single way Pulley.
▪ Hammer
▪ Ring Spanner
▪ D Spanner (as per requirement)
▪ Box Spanner (as per requirement).
▪ Drift Pins
▪ Safety Belts
▪ Centre Punch
▪ Helmets
▪ Crow Bar
▪ Portable Welding Machine
▪ Mobile Crane
▪ Fall arrestor rope with safety camp
▪ Retractable fall arrestor
➢ TOWER CONCRETING:
▪ The cement concrete used for the foundations with Cement: Sand: Course Aggregates as M10, M15 & M20
Grade. The sand shall be free earthy or organic matter and deleterious salts.
▪ The aggregate shall be of clean broken hard granite or other stone specified or approved by AGEL.
It shall be hard close-grained quality. It shall also be as far as possible cube like, preferably angular but not
flaky, perfectly clean and free from the organic or other deleterious matter.
▪ Portable water shall be used for mixing concrete.
▪ The water to Cement ratio of the above concrete mix shall not be more than 0.50
▪ The concrete shall be mixed as stiff as the requirements & concrete to be poured into pole/tower pit up to
the ground level.
▪ Verticality shall be ensured prior to concreting & pole/stub movement to be arrested. Pour the concrete and
ensure compaction around the pole/stubs.
➢ DE-SHUTTERING & CURING OF CONCRETE:
▪ After 12 hours of completion of concreting, the exposed concrete surface shall be kept constantly wet for at least 07
days.
▪ De shuttering for vertical faces of concrete shall be done after 24 hrs, sides of raft concrete up to raft top
▪ After de shuttering, honeycombs in the concrete if any have to be rectified by removing the loose material and the
surface shall be prepared wet or apply cement slurry in the honeycombed area and finish with CM 1:3 and shall
proceed for further works.
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➢ BACKFILLING:
▪ Backfill shall not be dropped directly upon or against structure or facility where there is danger of
displacement or damage.
▪ Backfill shall be placed in horizontal layers not exceeding 150 mm in thickness. Each layer shall be compacted
with proper moisture content.
➢ CURING:
As the uplift strength of the foundation depends upon proper consolidation of backfilled earth, extreme care shall
be taken in this regard with special emphasis. Thereafter both the backfilled earth and exposed chimney top shall
be kept wet for the remainder of the prescribed time of 14 days.
➢ TOWER ERECTION BY BUILT UP OR PIECEMEAL METHOD:

▪ This method is most commonly used for the erection of 33 KV to 400 kV transmission line towers due to the following
advantages:
▪ Tower materials can be supplied to site in knocked down condition, i.e. in pieces which facilitates easier and cheaper
transportation.
▪ It does not require any heavy machinery such as cranes, etc.
▪ Tower erection activity can be done in any kind of terrain and throughout most of the year.
▪ Availability of workmen at cheaper rates.
▪ This method consists of erecting the tower member by member.
▪ The tower members are first set out and kept on the ground serially according to erection sequence to avoid time
loss due to searching for them as and when required.
▪ In order to maintain speed and efficiency, a small assembly party can be sent ahead of the main erection gang for
sorting out the tower members, keeping the members in correct position on the ground and assembling those panels
on the ground which can be erected as a complete unit. The main corner leg members are prepared by fitting all
cleats / plates for joints & bracings and step bolts.
▪ The erection progresses from the bottom upwards. More than one leg section of each corner leg may be bolted
together at the ground and erected in case they are short in length and light in weight.
▪ The main legs of the tower to be attached to the stub would be lifted by individual pieces and fixed with the stubs
using the cleats, plates and bolts as per the drawing.
▪ Since the legs are not self supported at this stage, they would be anchored individually using guyed ropes
diagonally.
▪ After erections of each leg ensure that the guy must be supported by 32mm crowbar & the angle of guy must be
30°-45° degree from horizontal.
▪ After this the lattices & bracings are lifted and joint with each other. This completes erection of base structure (leg
extension or body extension).
▪ Then the gin pole is to be attached to a suitable corner. With the help of hook provided on gin pole’s base the leg &
pole are fixed together on a support strut.
▪ Proper care shall be taken to provide soft/cushioning material between the pole & leg member to avoid abrading of
galvanizing due to friction & pressure.
▪ The top of a single gin pole is kept in the center of the structure by suspending it from the leg members at any
elevation using guys & temporary ground anchors.
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▪ Two wire-guys about 60° to 90° apart in the plan view are attached to the top of the gin pole to resist or support
the load to be lifted.
▪ For safety, a third, and preferably a fourth guy, is installed in front to prevent the pole from falling over backward in
the event of an unexpected impact or the sudden release of load.
▪ It is recommended to use 10t capacity turn buckle at the guying support.
▪ For smaller base towers / vertical configuration towers, one derrick / gin pole is used. For wide based towers and if one
assembled section / panel of the tower is to be erected, then two derricks / gin poles are placed, one each on the top
of diagonally opposite corner legs.
▪ A rope is passed thru the pulley block attached to the top end of the gin pole & other end from the pulley block
affixed to the bottom of stub. The free end at bottom of stub is tied to the winch for pulling & the other end is left
free for clamping to the members to be lifted.
▪ First, the leg members of the second section are hoisted and assembled. The temporary rope guys are shifted to the
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legs of the second section when they are being raised for erection. The legs of the second section / storey are kept in
position by fixing the temporary rope guys. The bracings of the second section are then hoisted and assembled.
▪ The derrick is then shifted to the corner leg member on the top of the second section to raise the parts of third section
of the tower in position for assembly. Derrick(s) / Gin pole(s) and the temporary rope guys for the leg members are thus
moved up as the tower is built up. This process is continued till the complete tower is erected.
▪ Cross - arms are assembled on the ground.
▪ The bird guards and hangers for suspension towers are fitted on the cross - arms.
▪ A rope is passed through a pulley fixed on the tower peak. The cross - arms are raised up with this rope and fixed to
the main body of the tower.
▪ The method of erection is shown below.
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▪ For heavier towers, a small boom is rigged on one of the tower legs for hoisting purposes.
▪ The
members
/ sections
can be
hoisted
either
manually
or by
pulling
with a
winch
machines
operated
from the
ground.
➢ SECTION METHOD:
▪ The major sections of the tower are assembled on the ground and the same are erected as units. The derrick / gin
pole used is approximately 10m long and is held in place by means of guys on the side of the tower to be erected.
▪ The two opposite sides of the tower section of the tower are assembled on the ground. Each assembled side is then
lifted clear of the ground with the derrick / gin pole and is lowered into position on bolts to stubs or anchor bolts.
One side is held in place with props or rope guys while the other side is being erected. The two opposite sides are
then laced together with cross members and bracings / diagonals, and the assembled section is lined up and made
square to the line.
▪ After completing the first section, the derrick / gin pole is set on the top of the first section. The derrick / gin pole is
made to rest on a strut of the tower immediately below the leg joint. The derrick/ gin pole has then to be properly
guyed into position.
▪ The first face of the second section is raised. To raise the second face of this section, it is necessary to shift the foot
of the derrick / gin pole on the strut of the opposite side of the tower. After the two opposite faces are raised, the
bracings on the other two sides are fitted and bolted up.
▪ The last lift raises the top of the towers. After the tower top is placed and all side bracings have been bolted up, all
the guy are removed except the one which is to be used to lower the derrick / gin pole.
▪ Sometimes, one whole face of the tower is assembled on the ground, hoisted and supported in position. The
opposite face is similarly assembled and hoisted and then the bracing angles connecting these two faces are fitted.
▪ The cross - arms are assembled and erected in the manner given above.
➢ LAYING & STRINGING OF CONDUCTORS:

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➢ PREREQUISITE:
▪ Generic Contract Documents (as applicable)
▪ Field Quality Plan (FQP)
▪ Approved sag charts & profile drawings
▪ Approved insulator assembly drawings
▪ Stringing Schedule
▪ Drum Schedule
▪ Tower completion & inspection report.
▪ Tested handling equipments, Tools & Tackles.
▪ Availability of skilled manpower.
▪ Availability of all PPEs.
➢ EQUIPMENT AND ACCESSORIES:

▪ Tensioner & Puller
▪ Rollers
▪ Traveler
▪ Reel Stand
▪ Pilot Line Winder
▪ Swivel
▪ Running Board
▪ Theodolite
▪ Crimper
▪ Discharge rods
▪ And any other equipment / accessories required for safe handling & work purpose.
➢ Tension Stringing–
▪ This method is generally used preferred for all type of transmission line stringing work. Using this method the
conductor is kept off the ground thus minimising the damage caused by friction. The following steps are to be
considered for this type of stringing.
➢ Equipment/Material Transportation & Storage:
▪ The material along with the equipments (like conductor drums, conductor bits, pullet, tensioner, pulling ropes, pilot
wire etc) shall be transported & stored with care.
▪ Planning to be done in advance so that the material & equipment are available at site before starting the work.
▪ For handling and installation of equipments the handling or user manual from manufacturer must be referred.
➢ Paving Out of Conductor

▪ A pilot wire is first paved out by passing through the rollers / travelers fixed on the cross arms.
▪ The Supervisor will confirm if all pilot wires are positioned in the rollers and that the connector is properly secured.
▪ Pilot wires are pulled in under tension. The pilot wire is connected to a single conductor through swivel link, or to
bundle conductors through swivel links thru woven grip and a running board, sometimes pilot lines are used to
pull a heavier pulling line which in turn is used to pull the conductors.
▪ The conductors shall be run out of the drums from the top in order to avoid any damage due to chafing.
▪ On confirmation of above, pulling will be started, slowly but steadily by synchronizing the operation of Puller and
Tensioner, through radio communication.
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▪ Conductor and earthwire will be kept off the ground and other obstructions by controlled tension at any time of the
operation.
▪ The spinning of the conductors and ground wires shall be prevented during stringing.
▪ The conductor shall be continuously observed for loose or broken strands or any other damage.
▪ The maximum tension imposed on a conductor during stringing operations shall not exceed than that necessary to
clear obstructions on the ground.
▪ In general stringing tension of about one-half of sagging tension is a good criterion.
▪ The sequence of running out shall be from top to downwards, that is, the earthwire shall be run out first, followed
by the conductors in succession.
▪ Unbalances of loads on towers shall be avoided as far as possible.
▪ Outer phases of line conductor-shall be strung before the stringing of the middle phase is taken up.
▪ Adequate steps shall be taken to prevent clashing of sub-conductors from paving out to the installations of the
spacers/spacer dampers.
▪ Care shall be taken that both sub-conductors of a bundle are from the same conductor supplier and-preferably
from the same batch.
▪ When approaching end of a drum length at least three coils shall be left then the stringing operations are to be
stopped.
▪ These coils are to be removed carefully, and, if another length is required to be run out, a joint shall be made as
per the recommendations of the conductor manufacturers.
▪ It is recommended that the pulling to be continued until the conductor end is approximately 5 meters through
winch tower, in order to facilitate sagging and tying in with tower cross arm.
▪ It is recommended that the speeds of 3 – 4 km / hour should be maintained so as to provide a smooth passage of
the running board or connecting hardware, or both, over the travellers. Slower speeds may cause significant
swinging of the traveller and insulator hardware assemblies. Higher speeds may create a potential hazard of greater
damage in case of a malfunction.
▪ Hold-down blocks or similar devices will be used to uplift locations.
▪ Full tension joints shall be pressed during paying our and covered with joint protectors which will be removed at the
end of the pull before sagging.
▪ After being pulled the conductor/ earthwire shall not be allowed to hang in the stringing blocks for more than 96
hours before being pulled to the specified sag. (IS5613- 17.1.1)
➢ Splicing/Joints
▪ All the joints on the conductor and earthwire shall be of compression type, in accordance with the recommendations
of the manufacturer for which all necessary tools and equipment like compressors dies process, etc, shall have to be
arranged in advance.
▪ Each part of the joint shall be cleaned by wire brush to make it free of rust or dirt, etc. and properly greased with
anticorrosive compound before the final compression is done with the compressors.
▪ All joints or splices shall be made at least 30 metre away from the structures. (IS5613-18.2)
▪ No joints or splices shall be made in spans crossing over main roads, railways, small rivers in tension spans.
▪ Not more than one joint per sub-conductor shall be allowed in one span.
▪ The compression type fitting used shall be of self-centering type or care shall be taken to mark the conductors to
indicate when the fitting is centered properly.
▪ During compression or splicing operation, the conductor shall be handled in such a manner as to prevent lateral or
vertical bearing against the dies.
▪ After pressing the joint the aluminum sleeve shall have all corners rounded, burrs and sharp edges removed and
smoothened.
AGEL/CM/SOP/
➢ Sagging
▪ Sagging processes consist of sag matching with the sag details mentioned in sag chart. The following considerations
are to be made before sagging.
▪ Regulating spans or sag sighting spans identified.
▪ Sag Section.
▪ Sagging is generally carried out by Sagging winch and a 4 way + 4 way pulley arrangement.
▪ Sagging thermometers shall be installed sufficiently prior to the actual sagging operation to allow temperature
stabilization and shall be mounted far enough above the ground to avoid the effect of ground heat radiation.
▪ Thermometers shall be inserted in a conductor section (about 0.5 m in length) to represent the temperature
internal to the conductor. Two thermometers shall be used in the sag spans, which are near, or at the ends of the
sag section.
▪ One steel wire rope lead is passed through an equalizing pulley, of diameter equal to the sub – conductor spacing,
and its ends are connected to both the come along clamps on the conductors. This is done so that the tension on
both the conductors remains the same. The equalizing pulley is connected to one end of the pulley system.
▪ The other end of the pulley system is connected to the dynamometer. The double tension hardware is hoisted and
anchored on the cross arm. The dynamometer is connected to the yoke plate of the double tension hardware.
▪ The running blocks, when suspended from the transmission structure for sagging shall be so adjusted that the
conductors on running blocks will be at the same height as the suspension clamp to which it is to be secured.
▪ Two leads and two pulley systems, one for each conductor, can be used in place of equalizing pulley. Both the pulley
systems are connected to the yoke plate of the double tension hardware and tensioned together one by one as
shown in following figures.
▪ However, dynamometer is used only on one conductor and the sag on the other conductor is matched with the sag
of the first conductor.
▪ A come along clamp is fitted on each rough sagged conductor at a distance from the tower on which the final
sagging is being carried out.
▪ The come along clamp is then connected to the pulley arrangement which is being used for final sagging through a
steel wire rope which is generally referred to as “lead”.
▪ The length of this lead is such that, after final sag, the come along clamp remains far enough from the tower so that
the loose portion of the conductor on the tower side can be pulled up to the cross arm for the purpose of
measurement.
▪ Now the tensioning is done in the wires so as to provide final sag, which is measured to complete the sagging of
conductor/earthwire/OPGW.
▪ The conductors shall be pulled up to the desired dag and left in running blocks for at least one hour after which the
sag shall be rechecked and adjusted. If necessary, before transferring the conductors from the running blocks to be
suspension clamps.
▪ The conductors shall be clamped within 56 hours of sagging in. (IS5613-19.1)
▪ The sag will be checked in the first and the last span of the section in case of sections up to eight spans and in one
intermediate span also for sections with more than eight spans.
▪ The sag shall also be checked when the conductors have been drawn up and transferred from running blocks to the
insulator clamps.
➢ Recommendations for Sagging of The OPGW Cables:

The specific recommendations for OPGW are as follows
▪ At the time of sagging, the attachment fittings must also be installed to prevent damage to the OPGW cable.
• While holding of OPGW wire, exact size groove type clamp should be used for holding the rough sag load of the
OPGW wire.
AGEL/CM/SOP/
• Over sagging for OPGW wire should not be done, as per sag chart only load should be taken to avoid damage to the
fibre inside & earth peak bend.
• After completion of sagging and clipping, the surplus OPGW is to be laid temporary on the tower body in coil
(Diameter of coil is approximately 1.0 - 1.5 m) and fixed on the tower. It is important that precautions must be taken
to prevent any damage to OPGW.
• While connecting the OPGW to down lead clamp bending radius should be maintained as mentioned above
otherwise fibres inside OPGW may get damage.
• Sealing of both ends to be done properly of OPGW cable, if Splicing / jointing work is not under progress.
• Ensure that the 15-20 meter extra cable should be kept at both ends in addition to the tower height.
▪ Surplus length of OPGW is necessary to lead down from the strain clamp on the top of tower to the joint box along
with the arm and tower structures. The position of joint box is near the bottom cross-arm and excess OPGW shall be
coiled in such a way that the OPGW remains above the bottom cross- arm of the tower.
▪ After splicing, each joint is to be optically verified using OTDR in order to ensure that the attenuation values are within
the required margins.
OVERVIEW OF STRINGING
AGEL/CM/SOP/
➢ Clipping In
▪ Clipping of the conductors in position shall be done in accordance with the recommendations of the
manufacturer.
▪ Conductor shall be fitted with armour rods where it is made to pass through suspension clamps.
▪ The jumpers at the section and angle towers shall be formed to parabolic shape to ensure maximum
clearance requirements.
▪ Pilot suspension insulator string shall be used, if found necessary, to restrict the jumper swings to the design
values.
▪ The security clip shall be properly opened and sprung into position.
➢ Fittings/Accessories Installation
▪ Spacers, spacer dampers, vibration dampers and other conductor and earthwire accessories shall be installed
as per the design requirements and respective manufacturer’s instructions.
▪ Spacers shall be fitted within 24 hours of the conductor clamping. (IS5613-22.1)
▪ While installing the conductor and earthwire accessories proper care shall be taken to ensure that the
surfaces are clean and smooth and no damage shall occur to any part of the accessories.
▪ Fasteners in all fittings and accessories shall be secured in position using torque wrench.
➢ TOWER ACCESSORIES:
▪ Step Bolts: Each tower shall be provided with step bolts conforming to IS: 10238 of not less than 16mm diameter
and 175mm long spaced not more than 450mm apart and extending from 3.5 metres above the ground level to the
top of the tower. For double circuit tower the step bolt shall be fixed on two diagonally opposite legs up to top of the
towers. For single circuit tower the step bolt shall be fixed on one leg up to waist level and on two diagonally opposite
legs above waist level up to top of the towers.
▪ Bird Guards: These are fixed to the cross-arms of tangent towers to prevent birds from perching over the insulator
strings. If such provision is not made, the droplets may foul continuously with the insulator string resulting in
breakdown of insulation. The bird guard is made of 18 gauge M.S sheet.
▪ Anti-Climbing Devices: These devices are provided to towers at a height of about 3.00 Mtrs. from ground.
These anti climbing devices prevent persons from reaching the live power conductors or their vicinity. The
anti-climbing devices are made of M.S angle and barbed steel wire. Barbed wire of 3500 mm per pole
should be wrapped at a height of 3000 mm above ground level stretching about 1000 mm height.
Both ends of barbed wire should be clamped (25 x 5mm GI Flat) suitably to avoid coming
down from its location.
▪ Danger Plates: 16 gauge M.S. sheet of size 200 x 325 Mtr. is used as Danger Plate. The word 'DANGER' in English and
Local Language shall be inscribed on the Plate. Danger sign depicting of a skull above two bones is painted on the
Danger Plate. The voltage at which the EHV line is charged is also indicated on the plate. Provision is made in the
danger plate to fix it on the tower leg with 16mm bolts.
▪ Number Plates: Each tower in any transmission line is allotted a number in a serial order commencing from one
terminal tower and ending with the terminal tower on the other end. The number plate is made of 16 gauge sheet of
100 x 150 Mtr. Size. The number is enameled in Red on white enameled background. The number plate is fixed to the
tower body at about 4 Mtrs ground level.
AGEL/CM/SOP/
▪ Phase Plates: Each angle tower is provided with a set of three circular discs of 0.100 mtr. dia each enameled in Red,
Yellow and Blue. These phase plates are fixed to the towers at a height of about 4 mtr, above ground.
➢ TESTING AND COMMISSIONING OF TRANSMISSION LINE:

▪ When the line is ready for energization, patrolling should be done and thoroughly inspected in respect
of the following:
▪ Proper alignment of poles, concreting and muffing of poles.
▪ Cross-arms-Proper alignment.
▪ Binding, clamping and jumpers - To check whether these are properly tightened.
▪ Conductor and ground wire - Proper sag and to check whether there are any cuts, nicks etc.
▪ Stay: To check whether the stay wire is tight and whether the Guy insulators are at specified height.
▪ Earthing System: To check whether the earthing connections of supports and fittings are intact. Measure
earth resistance with earth tester.
▪ Ensure for guarding provided at necessary crossings.
▪ It shall be ensured that all men, tools & tackles are away from the entire length of transmission line.
▪ After the visual inspection is over and satisfied, the conductor is tested for continuity / ground, by means
of IR tester. At the time of testing, using IR tester; persons should not climb on the pole or be in contact
with guarding, conductor, guy wire etc.
▪ Before energizing any new line, the officer-in-charge of the line shall notify to the workmen that
the line is being energized and that it will no longer be safe to work on line.
▪ Publicity by announcing in all the localities through which the line, that is to be energized passes,
intimating the time and date of energizing and warning public against the risk in meddling with the line.
5. FAQS (FREQUENTLY ASKED QUESTIONS):

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ADANI GREEN ENERGY LIMITED

Document No. Issue No/Date Revision No/Date

ADANI GREEN ENERGY LIMITED

STANDARD OPERATING PROCEDURE

DEPARTMENT : CONSTRUCTION MANAGEMENT

SECONDARY: Project Manager & Site Head.

PROCESS FLOWCHART FOR CONSTRUCTION OF TRANSMISSION LINES:

3. CONSTRUCTION OF TRANSMISSION LINE:

➢ EQUIPMENTS REQUIRED FOR CONCRETING:

➢ LEAN CONCRETE (PCC)

➢ MEASUREMENT OF CONCRETE PRIOR TO MIX

➢ BATCHING & MIXING OF CONCRETE:

➢ PLACEMENT & COMPACTION OF LEAN CONCRETE (CASTING)

▪ Foundation Material Checklist

➢ RIGHTS OF WAY (ROW):

Sl.No. System Voltage ROW requirement

➢ MINIMUM ELECTRICAL CLEARANCE:

Sl.No. System Voltage Phase to Earth in mm Phase to Phase in mm

4 110 kV AC 863.3 990.6

5 132 kV AC 1068.8 1219.2

6 220 kV AC 1778 2057.4

➢ MINIMUM CLEARANCE BETWEEN LINE CROSSING EACH OTHER:

Sl.No. System Voltage 132 KV 220 KV 400 KV

2 132 kV AC 3.05 4.58 5.49

3 220 kV AC 4.58 4.58 5.49

4 400 kV AC 5.49 5.49 5.49

➢ MARKING OF TOWER PITS:

➢ EXCAVATION OF TOWER PITS:

➢ PCC CONCRETE PADDING FOR POLE PIT:

leveled before erection of the pole/stubs.

➢ TOWER ERECTION BY BUILT UP OR PIECEMEAL METHOD:

➢ LAYING & STRINGING OF CONDUCTORS:

➢ EQUIPMENT AND ACCESSORIES:

➢ Paving Out of Conductor

➢ Recommendations for Sagging of The OPGW Cables:

➢ TESTING AND COMMISSIONING OF TRANSMISSION LINE:

5. FAQS (FREQUENTLY ASKED QUESTIONS):

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