KEC-Q-TL-SOP-

Standard Operating (Work) Procedure Document No.

0017

STRINGING Sheet No 1 of 36

PROCEDURE FOR STRINGING WITH GUIDELINES

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STRINGING Sheet No 2 of 36

CONTENTS

S. N. DESCRIPTION PAGE NO.

I COVER SHEET 1
II CONTENTS 2
III ABBREVIATIONS 3
1 PURPOSE 4
2 SCOPE 4
3 EXCLUSION 4
4 APPLICABILITY 4
5 REFERENCE DOCUMENTS 4
6 RESPONSIBILITY 4
7 PREREQUISITE 4
8 EQUIPMENTS 5

9 PROCEDURE 5 to 18

10 ACCEPTANCE CRITERIA 18
11 SAFETY MEASURES/PRECAUTIONS 18 to 19
12 RECORDS 19
13 ANNEXURE I 20
14 ANNEXURE II 21 to 29
15 ANNEXURE III 30 to 31
16 ANNEXURE IV 31 to 33
17 ANNEXURE V 34 to 36
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STRINGING Sheet No 3 of 36

ABBREVIATIONS

FQP - Field Quality Plan

MS - Mild Steel
OEM - Original Equipment Manufacturer
OPGW - Optical Ground Wire
OTDR - Optical Time-Domain Reflectometer
PM - Project Manager
QCE - Quality Control Engineer
SI - Store In Charge
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STRINGING Sheet No 4 of 36

1. PURPOSE:

This document describes the step wise work procedure to carry out the stringing work of 132 / 220 / 400 / 765 kV
D/C, 800 kV HVDC or other kind of Transmission Line work in planned and controlled manner with reference to the
drawings, technical specification and standards.

2. SCOPE:

It includes stringing methods for all types of Towers as indicated on Technical Specification / Drawing. The work shall
be carried out in accordance with the specification and corresponding approved drawings.

3. EXCLUSION :
In case of very specific & mandatory customer’s need their processes & formats can be followed as a part or in full.
However in case of any conflict most stringent norms must be followed.

4. APPLICABILITY:
This procedure is primarily developed for Transmission works but same can be used in similar kind of Railway &
Distribution works, at sites across all locations as per specification.

5. REFERENCE DOCUMENTS:
Following Documents / Drawings / Codes have been referred for the preparation of this procedure:-
a) IS : 5613 (Part 2 / Section 2) - 1985, IS : 5613 (Part 3 / Section 2) – 1989 (Installation of lines)
b) IS: 4082-1986 (Storage of construction material at site)
c) IS: 7293-1974 (Safety code for working with construction machineries)
d) Welding specs as per requirement
e) IS: 13416 Part1- 1992 (Falling material hazards prevention), IS: 13416 Part2- 1992 (Fall Prevention)
f) A few international standards and recommendation from (Saudi, Africa etc) were referred.

6. RESPONSIBILITY:
Responsibility of implementation of this procedure rest with below mentioned officials
a) PRIMARY: Section In-Charge, Stringing Supervisor, Stringing Engineer
b) SECONDARY: Project Manager, Store In-charge (SI), Quality Control Engineer (QCE)

7. PREREQUISITE:
a) Generic Contract Documents (as applicable)
b) Field Quality Plan (FQP)
c) Approved sag charts & profile drawings
d) Approved insulator assembly drawings
e) Stringing Schedule
f) Drum Schedule
g) Tower completion & inspection report.
h) Tested handling equipments, Tools & Tackles.
i) Availability of skilled manpower.
j) Availability of all PPEs.
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8. EQUIPMENT AND ACCESSORIES:

a) Tensioner & Puller
b) Rollers
c) Traveler
d) Reel Stand
e) Pilot Line Winder
f) Swivel
g) Running Board
h) Theodolite
i) Crimper
j) Discharge rods
k) And any other equipment / accessories required for safe handling & work purpose.

9. PROCEDURE:
9.1 INSULATOR HOISTING:
 Ensure complete and apposite assembly of insulator with accessories as per the approved drawing on the
ground before lifting.
 Ensure that the assembly is done on clean and dry surface.
 Ensure that no damaged insulator is taken for assembly.
 Ensure insulator handling as per recommended by the OEM (Original Equipment Manufacturer).
 Clean each insulator before hoisting, in such a manner that it will not scratch damage or spoil the surface of
the insulator, but in no case oil should be used for cleaning. (IS5613 15.1)
 The corona rings shall be fully installed on their respective hardware before such hardware or insulator
assembly is installed on the structure as per requirement.
 The insulator assembly shall be attached to the structure as indicated on the applicable drawing.
 Insulator assembly shall be carefully pulled up using pulling arrangement at the place of installation.
 Once it reaches its position it should be firmly fitted as per drawing.
 An insulator consisting of multiple insulator units, which shall be supported and protected during installation
to prevent damage.

9.2 PRE-REQUISITE ACTIVITIES

9.2.1 Site Selection –
 Sites are to be selected keeping in view the accessibility of site for pullers, tensioners etc.
 Choose equipment location such that the sub structures shall not be overloaded.
 Drum length for conductor/OPGW/Earthwire should be considered before selection of the stringing section.
 Splicing position is to be considered depending up on the drum length, position of tower & tower access.
 A detailed patrolling of the site is to be done to know the condition of soil especially during rainy season.
 Clear all the area from obstacles.

9.2.2 Government Clearance–

 Ensure that a proper application is given to the section in-charge of electricity distribution division to obtain
a shut down where stringing work encounters live lines.
 After obtaining this, it should be sent to the corresponding substation for obtaining the shut down.

9.2.3 Route Clearing–

 Trees and tall scrubs shall be cleared on either side of the centre line of the route or as would be finally
required by the Client.
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 In addition, tall trees outside the area, of such height that they could fall within three meters of conductors
shall be cut down after obtaining necessary permission.
 Before commencement of any tree cutting operation proper approval from authorized department has to be
taken.

9.2.4 Resources Accumulation–

 Ensure that every tool and tackle that is required to carry out the work is available and in good working
condition.
 Ensure the equipment (puller, tensioner etc) are in good condition and with a valid test certificate.
 Ensure skilled manpower is available.
 Ensuring the proper drum schedule so that unnecessary mobilization of conductor drums / earthwire drums
may be avoided to minimize the damage risk factor.
 Ensure availability of stringing material (conductor, crimper, traveler etc)

9.2.5 Weather Condition–

 Check the forecast of climate for the entire period of work.

9.2.6 Reinforcement of End Support–

 Double stays are provided on all cross arms and single stay is provided on the peak(s) of the angle / section
towers.
 Anchor spikes/blocks have to be positioned adequately away from tower base, so that it is not exceeding 45
with horizontal (ground) as far as the topography permits the same.
 Earth anchors of sufficient capacity to be used for providing back stay for the towers.
 Steel stay wires are fixed on the cross arms / peaks using D – shackles and pulled up to the stay pit. They are
connected to the stay lead from the pit through a turnbuckle using bulldog clamps.
 The turnbuckle is then tightened to a tension sufficient to balance the load which will be imposed on the cross
arms / peak(s) when stringing is carried out on the other side of the tower.

9.3 INSTALLATION OF TRAVELER/ROLLER/RUNNING BLOCKS

 Install rollers (single/triple sheave) directly to the insulator in case of suspension tower for single conductor.
 Rollers are to be connected directly to yoke plate for V Strings.
 For bundle conductors travelers must be installed to the end of the insulator (suspension).
 For angle towers travelers are to be installed with a string attached to the cross arm.
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 If substantial line angles are involved, two rollers in tandem may be required to reduce the bending radius of
the conductor or the load on each traveler, or both.
 The running blocks shall be suspended in a manner to suit the design of the cross-arm.
 All running blocks especially those eat the tensioning and, will be fitted on the cross-arms with jute cloth
wrapped over the steel work and under the slings to avoid damage to the slings as well as to the protective
surface finish of the steel work.
 The rollers/travelers shall be having a groove to accommodate a semi circular section of conductor and larger
than the diameter of the conductor/earthwire with enough space for free movement of the conductor wire
inside it, so that it does not slip over or rub against the sides.
 The rollers/traveler’s groove shall be lined with hard rubber or neoprene to avoid damage to conductor and
shall be mounted on properly lubricated bearings.

9.4 STRINGING OF CONDUCTOR

Usually there are 2 methods used for stringing the conductors and ground wires as stated below.
a) Slack or Layout Stringing (Installation by Pulling Lines).
b) Tension Stringing.

9.4.1 Slack or Layout Stringing (Installation by Pulling Lines)–

 In this method, the conductor reel is carried along the line on a vehicle and the conductor is deposited on the
ground. The conductor reels are positioned on reel stands mounted on a transporting vehicle at the start of
stringing section.
 The conductor is unreeled from the shipping reel & dragged along the ground by means of a vehicle or pulling
device.
 Braking device is normally provided to prevent overrunning and backlash.
 When the conductor reel is carried past a supporting structure, pulling is stopped and the conductor is placed
in the travelers attached to the structure before proceeding to the next structure.
 The conductor is then reattached to the pulling equipment and pull is continued till the next structure.
 This method is generally not recommended due to the damage to the conductor surface from dragging over
ground, though it can be used where pulling equipments (tensioner, puller etc.) can’t be moved on the site
with permission from the customer.

9.4.2 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.
 For more details about conductor drum transport & Handling refer KEC-Q-WP-0005 & Special
recommendations attached in Annexure I.
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 Equipment Placement/Location
 Once the pull sections are identified the placement of the puller, tensioner, reel stand etc can be
done.
1) Drum:
 The drum is placed at the selected site (with the space required for its location) so that the cable
outlet is on the upper part and aligned with the planned laying direction.
 The drum must be located at a suitable distance from the tensioner to allow enough fleet angle
for the conductor leaving the reel and entering the bullwheel of the tensioner, so that no damage
or scuffing of the conductor can occur.
 The lifting components usually used are hydraulic jacks and a bar with the suitable dimensions
inserted in the central opening of the drum.
 The drum must be located at a sufficient height from the ground for free rolling movement.
 Level of the surface should be such that while rolling movement of the drum due to conductor
pull is done it should not be unbalanced.
 Care shall be taken to insure that the conductors from the reels carry no dirt. Reels shall be
properly cleaned before starting stringing operations for any line section.
 Before placing the drum reconfirm the length.
2) Puller & Tensioner:
 Either the puller & the tensioner must be placed at a minimum distance from the tower equal to
or more than twice the tower’s height at respective positions.
 The tensioner as well as the puller should be placed aligned with the conductors.
 Tensioner machine will be anchored using spikes driven in the ground to counter the pull force.
 Care will be taken to ensure the Tensioner is positioned on almost level ground level and also at
minimum off-set from centre line as far as possible.
 Care has to be taken to minimize the angle of pull line with a maximum limitation of thirty degree
from centreline axis of stringing section.

Tensioner & Puller In Use

3) Tools & Tackles:
 All the tools & tackles i.e. Pulleys, Anti-Twisting devices, swivel, pulling grip, clamps & suitable
pulling ropes used must be placed near to the working area.
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STRINGING Sheet No 9 of 36

 Grounding Equipments
 Temporary electrical grounds shall be placed at both ends of the section and at intervals along
the line, which is under construction.
 The grounding sets installed at both ends of the section shall remain in place until the completion
of the work and shall be removed as the last phase of the cleanup.
 Hot stick shall be used for installing and removing the grounding sets.
 All temporary grounds installed for protection shall be clearly visible for inspection and shall be
flagged by use of a red cloth placed at the point of grounding.
 All pulling and tensioning equipment shall be bonded and effectively grounded with approved
type driven grounds securely attached to the equipment.
 At least two driven grounds shall be used at both the pulling and tensioning setup.
 All conductive parts of the tensioning setup and equipment shall be operated from grounded or
insulated platform.
 All existing lines, which are de-energized for crossing, shall be short circuited and grounded at
each side of the crossing. Use of discharge rod is necessary at both the ends of a line crossing.
 All grounds, except those placed at both ends of the section, and red flags shall be removed when
they are no longer needed for protection.
 Guy wire or temporary guy wire shall not be used for grounding.
 The pulley block on each tower must be earthed and grounding roller to be used on drum side to
ensure grounding of any induction current developed during installation.

Figure Shows the Tensioner Being Grounded

 Communication Method
 Communication will be established between winch and tensioner area and at designated points
along pulling section by walkie-talkies.
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 It is recommended to provide Green / Red flag in each & every tower of the stringing section.
 For stringing of bundled conductors with running board, it will be desirable to observe the running
board as it passes through each traveler so in case of any blockage the observer can communicate
to the puller & tensioner end.
 A back up communication system must be available during actual stringing, in case if one of it fails
during the work.

 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.
 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.
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 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.

 Considerations on Crossings
 Scaffoldings are to be used wherever there is road crossing, line crossing, railway lines etc are to
be crossed during the stringing operations.
 It is to be ensured that the other work (viz. road traffic flow, etc) isn’t affected due to stringing of
the tower.
 It is to be ensured that the scaffolding provided for the crossing is of adequate strength so as to
bear the loads of stringing operation.

Figure Shows the Scaffolding Used for Line Crossover

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STRINGING Sheet No 12 of 36

 Ensure that the shutdown permission is obtained from the concerned authority in case of electric
line crossing.
 The shutdown procedure as stated below shall be followed.
 Ensure that the DB is switched off with a person present at DB all time possessing communication
equipment (two way radios/mobile).
 Ensure that for each line conductor there are 2 discharge rods available for shutdown.
 Electrical rubber hand gloves with rod for discharging cable fitting should be present at the
site/location.
 First grounding/earthing of the mild steel (MS) rod should be done as shown overleaf.

Pole To Pole Shutdown Telescopic Discharge Rod

 Then the cable to be earthed to the earthing rod.

 Then one by one discharge cables to be tightened to the electrical lines/phases with the help of
discharge rods.
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 All the shutdown procedure form/ Permit to work form should be submitted by the
supervisor/Engineer.

 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.
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STRINGING Sheet No 15 of 36

Figures Above Show the Sagging Arrangement Using 4 Ways + 4 Ways Pulley Arrangement

 Measurement of Sag
Sag can be measured by one of the following methods (at site as agreed by Engineer).
 Using sagging transit and sag board for
- Equivalent span method
- Maximum span method

 Equivalent span method:

In this method of measurement following steps are to be followed.
 Check for the equivalent span details mentioned in the chart.
 Select the closest value from the table (initial stringing chart).
 Now select that location number for fixing sag board.
 Measure ambient temperature with the help of thermometer at site.
 At the respective temperature observe the distance value in table (final stringing chart).
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 Now from bottom cord of middle cross arm extend a steel measuring tape up to the required
length as per chart.
 Now fix the sag boards at that position, taking care that it should be easily visible & horizontal.
 While measurement of sag see whether the conductor’s sagged portion is in line with the markers
visually.
 If sagged portion is above the markers, loose the conductor or if below then tighten the
conductor.

 Maximum span method:

In this method of measurement following steps are to be followed.
 Select the maximum span tower for fixing sag board.
 Measure ambient temperature with the help of thermometer at site.
 At the respective temperature observe the distance value in table (final stringing chart).
 Now from bottom cord of middle cross arm extend a steel measuring tape up to the required
length as per chart.
 Now fix the sag boards at that position, taking care that it should be easily visible & horizontal.
 While measurement of sag see whether the conductor’s sagged portion is in line with the markers
visually.
 If sagged portion is above the markers, loose the conductor or if below then tighten the
conductor.

 Once the final sagging of each span is completed the rollers can be lowered down using the slings.
 The maximum tolerance in final still air sag at maximum temperature shall be ±4 percent of such sag, in
any span as obtained from the sag tension chart.
 The sag of any conductor in a span shall not depart from the mean sag of all conductors in the same span
by more than 3 percent or as specified by the client. (IS5613-5.1)

 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.
 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
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STRINGING Sheet No 17 of 36

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

 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.
 Spacing bicycle/ trolley may also be used for fixing conductor accessories.
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STRINGING Sheet No 18 of 36

9.5 Post Installation Tests/Checks

The conductor & OPGW is required to be tested for continuity, attenuation values etc tests as required by client
after completion of final sagging.
 Conductor
 Continuity test are carried as per the client’s requirement for ensuring that there is proper
continuity and there is no breakage in the conductor.
 OPGW
 The OPGW is verified optically using OTDR in order to ensure that the attenuation values are
within the required margin. Also the values are matched with the values obtained before
installation & after installation.
The checks are to be carried out & recorded in presence of client, as mentioned in the checklists attached in
annexure.

10. ACCEPTANCE CRITERIA

 Conformity of Sag.
 Conformity of Attenuation before & after laying.
 Conformity to client’s specification/Technical Standards.

11. SAFETY MEASURES/PRECAUTIONS:

 Ensure that the instructions as stated in the pre-inspection checklist (KEC/Corp EHS/FT-005/Rev-00) are starkly
followed.
 Use of safety PPEs is must.
 All precautions & safety measures as per instructed for safety at height work must be strictly adhered to.
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STRINGING Sheet No 19 of 36

 Loading and unloading o f OPGW drums shall be done using suitable arrangement / crane.
 Ensure water shall not penetrate in to the OPGW cable.
 While working near moving/ rotating equipment special care has to be taken & close proximities to be avoided
while the instrument is running.
 While laying the conductor/earthwire/OPGW care shall be taken that it doesn’t rub to the ground at any point
of work.
 Proper and sufficient anchors & back stays are provided to the equipment under load.
 Equipment to be handled as per the manufacturer’s instructions.
 Ensure that shutdown is obtained prior to starting of stringing work near power line crossings till the completion
of final sagging activity.
 Earthing shall be done at both the sides of phases before fixing the roller.
 Both sides of the winch machine shall be earthed.
 Equipment like OPGW, existing ground wire and pulley block are to be connected to Individual copper cable and
connect to the tower earthing.
 Grounding clamp shall be cleaned well and ensure proper contact.
 Grounding is to be perfectly done to ensure safe level of working. Proper grounding is to be ensured during
operation like clamping work to avoid fault current likely to be encountered.
 Grounding cables shall be connected to the ground source first and then to the equipment. When removing the
grounds, the ground must be removed from the equipment first and then from the ground source.
 Ensure that only a competent & authorized person is operating the equipment.

12. RECORDS :
 Stringing Checklist Conductor/Earthwire (KEC-Q-TL-SA-CL-0018, Annexure II)
 Stringing Checklist OPGW (KEC-Q-TL-SA-CL-0018, Annexure II)
 KEC-Q-TL-SOP-
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STRINGING Sheet No 20 of 36

ANNEXURE I
Special Recommendation for Transporting & Handling of Conductor/OPGW

TRANSPORT, LOADING, UNLOADING AND STORAGE:

 The drums should always be transported in vertical position with the cable ends fixed to prevent cable from
slackening. All of the staves and safe guards should be maintained until the drums are situated for immediate
installation.
 After the transport, the drums should be inspected to verify that they have not been damaged and that none of
the staves and / or safeguards is broken.
 The drums should never, in any case, be thrown from the lorry during unloading, or moved by uncontrolled rolling.
 Loading and unloading are performed so that the drum remains in vertical position and the sides of the drum are
not damaged by using suitable method.
 The direction of the drum turns should follow the instruction of the mark on the drum.
 In any case the drum should not be stored horizontally.
 The ends of the cable should be sealed to prevent water penetration.
 The drums can be moved by rolling a short distance ensuring that there are no objects that may damage the staves.
The direction in which the drum turns should be the same as that in which the cable is wound during manufacture.
 If available the handling and storage should be done as per the recommendations of the OEM.
 The drum should not be stored on its side under any circumstances whatsoever.
 The ends of the cable should be sealed to prevent water penetration.
 The drums should be stored on flooring that is strong enough to prevent sinking.
 The drums should be stored to facilitate handling and loading. They should be located far from any activity that
may damage them.
 KEC-Q-TL-SOP-
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STRINGING Sheet No 21 of 36

ANNEXURE II
Checklists:

Document No. KEC-Q-TL-SA-CL-0018

CHECKLIST Rev. No 00
KEC / Client Name /
Stringing Earthwire/Conductor Report No.
Project / Location No. / 001
PROJECT :
CLIENT NAME :
Date:
A Pre-stringing checks Status Remarks
Backfilling of soil and revetment/Benching wherever required is
1 Yes/No.
done
Towers are tightened properly and all the members, Nut/Bolts are
2 Yes/No.
provided
3 Trees in the corridors removed to facilitate smooth stringing. Yes/No.
All line materials tested T&P, safety equipments and relevant
4 Yes/No.
drawings available for stringing
5 Shutdown of Power line /Railway block if required is arranged. Yes/No.
Necessary Protection/scaffolding/warning signals Provided for
6 Yes/No.
Railway/Power line/P&T line/Road
7 Towers vulnerable for one side load are guyed properly Yes/No.
8 Tower footing resistance is within permissible limit of 10 ohms Yes/No.
9 Condition of drums received is good & undamaged Yes/No.
B Paving Out of Earthwire
1 Work is being carried out with full safety measures as per guide line Yes/No.
2 Travelling rounds are provided Yes/No.
3 Paving out is carried out as per approved drum schedule Yes/No.
4 All pulleys fixed on towers for paving out are moving freely Yes/No.
Effective communication exists through walkie-talkie and through
5 Yes/No.
persons on towers
Earthwire is being constantly checked for damages as it is
6 Yes/No.
unwounded. Damaged portion, if any, is remove
Necessary arrangement have been provided to avoid rubbing of
7 Yes/No.
earthwire against hard ground (Use of ground rollers)
Necessary details of earthwire, M.S. Joints Recorded as given
8 Yes/No.
overleaf
 KEC-Q-TL-SOP-
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STRINGING Sheet No 22 of 36

Checklists:

Details of Earthwire
Make
Batch No
Quantity and Location

Length Paid between

Length
S.N. Drum No. Marked on Phase Wire No.
Paved
Drum From Loc.No. To Loc No.

There is no damage to earthwire before or during stringing. Strands are in

Yes/No.
perfect position

Details of MS Joint for Earthwire

Make
Batch No
Quantity and Location

Section Phase Wire No. Joints Details

No. of Joints Between Loc. No.

Dimension-Recorded. Yes/No.
M.S. Joint has been provided at least 30 meters away from tower. Yes/No.
There is no M.S. Joint over railway/River/Main road crossing. Yes/No.
Not more than one M.S. joint provided in one span for each
Yes/No.
earthwire/conductor.
Repair sleeve shall be used if number of damaged strands is not more than
1/6th of the total strands in the outer layer. If damage is more, than the Yes/No.
damaged portion shall be removed and M.S. Joint provided.
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STRINGING Sheet No 23 of 36

C Paving out of Conductor

1 Work is being carried out with full safety Measures as per guideline. Yes/No.
2 Tensioner/puller are properly placed, firmly Anchored and earthed. Yes/No.
3 Conductor drums are placed properly to avoid bird caging. Yes/No.
Sequence of paving out is such as to avoid unbalancing of load on
4 Yes/No.
tower.
5 Details of insulators and fitting are recorded As per Ann. CF-III & CF-IV. Yes/No.
6 Paving out is carried out as per approved Drum schedule. Yes/No.
7 Travelers fixed on towers are moving freely. Yes/No.
Effective communication exists through walkie-talkie and through
8 Yes/No.
persons standing on towers for smooth and
Conductor is checked continuously for damage as it is unwounded
9 Yes/No.
from drum. Damaged portion, If any, is removed/ repaired.
Proper arrangements made to avoid rubbing of conductor on
10 Yes/No.
ground/hard surfaces (Use of ground rollers).
There is no damage to earthwire before or during stringing. Strands
11 Yes/No.
are in perfect position
Details of conductor and M.S.J./repair sleeve are recorded as given
12 Yes/No.
below

Details of Conductor
Make
Batch No
Quantity and Location

Length Paid between

Length
S.N. Drum No. Marked on Phase Wire No.
Paved
Drum From Loc.No. To Loc No.

There is no damage to earthwire before or during stringing. Strands are in

Yes/No.
perfect position
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STRINGING Sheet No 24 of 36

Details of MS Joint for Earthwire

Make
Batch No
Quantity and Location

Joints Details
Section Phase Conductor Wire No.
No. of Joint Between Loc No.

Dimension-Recorded. Yes/No.
M.S. Joint has been provided at least 30 meters away from tower. Yes/No.
There is no M.S. Joint over railway/River/Main road crossing. Yes/No.
Not more than one M.S. joint provided in one span for each
Yes/No.
earthwire/conductor.
Repair sleeve shall be used if number of damaged strands is not more than
1/6th of the total strands in the outer layer. If damage is more, then the Yes/No.
damaged portion shall be removed and M.S. Joint provided.

Details of Repair Sleeve for Conductor

Make
Batch No
Quantity and Location

Details of Repair Sleeve

Section Phase Conductor Wire No.
No. of Repair Sleeve Between Loc No.

Dimension-Recorded. Yes/No.
Not more than one M.S. joint provided in one span for each
Yes/No.
earthwire/conductor.
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STRINGING Sheet No 25 of 36

Details of Insulators
Make
Batch No
Electro Mechanical Strength
Quantity and Location

Qty. in Right Side Qty. in Left Side

Loc. Qty. as per
S.N Phases Phases Remarks
No. specification
Top Middle Bottom Top Middle Bottom

Insulators are completely cleaned with soft cloth. Glazing is proper. There is
Yes/No.
no crack, scratch or white spot on its surface
‘R’ clips in insulators are fitted properly, while hoisting, no damage caused to
Yes/No.
insulators

D Final Sagging & Tensioning of Earthwire & Conductor Status Remarks

Sag board is fixed correctly after taking into account length of
1 Yes/No.
suspension clamp/fittings
2 No. of sag boards fixed in a section is as per technical specification. Yes/No.
Sag is measured correctly at prevailing Temperature. Details are
3 Yes/No.
recorded as below
Sag mismatch is within permissible limits of 40mm as checked with
4 Yes/No.
theodolite
After measuring sag, marking/cutting of earthwire/conductor is done
5 Yes/No.
correctly to fix tension clamp/fittings
6 Details of hardware fittings are recorded as given below Yes/No.
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STRINGING Sheet No 26 of 36

Details of Hardware Fittings

Make
Batch No
Type of fitting-I/V, Single/Double, Suspension/Tension
Quantity and Location

No. of Fittings
S.N. Loc No. Phases Remarks
Top Middle Bottom

All nuts/bolts properly tightened Yes/No.

All components of fittings have been provided as per approved
Yes/No.
drawings. Dimensions and galvanizing are Ok
Fitting is cleaned and there is no damage to any component
All split pins properly provided
In Case of Tension fittings, dimensions before and after compression
recorded

E Clipping of Earthwire and Conductor

For clipping, the marking is done correctly so that suspension
1 Yes/No.
clamp/fitting hangs exactly vertical.
2 Before clipping of conductor, proper earthing is provided. Yes/No.
Following line material provided as per specification & details
3 Yes/No.
recorded as shown below.
a) Suspension clamp of earthwire and conductor as given below Yes/No.

Details of Tension/Suspension Clamps

Make
Batch No
Quantity and Location

S.N. Wire No. Loc No. Remarks

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STRINGING Sheet No 27 of 36

All Components of clamps have been provided as per approved

Yes/No.
drawings. Dimensions and galvanizing are Ok
Clamp are cleaned and there is no damage to any component Yes/No.
All Nuts & bolts have been properly tightened Yes/No.
Spilt pins have been properly fixed Yes/No.
In case of tension clamp, dimensions before and after compression is
Yes/No.
recorded

b) Vibration Dampers for earthwire as given below Yes/No.

Details of Vibration Damper

Make
Batch No
Quantity and Location

S.N. Fixed on Loc. No. Fixed towards Loc. No. Phase/wire No. No. of Vibration Damper.

All Components of vibration damper have been provided as per

Yes/No.
approved drawings. Dimensions and galvanizing are Ok
Vibration Dampers are cleaned and there is no damage to any
Yes/No.
component
All Nuts & bolts have been properly tightened Yes/No.
Vibration Dampers are fixed as per approved placement chart Yes/No.

c) Acer/spacer damper/jumper spacer as given below Yes/No.

Details of line Spacer/Spacer Damper/ Jumper Spacer

Make
Batch No
Quantity and Location

S.N. Span/Loc No. Phase No. of Spacer

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STRINGING Sheet No 28 of 36

All Components of spacer have been provided as per approved

Yes/No.
drawings, dimensions and galvanizing are Ok
Spacer is cleaned and there is no damage to any component Yes/No.
All Nuts & bolts have been properly tightened Yes/No.
Spacer/spacer damper fixed as per approved placement chart Yes/No.

Sag/tension again measured after clipping and found Ok.

4 Yes/No.
Details recorded as below.

SAG Measurement for Earthwire

Sag board fixed between Loc No & Loc No
Temperature °C
Measurement of Sag/Tension

Item Phase/Wire No. As per Sag/Tension chart Actual

Sag

Tension

During paying out/rough sagging, tension in Earthwire was as per

Yes/No.
technical specifications.
For final Sagging, initial stringing chart for conductor and final
Yes/No.
stringing chart for earth wire are used.

SAG Measurement for Conductor

Sag board fixed between Loc No & Loc No
Temperature °C
Measurement of Sag/Tension

Item Phase/Wire No. As per Sag/Tension chart Actual

Sag

Tension
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STRINGING Sheet No 29 of 36

During paying out/rough sagging, tension in conductor was as per

Yes/No.
technical specifications.
For final Sagging, initial stringing chart for conductor and final
Yes/No.
stringing chart for earth wire are used.

All line materials provided as per specification and approved

5 Yes/No.
drawings. All necessary details recorded for traceability.
Jumpers tightened properly. Live metal clearances are as per
6 Yes/No.
specification.
Minimum Ground clearance, clearance over Power line/railway
7 Yes/No.
line/river crossing is as per specification.

19 Remarks (if Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT FOR CLIENT
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STRINGING Sheet No 30 of 36

ANNEXURE III
Checklists:

Document No. KEC-Q-TL-SA-CL-0019

CHECKLIST Rev. No 00
KEC / Client Name /
Stringing OPGW Report No.
Project / Location No. / 001
PROJECT :
CLIENT NAME :
Date:
A Pre-stringing checks Status Remarks
OPGW drum is being checked using OTDR & details recorded before
1 Yes/No.
laying / dispatch from Store
Other checks whichever applicable as per checklist number KEC-Q-TL-
2 Yes/No.
SA-CL-0018 are done
B Paving Out of OPGW
All the accessories of jointing box are provided as per approved
1 Yes/No.
drawings through persons on towers
Other checks whichever applicable as per checklist number KEC-Q-TL-
2 Yes/No.
SA-CL-0018 are done
C Final Sagging & Tensioning of OPGW
Other checks whichever applicable as per checklist number KEC-Q-TL-
1 Yes/No.
SA-CL-0018 are done
Optical ground wire is being checked using OTDR after final sag &
2 Yes/No.
details recorded \as given below.

POST INSTALLATION OTDR TESTING DETAILS

Date: Location No. From to

Drum Length: Succeeding Span length (km)
Preceding Span length (km )
Drum No:
Joint Location No.

Wave Length Max. Attenuation

1550 nm 0.21 db / km
1310 nm 0.35 db / km

Spool Actual Fiber Attenuation Attenuation

Tube Fiber Fiber Length
Length Length @ 1550 @1310 Remarks
Colour Number Colour (MTR.)
(MTR.) (MTR.) (db / km) (db / km)
1 BLUE
BLUE

2 ORANGE
3 GREEN
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STRINGING Sheet No 31 of 36

4 BROWN
5 GRAY
6 WHITE
7 RED
BLUE

8 BLACK
9 YELLOW
10 VIOLET
11 PINK
12 AQUA
13 BLUE
14 ORANGE
15 GREEN
16 BROWN
17 GRAY
ORANGE

18 WHITE
19 RED
20 BLACK
21 YELLOW
22 VIOLET
23 PINK
24 AQUA

Remarks (if Any)

(Site Engineer) (QA / Q C Engineer) (Site Engineer) (QA / QC Engineer)

for KECIL for KECIL For CLIENT FOR CLIENT
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STRINGING Sheet No 32 of 36

ANNEXURE IV
Dos & Don’ts:
Right Wrong

No Scaffolding Provided, Conductor

Scaffolding Provided Rubbing on Ground
Old Pic, Now Full Body Harness is Mandatory

Use of Ladder Use of Insulator as ladder

Use of Ground Rollers Conductors Directly Laid on Ground

 KEC-Q-TL-SOP-
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STRINGING Sheet No 33 of 36

Dos & Don’ts:

Right Wrong

DOs DON’Ts
Checking of tower for proper fitment before starting Stringing work directly started without checking
the stringing work. the towers to be stringed.
All material like drums, insulators, equipment are
Material is brought to the site at last moment of
transported at required location before
commencing the work.
commencement of work.
Conductors & Insulators are handled as per the
storage & handling instructions form OEM or Materials handled roughly and carelessly.
standard procedure.
Tractor is used for pulling of the pilot line or
Pullers are used to pull the conductors, pilot lines.
conductors.
Ground rollers are used to avoid conductor’s
Conductors are dragged along the ground
contact with ground.
While working on insulators ladder or a safe
Insulators are used for ascending & descending
arrangement for descending and ascending is
for stringing work.
used.
Sag boards are fixed at the specified location as Sag boards are fixed at different location than
per chart. stated in chart.
Device used to measure the temperature is Non calibrated or faulty device used for
calibrated and in good working condition. temperature measurement.
Proper communication is held at every time while Communication is vague and sometimes
working thru walkie-talkie. communicated thru signs instead of 2 way radios.
While stringing all safety precautions as mentioned
Safety instructions are neglected while working.
in the manuals & standards are taken care off.
There are missing components/accessories (viz.
All components/ accessories are starkly fitted.
split pins, nuts etc)
Proper crimping & clipping is done. Improper clipping & crimping done.

Wires are not bent over the specified radius Wires are bent over the specified radius.
 KEC-Q-TL-SOP-
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STRINGING Sheet No 34 of 36

ANNEXURE V
Pre-Inspection Checklist:

Pre-Inspection Checklist for Stringing

KEC/Corp EHS/FT-005/Rev-00
Date of Inspection :
Name of Section/Line and Location Number :
Manpower Strength :
PM/Construction Manager/Engineer :
EHS Manager /Engineer/Officer :
S. NO. Check point Status Remark, IF Any

Earthing of Towers, Tensioner Machine, Puller machine, Winch

1
machine should be done before start up of stringing work.

Winch Machine Final sag work should be carried out with Winch
2
Machine only.

Back Stay arrangement should be made with specification 18

3
mm dia steel wire rope & 10 MT capacity Turn Buckle.
Deadment wood should be of dia 10 to 14 inch with 5 feet of
4
Length.

Deadment pit should be minimum 6 feet deep.

5
Minimum three Bull dock clamps should be used.

Check all tower members before undertaking pilot and conductor

6
paying out work.
All Nuts and Bolts including step bolts should be tightened &
7 punched properly before starting the job No blank holes should
be ensured.

8 Stringing / final sagging should be supervised.

Adequate barricade / caution tape displaying of danger sign,

9 warning sign / protection to public / children moving nearby
ensured (RED FLAGS / CAUTION TAPE / ROPE / BOARDS).

Only stringing team members should be allowed to stand near

10
the tower while stringing is in progress?

Availability of sufficient winch machine with required load

11
capacity for Sagging work..
Only tested lifting equipment, tools & tackles to be used for
12
stringing work and record available.
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STRINGING Sheet No 35 of 36

13 All lifting T&Ps must be color code and proper identification.

Visual inspection of Polyprolene / Fiber rope before use like
14 strength of rope, free from damage, no joint etc. and PP rope not
less then 20 MM

Visual Inspection of wire rope slings before use like sling not
15
corrosion, bend without cracking, no wire cut etc.
Visual Inspection of four sheave pulley, equalizer pulley, pulley
before use like side flat size not more than 08 mm, gap between
16
roller and side not more than 33mm, proper locking and safety
pin in open type pulley.
Visual inspection of all winch machines, pilot wire, head board
17
before use for Stringing work.
Visual Inspection of D-shackle before use like pin in seated,
18
identification of load, check the wear etc.
Availability of sufficient winch machine with required load
19
capacity for Sagging work..

20 Availability of Fall arrestor clamp in sufficient quantity at site.

Ascending & Descending the tower should be done through the

21
steps bolts with usage of Fall Arrestor rope & clamp.

Practice of ascending on and descending from the tower

22
through the tower members should be strictly disallowed.

Availability of Retractable fall arrestor as per insulator height and

23
used while working on insulators or hanging hardware fittings.

Scaffolding should be provided at Road/Railway and Power line

24
crossings.

While sagging two clamps should be used (both bolted or

25
combination but not both automatic)

Separate four sheave pulley arrangement for each conductor for

26
safe sagging.

27 Roller grooves should be rubber coating.

28 Enough numbers of Walkie Talkies should be available at site

Deadment Pit should be separate for each phase while rough

29
sag.

All the Fitters (Height workers) should undergo medical fitness

30
tests.

Height pass should be available to all the workers those are

31
working for stringing activity.
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STRINGING Sheet No 36 of 36

PTW should be obtained from the competent authority for

32
working near to EHV/HV/LT lines and take proper shut down.

Pole Isolation methodology shutdown procedure must be

33
followed during the shutdown procedure.

Not Applicable for Stringing work. However any well / pit nearby
34
the Stringing site should be properly barricaded.

35 Any other:

36 Any other:

37 Any other:

Comments / Remarks:

Note : No work carried out with short contingency deviation, It must cascaded to senior management, so if it is minor
deviation than need to be approval from Regional EHS Manager / RM, or if it is major deviation than need to be approved
corporate South Asia / T&D-EHS.

(PM/CM/Engineer) (EHS Manager/Engineer/officer)