Stringing Manual - Rev2
Stringing Manual - Rev2
MTS/TL/12
Rev:0/01-02-09
1.STRINGING METHOD
1.1 Introduction
1.2 Method
First Nylon pilot wire will be paid out through the rollers hanged
on the suspension towers in the section manually. After pulling the
entire length of Nylon pilot, puller end of the Nylon pilot will be
fixed in the puller capstan and tensioned slightly. Earthwire will
be coupled to the Nylon Pilot using swivel and wire meshed sock.
OPGW will be coupled to the Nylon Pilot using swivel and a Head
Board.
For the paying out of conductor, steel pilot will be used. Steel
Pilot wire of 12 to 13mm diameter available in the suitable reels
will be coupled to the Nylon pilot using swivel joint. After paying
out the steel pilot, end of the steel pilot toward the tensioner
will be coupled to the conductor using swivel and wire meshed
socks.
The conductor drum will be mounted on the drum setting jacks. The
conductor will pass through the tensioner and connected to the
pilot wire using socks and swivel. The puller will be stationed at
the other end, and the end of the other side of the pilot wire will
be secured to the puller and initial load will be given. While the
pilot wire gets tightened, care will be taken on all the spans to
see that the wire does not get stuck or damaged due to any
obstruction.
Once the pilot wire is tighten and communication system switched on
with controlling staff at crucial points, the pulling of conductors
will be started by simultaneously releasing the brake of the
tensioner and switching on the puller. Adequate number of staff
shall be engaged to monitor the stringing work and paying out
throughout the section to avoid any problems.
Depending on the height above the ground level at which the
conductors are desired to travel, the brake / tension is adjusted.
Control will be made to check that the conductor presses smoothly
through the roller and pulling speed will be made adjusted to
maintain required tension. After paying out of the drum, the end of
the conductor at tensioner point will be anchored by
automatic/bolted clamps to ensure that the paid out conductor does
not release to the ground.
METHOD STATEMENT -3-
MTS/TL/12
Rev:0/01-02-09
1. Slide aluminium body over conductor well sway from the end.
2. The Conductor to be terminated should be out square and the
outer surface should be clean and dry. To prevent
inadvertent un-stranding or deformation of the aluminium
wires, it is advisable to apply a tape or wire binder at
approximately 20mm from the intended cutting position.
STEEL TAIL
3. Cut back aluminum strands making sure not to cut steel
strands to allow steel core to be inserted fully into the
steel tail.
LENGTH OF STEEL TAIL +10mm
4. Insert steel cores fully into the steel sleeve, making sure
they meet at the centre of the sleeve.
5. Using the nominated AF hexagon dies and commencing at the
center of the sleeve, apply overlapping compressions to the
conductor ends. The dies MUST CLOSE FULLY at the end of
each bite. The flats of each bite should be aligned with
and overlap the previous ones by a minimum of 5mm. Wipe
clean any surplus grease.
BODY
6. Mark the conductor to ensure that the aluminium sleeve can
be located centrally over the steel sleeve.
METHOD STATEMENT -7-
MTS/TL/12
Rev:0/01-02-09
Sub sections are selected as per the site conditions and the
pulling and breaking capacity of stringing machines. However,
paying out tension of the conductors should not exceed the 75% of
the final tension.
• The anchor blocks will be laid inside the pit of depth 2.2m
(approximately) and duly backfilled and compacted. Each anchor
points must be anchored separately.
• The blocks will be laid at a distance of 11/2 times the tower
height.
• Steel wire ropes (18-20mm) will be used to connect the blocks
with all the cross arms and earthwire peaks of the tower.
• The ends of the wire of the anchor block will be tied with
turn-buckle and secured by bulldog clamps.
METHOD STATEMENT - 12 -
MTS/TL/12
Rev:0/01-02-09
The sag of any one conductor shall not deviate more than 150mm from
the sag of the line conductors in the span.
2.3.1 - Case 1
b. Obtain the required sag ‘D’ corresponding to the span and the
ambient temperature.
2.3.2 - Case 2
2.3.3 - Case 3
e. Set the level for a horizontal line of sight and adjust the
conductor sag tangent to this line of sight.
METHOD STATEMENT - 18 -
MTS/TL/12
Rev:0/01-02-09
2.3.4 - Case 4
c. Determine D1 as in Case 3.
e. Set a level rod on the bench mark with the target adjusted to
the elevation of a point at distance D1 below the lower
conductor support.
2.3.5 - Case 5
Conductor sagging by calculated angle of sight:
Method of Use
a. Obtain sag for the span corresponding to the ambient
temperature.
b. Set up a sag-scope at the structure at the lower end of
span.
c. Measure the vertical distance D1 from the conductor support
to the line of sight of the sag-scope.
d. Calculate the angle of sight ‘F’ by the formula.
tan F = [H – 4D + 4D√(D1/D)] / A
where,
H = Deference in elevation between conductor supports(m)
D = Sag (m)
D1 = Distance the sag-scope is set below cond. support(m)
A = Span (horizontal distance between the supports)
e. Set the sag-scope at the angle of sight calculated above.
f. Adjust the conductor sag tangent to the line of sight.
METHOD STATEMENT - 20 -
MTS/TL/12
Rev:0/01-02-09
2.3.6 - Case 6
Supports at unequal elevations and lowest point of sag falls
outside the span.
Legend:
A - Span (m)
H - Elevation difference at supports (m)
T - Tension on conductor (kg)
W - Weight of conductor (kg/m)
D1 = X tanF ………………………………………………………………………(4)
D2 = y – (D1-D) ……………………………………………………………(5)
METHOD STATEMENT - 21 -
MTS/TL/12
Rev:0/01-02-09
Method
1. At one end of the span measure distance ‘D2” vertically down
the structure from the conductor support and place a mark on
the structure.
2. Similarly place a mark in the other structure at a distance
‘D’ below the conductor support point.
3. Mount sag-scope at the mark on one structure, sight to the
mark in the adjacent structure and adjust the conductor sag
tangent to the line of sight.
METHOD STATEMENT - 22 -
MTS/TL/12
Rev:0/01-02-09
Note:
1. Conductor shall be about 45cm long.
2. Thermometer should be installed sufficiently prior to the
actual sagging operation to allow temperature stabilization.
3. Remove steel core and insert thermometer in end of cable.
METHOD STATEMENT - 23 -
MTS/TL/12
Rev:0/01-02-09
Nomenclature:
H = Horizontal component of the conductor tension (kg)
V1 = Vertical load at support (kg)
W = Weight of conductor per unit length (kg/m)
Wc = Weight of conductor from low point to DE assembly
Ws = DE assembly length (m)
Xs = Ls and Lc
S of Vertical Forces = 0
V1 = Ws + Wc ………………………… (1)
S of moments about point p = 0
ds = [(V1.Xs) – (Ws.Xs)/2] / H
= [(Ws+Wc).Xs – (Ws.Xs)/2] / H
For dead-end assembly in semi-span replace by conductor length Lc
with vertical load at support equal to V2
V2 = Wc + W.Xs
P V2.Xs – H.dc – WXs.Xs/2 = 0
dc = [(V2X2) – (WXs.Xs/2] / H
= [(Wc+WXs).Xs – WXsXs/2] / H
Increase in conductor sag due to weight of
dead-end assembly = d s – dc
ds – d c = [(Ws+Wc).Xs – Ws.Xs/2]/H – [(Wc+WXs)Xs-WXsXs/2]/H
= Xs.(Ws – WXs) / 2H
Normally the above correction is considered whenever its value
is more than 5% of the conductor sag.
Typical Values:
Xs = 2.52 m
H = 1700 kg
Ws = 78 kg
W = 0.849 kg
Substituting the values
ds – dc = 2.52 × [78 – 0.849 × 2.52] / [2 × 1700]
= 0.056 m
As per above, sag correction is required when the sag is less
than 0.056×100/5 = 1.12m
Calculation of corresponding span:
Sag = W . (Span)2 / 8 × (Tension)
Span = [(sag) × 8 × (Tension) / W]½
= [1.12 × 8 × 1700 / 0.849]½
= 134 m
Therefore weight of the insulator assembly will be considered
when the span between two dead-ends is less than 134m.
METHOD STATEMENT - 25 -
MTS/TL/12
Rev:0/01-02-09
3.1 Scope
OPGW (Composite fiber-optic overhead ground wire) is generally
composed of optical fibers in the stainless tube and AS wires
(Aluminium-clad steel wires), aluminium alloy wires or EC-grade
aluminium wires. Accordingly, it is necessary to take care of OPGW
during its stringing to avoid any damages not only for its
mechanical and electrical properties, but also its optical
properties.
Installation procedure for OPGW is basically similar to that for
conventional overhead ground wires in overhead transmission line
construction, however particular attention must be taken for the
protection of optical component.
This paper describes the stringing manual of OPGW briefly in the
above mentioned view point.
3.2.2 Bending
For the protection of optical components housed inside
the OPGW, it is very important to avoid the bending at sharp
angle or the kink of OPGW during handling.
For instance, following general attention shall be paid.
a) Minimum diameter for coiling at site = 1 m
b) Ditto but for stringing sheave = 450 mm
c) Ditto but for tensioner’s capstan = 1.2 m
d) (When OPGW is lifted up, hook is prohibited to use and
suitable devices such as conductor saddle should be used.
3.2.4 Compression
For the protection of optical components housed inside
the OPGW, it is very important to minimize the stainless tube
deformation during construction. For instance, all the bolts
of accessories and fittings, especially for clamp, must be
correctly tightened up to the specified torque by means of
qualified torque wrench respectively. The short of fastening
torque causes the lack of gripping force and excessive
fastening causes the deflection of stainless tube.
Furthermore, it is important to use suitable wedge type
of come-along when OPGW is temporarily clamped. Any device to
apply compression force and deform the stainless tube, such as
so-called “Chicago Grip” or “Kito Grip”, should not be used
throughout the stringing operation.
3.2.5 Twisting
Preventing OPGW from twisting during paying out and
stringing works, following general attention shall be paid.
(i) Use the running board with two counter weight
tail
(ii) Use special stringing sheaves for OPGW
(iii) Use the tensioner of double-capstan type or shoe-
chain wheel type
(iv) Use the pulling wire with same lay direction as
OPGW for paying out work
METHOD STATEMENT - 28 -
MTS/TL/12
Rev:0/01-02-09
3.3.1 Tensioner
It is recommended to use the tensioner of double-capstan
type or shoe-chain wheel type, which is free from surging of
tension throughout the stringing works and also prevent OPGW
from twisting during paying off.
The minimum diameter of the capstan or wheel is
recommended as 1.2m.
(c)Acceleration of twisting on
conventional when weight of
sheave is heavy
Dimensions (mm)
Type of Suitable dia. of Weight
block OPGW (mm) (kg)
A B C D E F G H
F450 x 60 F 11.4 - 13.0 12.0 450 535 814 273 136 65 50 28
F450 x 170 F 13.1 - 19.4 16.5 450 546 907 342 143 75 50 32
F450 x 290 F 19.5 - 24.5 24.0 600 726 1,065 340 149 80 50 32
Dimension (mm)
Weight of Tail Total Weight
Dia. Of OPGW Weight (kgf) (kg)
A B C
F 11.4 - 15.2 1,367 2,543 700 7.5 39
F 15.3 - 24.5 2,050 3,948 767 11.0 55
OPGW
A (mm) B (mm) C (mm) D (mm)
2
Size (mm ) Diam. (mm)
70 11.4 110 110 850 13
120 15.2 110 110 890 13
3.3.5 Come-along
Wedge type of come-along should be used for OPGW, but the
wedge must be suitable to it in size and diameter in order to
prevent the stainless tube form excess deformation. When come-
along is installed on OPGW, rubber or similar suitable tube
shall be installed for protection of OPGW surface as shown in
Fig. 13.
3.5.2 Inspection
All tests shall be carried out accordingly and all OTDR
charts shall be printed out and recorded.
METHOD STATEMENT - 35 -
MTS/TL/12
Rev:0/01-02-09
3.5.2.5 Summary
The required test items are concluded as shown in Table
4.
When OTDR measurement is carried out, the proper scale
range on screen shall be selected to monitor fiber’s
characteristics accurately.
Table 4 Test item for fiber
Being the work value of this gang not very much, these
works can be taken compatibly by the preparation gang of
phase conductor stringing or others.
Appendix
Fiber Protector
This appendix is instructed about handling of “Fiber Protector” is
assembling joint boxes.
A. Material
Fiber protector is shown in the following photo.
This fiber protector shall be used to prevent optical fibers from
the sharp edge of optical tube after cutting it.
B. Instruction
B.2 Others
Regarding others, please assemble the joint box (splice case) in
accordance with splice case maker’s instructions manual not to
damage fibers carefully.
METHOD STATEMENT - 54 -
MTS/TL/12
Rev:0/01-02-09
No. Description
S-120 Hydraulic Puller ARS 400
S-220 Hydraulic Tensioner FRS 402
S-520 Hydraulic Reel Elevator CVI 600
S-540 Anti-twisting Steel Pilot Rope + Nylon Rope
S-570 Single Conductor Pulleys CAS 500 + CAS 404
S-630 Fixed Joint + Swivel Joint
S-650 Self Gripping Clamps MOT 001 + MOT 010
S-690 Thermometer + Cover Joints
S-720 Service Snatch Blocks
S-750 Lifting Tackles + Lifting Hoist
S-760 Tirfor
S-770 Zoom Sag-scope + Shears
S-780 Hydraulic Dynamometer
S-800 Working Platforms
S-850 Grounding Device
Dynamometer (Enerpac)
Temporary Mesh Sock Joints
Wedge / Mouth type Come-along Clamp
METHOD STATEMENT - 55 -
MTS/TL/12
Rev:0/01-02-09
No. Description
S-120 Hydraulic Puller ARS 400
S-220 Hydraulic Tensioner FRS 402
S-520 Hydraulic Reel Elevator CVI 600
S-540 Nylon Pilot Rope
S-570 Single Conductor Pulleys CAS 500 + CAS 404
S-630 Fixed Joint + Swivel Joint
S-720 Service Snatch Blocks
S-750 Lifting Tackles + Lifting Hoist
S-760 Tirfor
S-770 Zoom Sag-scope + Shears
S-780 Hydraulic Dynamometer
S-800 Working Platforms
S-850 Grounding Device
Dynamometer (Enerpac)
Temporary Mesh Sock Joints
Head Board
Wedge / Mouth type Come-along Clamp