Specific method description for stringing the towers

Project
Erecting of new 150km long 400kV double circuit overhead line
Endrup – Idomlund and Endrup - German border
Client
Energi Net – Denmark
Revision: 02
Data: 04.10.2021
1 General
A two system 400 kV overhead line, triple bundle, will be established between Idomlund-Endrup-German
border. The objective of this document is to outline main characteristics of the method for stringing.

The method is based on the following documents:

- Special work description Scope of Works - rev 1 – document n. 20/02069-12
- EGS-0205 Replacement-stringing of conductors for overhead lines – document n.
13/90592-349
- Drawings of towers, insulators, and fittings
- Tower list
- Detailed maps of the overhead line

1.1 Technical characteristics

Voltage level 400 kV
Length of line 150 km
Number of towers 436
Types of towers THOR-GI
Number of systems 2
Phases Triple bundle
Conductor and earth wire AAAC (diameter 36.2 mm)
Ground wire / OPGW ACSR Dorkin (diameter 16 mm), OPGW (diameter 16 mm)
Insulators Silicon-Long Rod insulator

1.2 Scope of works

-Handling and transportation of phase and earth conductors, insulators, and accessories from central
storage areas to site, including loading at storage and unloading on site.

-Establishing the necessary pulling sites.

-Secure crossing of infrastructure.

-Make all the necessary anchor points during stringing.

-Install insulators, conductors and all necessary accessories related to these.

-Handling and transport all waste to the main construction site including drums and empty boxes.

-Reestablishment of areas for example where machine has left markedly visible traces.
2 Handling of material and equipment
In the unloading, handling, and storage of equipment and materials, care should be exercised so as not to
damage the surface or surface coating, or deform the members. Bare wire conductors or steel chains
should not be used for handling without adequate protection of the surface. Structural members should
not be dumped, dragged, rolled, dropped, nor used as loading or unloading skids or blocking.

Heavy members should not be stacked on top of lighter members. The maximum weight of material
bundles should not exceed a specified weight, typically 1600–1800 kg, to facilitate handling and unloading.
Components with dissimilar finishes should not be stored over one another to minimize discoloration of
the lower members.

All members should be placed on wood pallets or other suitable material to ensure that the material to
be stored is not in contact with the ground. Pallets should also be used to separate layers of stacked
material.

It should be noted that oak wood pallets or oil-treated timbers can bleed and stain a structured finish.
Members should be supported in such a manner as to prevent bending and distortion as well as to allow
water to drain from the material.

Failure to provide for proper drainage of stacked, galvanized steel components could result in the
formation of “white rust.” White rust (zinc oxide) forms when two galvanized surfaces are closely nested
for an extended time without adequate ventilation. Ingress of water between the surfaces forms an
electrolytic cell which may, in time, erode some of the zinc layers.

During the course of the project, the material storage should be kept relatively neat and clean and the
growth of vegetation kept to a minimum. Good housekeeping minimizes damage and loss of material in
the storage, facilitates material handling and periodic physical inventories, and complies with
environmental considerations.

The drums with conductors and OPGW should always be stored, transported, and lifted in an upright
position (Figure 1). Storage of drums in an alternative position can lead to winding defects.
 Figure 1

When lifting the drums use a shaft through the center of the drum and a spreader beam (Figure 2). In
case the spreader is not used the rope may damage the flanges of the drum which can cause cable
damage.

Figure 2

When the drums need to be rolled due to some reason, always roll the drums in the direction of the arrow
marked on the drum flanges. This way the cable over the drum will not loosen. However, this does not
mean that the drum can be rolled freely for any distance. Limit rolling distance 5-10 meters. Once placed
in position, use a proper stopper to prevent drums from rolling.

During transportation, the cable drums should always be kept in upright position and be tied with a Chain
or Belt with wooden blocks that should be kept in between the flanges of each drum to avoid any jerks/
movements during transportation (Figure 3).
 Figure 3

The insulators should be stored indoors in their original packing in areas free of standing water and other
contaminants such as oils and petroleum derivatives. If the insulators have to be un-crated, no additional
material must be placed or stored on top of them. If they are stacked, care must be taken that the
metalware does not make contact with the housings of adjacent units. This is particularly important for
composite line posts which have heavy bases, often with sharp corners. For long rods, storage in plastic
pipes, as shown in Figure 4, offers good protection. Alternatively, they can be hung from suitably designed
racks with free-swinging hook, tongue, or ball attachments, as appropriate.

Figure 4

Wherever possible, the insulators should be transported to the site in their original, closed shipping crates.
If only part of a crate requires delivery and the insulators thus need to be removed from the
manufacturer's packing, they must never be transported loosely or without adequate protection. The
placing of other materials on top of insulators in transit must be strictly prohibited. The insulators must
not be tied down or tied together with chains, ropes, etc.

As composite insulators are particularly sensitive pieces of equipment, a detailed description of storage,
transport, and installation will be given in Appendix 5 of this document.

For all types of materials and equipment, on arrival at the storage, it must first be checked that the
quantities and type numbers of materials and equipment given on the order, the manufacturer's packing
slips, and the suppliers delivery note agree. Secondly, each package must be examined for any signs of
damage such as breakage due to dropping, a forklift tine having penetrated the wall, or collapse owing to
excessive weight having been packed on top. If damage is evident, the supervisor must be advised
immediately and the crate set aside for inspection by the investor and manufacturer's representative,
their insurance assessor, and the relevant utility technical and quality assurance personnel.

Where the package shows no signs of breakage or maltreatment, the extent of the quality control applied
on receipt of the goods could vary with, for example, the voltage level, the strategic nature of the project
for which they were purchased, or the reputation of the supplier. In some cases, quality assurance
personnel prefer to undertake a small sample inspection only, leaving most of the original packaging
undisturbed for the subsequent transport to the site. Inspections could, though, incorporate some or all
of the checks, as appropriate to the equipment type.

3 Preparation

3.1 Construction of scaffoldings

Before starting conductor stringing, the line section between the tensioner site and puller site needs to
be prepared accordingly. Scaffoldings are installed to protect objects intersected during conductors
stringing. Scaffoldings for the protection of roads, railway lines, low- and medium-voltage lines, telephone
lines, etc. should withstand the loads that might occur after the failure of a conductor or a connector
during stringing activities, thus preventing any contact with objects under the line. In special cases, plastic
nets are installed over the intersected object.

Protective measures are as follows:

- In situations where protection has not been built, it is the guard who approves when
traffic can pass during stringing operations.
- When the line is not secured with either fastening or clamping, a guard must be on
site.

3.1.1 Intersection with Path and exercise track and private road

A warning sign is set up before the intersection. The road is blocked off in such a way as to stop or greatly
reduce speed. The obstacle must be placed with the intersection within sight, a suitable distance of about
10-20 m. A guard who has radio contact with a puller and tensioner position guards the intersection. It is
the guard who approves when traffic can pass the intersection. When the line is not secured with either
fastening or clamping, a guard must be on site. A vertical distance of min. 7.5 m must be kept when pulling
conductors.
 Figure 5

3.1.2 Intersection with smaller roads, at max. 20 m from the far side of the post

A warning sign is set up before the intersection. A guard who has radio contact with a puller and tensioner
position guards the intersection. It is the guard who approves when traffic can pass the intersection. When
the line is not secured with either fastening or clamping, a guard must be on site. When the intersection
is closer than 20 m seen from the far side of the post, it is sufficient to build protection safety only on one
side of the intersection. A vertical distance of min. 7.5 m must be kept when pulling conductors. The
horizontal distance will be minimized in accordance with what is permitted.

The protection consists of posts and horizontally lying beams. A steel rope is used as a connection between
beams and posts. The rope must withstand a workload of min. 1500 kg. Shekels are used to connect the
ropes around the joint of the beam and the pole. The protection must have a minimum width of 2 times
the phase distance + 5m.
 Figure 6

3.1.3 Intersection with local roads

A warning sign is set up before the intersection. A guard who has radio contact with a puller and tensioner
position guards the intersection. It is the guard who approves when traffic can pass the intersection. When
the line is not secured with either fastening or clamping, a guard must be on site. Protection on both sides
of the line should be arranged. The protection must be built in such a way that a vertical safety distance
of min. 7.5 m is obtained. The horizontal distance must be minimized in accordance with what is
permitted.

The protection consists of posts and horizontally lying beams. A steel rope is used as a connection between
beams and posts. The rope must withstand a workload of min. 1500 kg. Shekels are used to connect the
ropes around the joint of the beam and the pole. The protection must have a minimum width of 2 times
the phase distance + 5m.
 Figure 7

3.1.4 Intersection with public road 1+1

A warning sign is set up before the intersection. A guard who has radio contact with a puller and tensioner
position guards the intersection. It is the guard who approves when traffic can pass the intersection. When
the line is not secured with either fastening or clamping, a guard must be on site. The protection on both
sides is provided. The protection consists of posts and horizontal beams as well as nets and ropes drawn
between the protections. A steel rope is used as a connection between beams and posts. The steel rope
must withstand a workload of min. 1500 kg. Shekels are used to connect the ropes around the joint of the
beam and the pole. The protection must have a minimum width of 2 times the phase distance + 5m. The
protection must be built in such a way that a vertical safety distance of min. 7.5 m is obtained. The
horizontal distance must be minimized in accordance with what is permitted.

Figure 8
3.1.5 Intersection with public road 2+2

A warning sign is set up before the intersection. A guard who has radio contact with a puller and tensioner
position guards the intersection. It is the guard who approves when traffic can pass the intersection. When
the line is not secured with either fastening or clamping, a guard must be on site. The protection on both
sides is provided. The protection consists of posts and horizontally lying beams as well as nets and ropes
were drawn between the protections. A steel rope is used as a connection between beams and posts. The
steel rope must withstand a workload of min. 1500 kg. Shekels are used to connect the ropes around the
joint of the beam and the pole. The protection must have a minimum width of 2 times the phase distance
+ 5m. The protection must be built in such a way that a vertical safety distance of min. 7.5 m is obtained.
The horizontal distance must be minimized in accordance with what is permitted.

Protection is required between the lanes. If not possible, a lane is closed so that there is room for cranes
that supports the conductor.

Figure 9

3.1.6 Intersection with a non-energized power line, max. 20 m from the far side of the tower

When the intersection is closer than 20 m seen from the far side of the tower, it is sufficient to build
protection only on one side of the intersection. The protection consists of posts and horizontally lying
slats. A strap is used as a connection between slings and posts. The strap must withstand a workload of
min. 1500 kg. Shackle should be used when coupling around the sling. The protection must have a
minimum width of 2 times the phase distance + 5m.

A vertical safety distance of at least 3 m from the intersecting line will be obtained. The horizontal distance
should be minimized by observing safety distances.
 Figure 10

3.1.7 Intersection with a non-energized power line

Protection should be built on both sides of the intersection. The protection consists of posts and horizontal
beams as well as nets and ropes drawn between the protections. A steel rope is used as a connection
between beams and posts. The steel rope must withstand a workload of min. 1500 kg. Shekels are used
to connect the ropes around the joint of the beam and the pole. The protection must have a minimum
width of 2 times the phase distance + 5m.

A vertical safety distance of at least 3 m from the intersecting line will be obtained. The horizontal distance
should be minimized by observing safety distances.

Figure 11
3.1.8 Intersection with a live power line

Protection on both sides of the line should be provided. Nets and ropes are pulled between the posts. The
protection consists of posts and horizontally lying beams A steel rope is used as a connection between
beams and posts. The steel rope must withstand a workload of min. 1500 kg. Shekels are used to connect
the ropes around the joint of the beam and the pole. The protection must have a minimum width of 2
times the phase distance + 5m.

Vertical safety distance will be obtained. The horizontal distance should be minimized by observing safety
distances.

The net must be fitted in such a way that if the line breaks in the vicinity of the protection, there will be
no possibility for the line end to swing under and hit the live wire. Nets and ropes must be able to handle
the specific weight of a phase.

Figure 12

3.1.9 Intersection with electrified railway

In accordance with the conditions from the tender documentation, the Investor undertook the obligation
to construct scaffoldings at the intersections with the electrified railway. For this reason, the methodology
of construction of this type of protection has not been presented.

3.2 Temporary anchoring of the towers

Except for terminal towers placed at the ends of the transmission line and which are calculated to
withstand the total tension force of the conductor, tension towers placed on the transmission line, either
in series or at an angle, do not withstand these forces. It is therefore necessary to place temporary anchors
on them, to enable the work of tensioning and sagging the conductors that abnormally strain the towers.

With the help of temporary anchors, the occurrence of deformations that could damage the towers should
be avoided.

During tensioning and sagging, the tower withstands the following stresses:

• Torsion, which occurs due to an unbalanced load of conductors that are tightened one after
another.
• vertical stresses resulting from the position of the puller or tensioner
• vertical and transverse stresses that occur due to force differences between conductors and
anchors.

To prevent these events, before anchoring the conductor at the end of the cross-arm, we place the anchor
rope at the opposite side of the conductor to be anchored (Figure 13). The anchor rope, which is put under
force T1, pulls the cross-arm and the cross-arm will be bend for the value d1 (horizontal displacement).
This initial bending will be used later to compensate for the bending that will follow after anchoring the
conductor on the other side of the cross-arm.

In order to anchor fulfill its task, the following equations need to be satisfied:

𝑑1 − ∆𝑎 × cos 𝛼 = 0

𝑇 − 𝑇2 × cos 𝛼 = 0

𝑇2 − 𝑇1
∆a = a ×
𝐸×𝑆

Where is:

T1 – tension force in the anchor rope, with the cross-section S, specific weight p, and coefficient of
dilatation E

T2 -tension force in the anchor rope after anchoring of the conductor from the other side

T – Tension in the conductor

a – length of anchor rope

Δa- a variation of rope length after force change from T1 to T2

α – the angle of the rope relative to the horizontal

H- the height of the tower

 Figure 13

After the calculation is performed, if it is proved that the difference between the values ∆𝑎 × cos 𝛼 and
𝑑1 is negligible, the data on the force 𝑇2 can be taken as valid for operating. By controlling this force with
a dynamometer, it provides us with information on whether undesirable bending of the cross-arm has
occurred.

The second option for controlling the tower position during anchoring of conductors is to measure of
tower position with a theodolite (Figure 14).

This method is based on the principle that the tower, exposed to vertical and horizontal loads, while
remaining vertical, does not suffer from additional stresses arising from the deformation of the tower
elements.

This method is reflected in the fact that the tension tower is kept strictly vertical and to avoid any
movement of the tower cross-arms during the process of anchoring the conductors. This method requires
no tension force calculation.

In practice, theodolite or total station is used to control the position of the cross-arms at any point in the
process of stringing, tensioning, and anchoring the conductors.

If the cross-arms are still moved, the length (tension force) of the anchor rope is adjusted to compensate
for this movement.
 Figure 14

In order to avoid excessive dynamic loads during the process of stringing and sagging of conductors, V
stringing chains at the suspension-angle towers will be anchored as well. As shown in Figure 15, the
anchor placement angle will depend directly on the swinging angle of the conductors. This angle will be
oriented in the opposite direction to neutralize the action of forces that could lead to damage to the
stringing chains and the tower cross-arms.

Figure 15
The swinging angle of the stringing blocks shall be also controlled corresponding to the swinging angle of
the conductors to help prevent the conductors from riding out of the pullies or excessive twisting during
installation. The conductors should travel through the lowest part of the groove. In the case of angle
towers, this will be done by anchoring the pulley at a certain angle, which also depends on the swinging
angle of the conductors.

Figure 16

3.2.1 Types of temporary anchors

The total force to be neutralized determines the number of anchors be installed. Anchors used to anchor
the towers are buried at a distance of at least two to three tower heights (a distance two-three times
greater than the height at which the anchoring rope will be attached to the tower).

As a primary method, where greater forces are expected, and anchoring by burring to the ground is
allowed, anchoring will be done with wooden beams on a steel frame. Anchors are bought as a finished
product and main characteristics are given by the supplier (depth of burial, dimensions of anchors –
depending on the required tension force and soil conditions). Dimensioning is performed by SS-EN-50341.

Figure 17

There are two cases for dimensioning the anchor size and depth:

1. Underground water is 1m or more from the ground level: the size of the anchor for 180kN tension
force is 550x2600mm with a burial depth of cca. 2.8m

2. Underground water is at 0-1m depth: the size of the anchor for 180kN tension force is
1100x2600mm with a burial depth of cca. 3m.

Size E depends on the angle between ground and anchor – cca 20°. Excavation is done with 1:1 slope.
After placement of anchors, the pit is filled with backfilling (gravel or other materials) with at least 1.8
t/m3 above groundwater level or at least 1.1 t/m3 density below groundwater level. Backfilling is carried
out in such a way that no gaps arise under and between the beams of anchors.

As an alternative to the primary method, anchoring with single wooden beams dug into the ground will
be used as shown in Figure 17. This method will only be used for lower anchoring forces.
 Figure 18

This figure represents an anchoring composed of a buried wooden beam 2.5 m long and 25 cm in
diameter. This type of anchoring can withstand a force of 7 tons without any movement. Anchoring
resistance can be also estimated based on the following formula:

𝐹=𝐿×𝑑×𝑃
F = Anchoring force in daN
L = Beam length in cm
d = Beam diameter in cm
P = Parameter which depends on the slope

As a second alternative, in places where it is not permitted to bury anchors in the ground, a method using
concrete blocks placed on a metal frame will be used.

For this purpose, we will use steel frames of approximate dimensions 2x1 m and concrete blocks weighing
1 t per block.

The steel frame will be laid on already laid steel plates for soil protection and after that concrete blocks
will be laid on them in the amount corresponding to the obtained calculated value in order to compensate
for the forces during stringing, tensioning, and anchoring of the conductors.

Before starting the stringing of the conductors, the anchors will be installed on the cross-arms on the
towers at the ends of the sections, Pulling and Tensioning machines and the drums stand. If it is necessary
to continue the conductors near the suspension towers, additional anchors will be installed at this place
in order to temporarily anchor the conductors.
 Figure 19

On the example of anchoring one cross-arm, we will show the basic principle of calculating the weight of
anchor blocks that are necessary for anchoring. Similar calculations will be performed for anchoring
machines, conductors, and drum stands.

For the case when we have tension tower that has loads applied from one side, and its not design to resist
thoose forces anchoring is neccesery. Input data for calculation the weight of gravity anchor (concrete
blocks):

cca 20 t

- Fricction coeficient for steel on steel surface is 0.8 (for statical friction)
- Max. tension force in the conducter is expected to be not greather than 20t
- The distance between the anchorage and the tower is 3 x Height
 10
𝑡𝑔𝛼 = 30 → 𝛼 = 18.43
𝑋𝑧 = 𝑐𝑜𝑠𝛼 ∙ 20 = 18.97𝑡
𝑌𝑧 = 𝑠𝑖𝑛𝛼 ∙ 20 = 6.32𝑡
𝐺𝑐𝑜𝑛𝑐𝑟𝑒𝑡𝑒 > 0.8 ∙ 18.97 + 6.32 > 𝟐𝟏. 𝟒𝟗𝒕 − 𝑚𝑖𝑛𝑖𝑚𝑎𝑙 𝑐𝑜𝑛𝑐𝑟𝑒𝑡𝑒 𝑏𝑙𝑜𝑐𝑘𝑠 𝑤𝑒𝑖𝑔ℎ𝑡

This calculation is only theoretical, for each tower type calculation for specific conditions is going to
be performed and amount of concrete block will vary. As showed in Figure 13 concrete blocks have
partial role in carying the tension force – the part of the force that exceeds capacity of tower elements
and may efect its unalowed deformation, is carried by concrete blocks.

4 Stringing

4.1 General requirements

Stringing works will be handled by an experienced crew, not only to prevent damage to the phase
conductors and earth wire but also to maintain the sags and tensions specified in the design. Correct sags
are essential to give the required mechanical safety, but it is just as important that the actual sags in the
line correspond to those used in the design, to ensure proper clearances to ground and obstacles.

To prevent dangerous voltages that may result from electrostatic induction by parallel energized lines,
safety measures will be adequately defined during conductor stringing.

Before stringing, all equipment will be checked and adjusted.

4.2 Stringing methods

Phase conductors and earth wire / OPGW will be installed under tension without touching the ground or
any obstacles. Touching ground or obstacles could cause damage to the conductors that would diminish
their mechanical and electric characteristics. Furthermore, the conductors could corrode because of
chemical products potentially present in the soil. Therefore, the conductors will run over pulleys
suspended on insulator strings at the supports, with sufficient tension to keep them clear of ground
surface or obstacles. For this purpose, the conductors are connected to a pulling rope at the tensioner
site and strung by a puller to the puller site, which can be installed some kilometers apart from the
tensioner site. To guarantee enough clearance to the ground during conductor stringing, an adequate
tensile force must be applied by means of a controlled tensioner.

The ends of the conductors are being held by come-along clamps to cross-arms after stringing at the
tensioner site as well as at the puller site. A line crew operating independently of the stringing procedure
adjusts the conductors and terminates them at the tension towers.
The stringing operation is carried out independently of the lengths of the conductors and the available
pulling ropes. If the tensioning section lengths are shorter than the conductor manufacturing lengths, the
conductor will be cut; if they are longer, they need to be extended by joints.
Handling and transporting of the conductor and accessories will be carried out in such a manner as to
minimize the possibility of damages from abrasion through rough handling or dirt and grit getting into the
reel of the conductor by touching or rubbing against ground or objects, causing damage to the conductor,
etc. Care will be always taken to ensure that the conductor does not become twisted or abraded in any
manner. If the conductor is damaged, the section affected will be replaced or repaired by putting joint or
using repair sleeves or polishing with emery cloth, to give satisfactory performance.

At all stages of construction, proper care will be taken so that the conductor surface is smooth enough to
be given satisfactory performance. All equipment used in handling or transporting the conductor such as
grips, pulleys slings, cable care, etc. will be so designed and maintained that the surface which may contact
the conductor, is kept free of defects.

Preassembled fittings are transported to the tower sites. The stringing blocks are fitted on insulator strings
instead of the suspension clamps. The size of sheaves for stringing of overhead line conductors depends
on the diameter of the conductor; the diameter of the stringing blocks at the groove basis should amount
to at least 20 times the conductor diameter. A sufficient width of the grooves should enable an unhindered
passage of temporary joints like swivels and woven wire grips (pulling socks). When selecting stringing
blocks, the maximum load expected due to the conductor rollover angle should be considered as well.
Therefore, it is recommended to use reinforced stringing blocks at tension towers close to the tensioner
and puller site. Neoprene-lined sheaves should be used to protect the aluminum layers of the conductors.

The stringing blocks are equipped with a lightweight, flexible pilot rope for leading the pilot rope through
the stringing block.

Eventually, the insulator strings can be hoisted in one piece and suspended from the cross-arm. Hoisting
can be carried out by a winch. During installation, articulated boom lifts will be used to lift workers to
height.

The tensioner site should be installed far enough from the tower to achieve only a small angle of the
conductor from the tower to the tensioner. The recommended distance is three times the height of the
nearest tower. The tensioner is adjusted in direction of the stringing block and anchored to the ground
taking account of the holding force to be expected. The reel stand is placed at a distance of at least 20
meters and aligned to the tensioner intake.
 Figure 21 - Distance between tower and tensioner

After placing the conductor reels in the reel stands, the reel cover is removed, and a pulling grip is fitted
to the conductor. Then, the conductor is guided through the grooves of the bull wheels using a plastic
pilot rope. The puller is installed sufficiently far from the tower site, aligned to the stringing block, and
anchored taking account of the stringing force.

All conductor stringing devices should be earthed precautionary to take care of possible short-circuit
currents, inductive currents, and atmospheric flashovers. Running earth should be placed in front of the
tensioner/puller on every conductor and between the tensioner and the conductor reel. The operating
area at the machines, such as steel grades, should be connected to the earthing of the stringing machine
for equipotential bonding.

Figure 22

Before starting the conductor stringing, communication channels will be installed between all linemen
active in the stringing operation.
The ability of the equipment operators, supervisory personnel, and observers at critical points in the pull
section (such as at energized line crossings); to communicate clearly and quickly with one another is
extremely important when using the tension stringing method of installing conductors. These personnel
will each have a hand-held radio system with a channel that is free from outside interference and is
located at their operating position. Included in this communication channel should be the puller operator,
the tensioner operator, and the supervisor and persons following the running board as it moves from
tower to tower, and persons at intermediate checkpoints.

Failure of any radio in the system will be cause for immediate stoppage of the pulling operation.

4.1. Temporary anchoring in the middle of the tension section

If a stringing section ends with a suspension tower, it is necessary to temporarily anchor those towers.
Anchoring will be done using steel ropes with a diameter that depends on the characteristics of the tower.

After stringing of such section, the conductors must be anchored as well during the stringing of the next
section. The anchoring steel rope is anchored to the ground close to the puller and holds the conductor
in place.

Figure 23

When the stringing of the next section is finished, the conductor is pulled with the same tensioning force
as in the first section, and conductors are joined with a compression joint. After a joint has been installed,
the conductors are slowly released and brought to the final position.
 Figure 24

4.3 Anchoring of machines

Anchors are normally required for holding equipment and conductors in place against tensions imposed.
The type of anchor is dependent upon the soil conditions and sagging and stringing tensions. This project
will primarily use anchoring using wooden beams attached to a metal frame and buried in the ground,
similar to what was previously described for the towers.

Figure 25

As an alternative, if the burying of anchors in the ground is not allowed at certain locations, anchoring
with concrete blocks will be used as shown in the following photographs.
 Figure 26 - Anchoring of stringing machines

Figure 27 - Position of pulling machine and with conductor drums

4.4 Stringing procedure

Before stringing the conductors, a steel or plastic pilot rope is installed passing over the pulleys at the
towers between the puller and tensioner site. If the pulling rope for conductor stringing is too heavy to
be strung directly, first a pilot rope is installed having a lower cross-section. This rope is used afterward to
string the pulling rope from the puller site to the tensioner site. The pilot rope is installed either by foot
or by light vehicles. The stringing blocks will be equipped with a lightweight, flexible rope for leading the
pilot rope through the stringing block. This enables workers to string the pilot rope through the stringing
blocks without working at height.
The rope needs to be held at tension to achieve a controlled unwinding from the storage reel or the drum
of a puller.

This can be achieved by reverse running of the bull wheel puller or by using a reel stand equipped with a
mechanical brake. If the rope stored on a reel is not long enough, it can be connected to the rope of
another reel by means of rigid connectors. At the tensioner site, the pulling rope is coupled with the
conductor or conductor bundle (using headboard).

Before the stringing begins, initial and final stringing charts for the conductor and earth wire showing the
sags and tension for various temperatures and spans along with equivalent spans in the line should be
available. The stringing will be done as per approved stringing charts.

At the beginning of the conductor stringing process, the pulling rope puller is moderately accelerated up
to the running speed envisaged. The tensioner must hold the conductor well-tuned, such that it does not
touch the ground surface or any obstacles. The conductors on the reel stand are braked accordingly to
achieve a sufficiently pre-tensioned intake of the conductors to the tensioner. After arriving of the
conductor at the puller site it is connected using a dead-end clamp connected to the tension insulation
string at the tension tower.

Figure 28

When the conductor on one reel is not long enough to fit between two adjacent tension towers,
permanent joints need to be installed. For this project will be used compression joints. The joints will be
installed following the manufacturer's instructions.

The earth wire will be strung and securely clamped to the towers before the conductors are drawn up.
The outer phases are pulled first and then the inner phases (toward the tower shaft).
During the pulling-out operation, the tension in each conductor and earth wire will not exceed the design
working tension of the conductor at the actual prevailing temperature.

Adequate steps will be taken to prevent clashing of sub-conductors after paying out of conductor before
spacers/spacer dampers are installed. Care will be taken that all conductors of the bundle are taken from
the same batch so that the creep behavior of these remains identical during sagging. Care will be taken to
eliminate differential sag as far as possible.

4.4.1 Sagging the conductor

The conductor can be sagged after the installation of the tension insulation string at the tension tower at
the puller site. Since the tensioner is equipped with a drive that can be used to haul the conductor into
the reverse direction, the conductor is being tensioned to such an extent that the required initial sag is
achieved.

There is also another method that will be used: after the conductor reaches the puller site, it is being held
for cross-arm (close to attachment point) by means of come along clamps and round slings. Then, the
conductor is being pulled by a tensioner to approximately achieve the required sag and being held on the
cross-arm of the tensioner tower close to the tensioner site in the same manner as to the tower close to
the puller site. A line crew operating independently of the stringing procedure adjusts the conductors and
terminates them at the tension towers.

Several procedures can be used to supervising the sags during conductor sagging.

Figure 29

If possible, horizontal sag battens are arranged at adjacent towers at heights corresponding to the initial
sag. Then, the conductor tensile force is modified until the viewing line between the sag battens coincides
with the lowest point of the conductor within the span. It is recommended to use field glasses with spider
lines, a telescopic sight, or a theodolite for sighting. To avoid sagging mistakes, it is necessary to carry out
additional checking measurements in a second span especially in the case of long tensioning sections.
4.4.2 Terminating the conductor

After sagging, the conductor can be terminated to the tension tower close to the tensioner site. For this
purpose, the position of the dead-end clamp must be marked on the conductor taking account of the
length of the dead-end set. The dead-end clamps can be installed from a working platform or boom lift
arranged at the tower.

4.4.3 Installation of the joints

Compression joints will be used. Installation of joints will be done according to the manufacturer
recommendations. Linemen who will execute this operation will be the ones with appropriate training.

The jointing of the conductors will be done from the working platform without lowering the conductors
to the ground. This process is shown in Figure no. 30.

Figure 30

The temporary mesh socks used to join the conductors are removed, and a permanent compression joint
between the conductor ends is made.

For compression of joints will be used hydraulic compressor tool with appropriate compression force.
Since the power unit will be located on the ground, hydraulic hoses of sufficient length will be used to
allow operation from the work platform.
If it is not possible to join the conductors from the working platform, the conductors will be anchored on
the adjacent towers and lowered to the ground. In this case, the connection will be made on the ground.

During the performance of this operation, the grounding system (ground clamps, cables, and ground rod
system) will be used as shown in the following figure.

Figure 31

After installation, measurement of resistance will be done. Results of measurement will be kept in the
installation record (Form in appendix).

4.4.4 Clipping-in of conductors

After the preparation of the dead-ends, the suspension clamps can be installed. Then the stringing blocks
are removed. Clipping-in will be done in respect of a vertical position of the insulator strings after clipping-
in. The conductor will be fitted with armor rods where it passes through suspension clamps and vibration
dampers.

Clipping-in will be made from articulated boom lifts for easier access to the conductor and insulator.
 Figure 32

4.4.4.1 Cliping-in of conductors at suspension-angle towers (V stringing chains)

Instead of using a single Lever Hoist to lift and remove the conductors from the stringing block, used when
clipping-in of conductors at the standard suspension towers, in this case two Lever Hoists will be used
which are placed on both sides of the stringing chains seen in the direction of the line.

In this way, part of the conductor between these two Lever Hoists is relieved and enough space is left for
the installation of the suspension clamps.

This is shown in Figure 33:

 Figure 33

These Lever Hoists are anchored by round slings to the tower cross arm, to a position that allows them to
follow the deflection of the conductors in the direction of the bending angle bisector. In this way, the later
positioning of the suspension clamps and the parts connecting them to be attached to the already
installed V chains is provided.

After removing the conductors from the stringing block, the stringing block is dismantled and the
suspension clamps and connecting equipment (yoke plate, straight clevis tongue, twisted double tongue,
etc.) are installed on the conductors (Figure 34). Before removing the stringing block, the position for the
installation of the suspension clamps is precisely marked.
 Figure 34

In the final phase, the suspension clams and connecting equipment are connected to the suspension V
chains (Figure 35). After that, the Lever Hoists and other work equipment are removed.

Figure 35
4.4.5 Installation of jumper loops

At each tension tower, the corresponding ends of the conductors terminated at tension strings need to
be connected such that they can conduct the current. In this case, compression joints will be used to
connect the conductors. This operation will be performed in the same way as in the case of midd-span
joints.

Linemen who will execute this operation will be ones with appropriate training passed.

The installation will be made from articulated boom lifts for easier access to the conductor and insulator.

4.4.6 Installation of dampers and bundle spacers

The installation of dampers and spacers for bundle conductors will be done using light engine-driven line
cars. The designed positions of dampers and distances between the bundle spacers are measured using a
meter counter arranged at the line car.

4.4.7 Stringing conductor with optical fibers OPGW

Conductors with optical fibers are frequently installed in overhead power lines. Stranded conductors with
integrated fibers are adopted as earth wires (OPGW - optical ground wire) and less frequently as phase
conductors. In general, the same tools and procedures are used for stringing conductors with optical fibers
as in the case of conventional conductors. For some conductors with optical fibers, the manufacturers
stipulate specific limits for the stringing tensile stress. To verify compliance with these limits, the tensile
force of the puller or tensioner needs to be recorded continuously. During the stringing procedures, the
conductors with optical fibers may not be handled with conventional working grips but only with adjusted
tension-proof armor rods. The whole procedure will be executed according to the Instructions Manual of
Investor. Tension force will be documented with according checklists and with pull and speed recorder.

After the OPGW installation is completed, the continuity of the optical fibers will be checked. In this way,
a check will be made to see if the fibers have been damaged during the installation process.

If the quality of the product itself is suspected, these tests will be performed before the start of the
installation. In this way, it will be checked whether there is damage to the fibers that occurred in the
process of production and delivery to the construction site.

4.5 Installation of conductor adjacent to or crossing energized lines

If the conductors would not be earthed, the electrical field may induce a voltage as much as 30 % of that
of the energized line voltage. Adequate earthing reduces the voltage to acceptable values. A current of
several amperes will flow through the earth.

The most important procedures on earthing of work sites are summarized here:
- The automatic reclosers should be disabled on all energized lines where physical contact may
occur because of an accident.

- Since the value of the grounding system depends on a low resistance path, a good electrical
contact will be ensured between the ground clamp and the surface to which it is to be applied.

- Ground clamps and cables will first be connected to the ground rod or ground source, and
then to the object to be grounded. When removing grounds, the ground clamp will first be
removed from the grounded object and then from the grounded source or grounded rod. The
object being grounded will not be damaged from using the ground clamp.

- All equipment used in the process of stringing conductors should have at least one ground
attachment point, usually at some convenient point on the frame.

- The conductor stringing equipment and temporary anchors should be earthed with an earth
rod.

- While stringing, the conductors should have running earthing systems located in front of the
puller and tensioner, respectively. (Figure 36) It is recommended that a running ground be
used on each conductor being installed.
 Figure 36 - Running earth

- The first towers in front of the puller and tensioner as well as every third tower should be
equipped with a stringing block earthing system.

- At the tower, where clipping-in takes place, all conductors should be earthed to a tower
member or earthing point. The same applies to attaching conductors to strain structures and
the installation of jumper loops.

4.6 Short description of activities during stringing

✓ Transport of tools, mechanization.
✓ Hoisting of insulator strings and stringing blocks.
✓ Marking of working area/place, securing of places of road crossing, and other objects.
✓ Preparation of mechanization and fixing of drums.
✓ Pulling of pilot wire.
✓ Placing of puller and tensioner and anchoring by concrete blocks or sleepers.
✓ Pulling the outer phase conductor and securing it by come along clamps and connection on towers.
All operations should be repeated for the other two phases towards the tower shaft.
✓ Sagging conductors in accordance with sag tables, terminating conductors with dead-end clamps, and
installation of tension strings. All operations should be repeated for the other two phases.
✓ Removing of empty cases, drums, a surplus of material, and other waste.
✓ Removing of marking, road signalization, and scaffolding.
✓ Clipping in with suspension clams
✓ Install jumper loops, spacers, and vibration damper.

NOTE: All activities should be repeated for the second system.

4.7 Final checking and testing

After completion of the works, final checking of the line is done to ensure that all the tower erection and
stringing have been done strictly according to the specifications and approved by the supervising
Engineer. All the works will be thoroughly inspected keeping in view the following main points:

- All the tower members are correctly used, strictly according to the final approved drawing, and
free of any defect or damage whatsoever.
- All bolts are properly tightened and punched.
- The stringing of the conductors and earth wire has been done as per the approved sag and
tension charts and desired clearances are clearly available.
- No damage minor or major to the conductors, earth wire accessories, and insulator strings still
unattended are noticed and rectified.
- After final checking, the line will be tested for insulation in accordance with the tests
prescribed. All arrangements for such testing or any other test desired will be done. Any defect
found out because of such tests, will be rectified.

In addition to the above, it will be ensured that the total and relative sags of the conductors and earth
wire are within the specified tolerances. Such tests will be carried out at selected points along the route
as deemed necessary.
5 Appendix 1- Specific plan for a Puller and Tensioner site
6 Appendix 2- Exampel of drum schedule
7 Appendix 3 - List of Tools and Equipment

TOOLS, EQUIPMENT AND MACHINES

Quantities
No. TOOLS AND EQUIPMENT
Stringing works
Vehicles and working machines
1 Hydraulic puller Zeck SPW 17 1
2 Hydraulic tensioner Zeck B1500/8x2 1
3 Hydraulic drum elevator with drum drive and hoses (for B1500/8x2) 3
4 Drums for pulling Machine (for B1500/8x2) 3
1 Hydraulic pulle Tesmec ARS 403 1
2 Hydraulic tensioner Tesmec AFS 411 1
3 Hydraulic drum elevator with drum drive and hoses (for AFS 411) 1
2 Drums for pulling Machine (for AFS 411) 1
3 Articulated boom lift 40 m 4
4 Tractor with crane 16 t 1
3 Truck with crane 20 t - MAN TGS 41.480 2
4 Pick-up Mitshubishi L200 11
Tools
1 Stringing block for 3 conductors 180
2 Stringing block for single conductors 80
3 Three bundled conductors balancing head board 2
4 Line car for with engine drive (for 2-4 conductor) 3
5 Cable cat with accessories 1
6 Metal chassis for concrete blocks 10
7 Concrete block 1 t 100
8 Temporary anchors system (steel frame + wooden beams) 35
9 Tool box 4
10 Water pump pliers 30 2
11 Polypropylene rope, diameter 14 Lr = 100 m 3
12 Cable cutter 2
13 Roundslings 8 t 20
14 Roundslings 5 t 20
15 Roundslings 2 t 40
16 Polyester roundsling Lr=1 m 40
17 Set of socket wrenches (dimeter 12 - 27) 1
18 Set of open-end wrenches (dimeter 12 - 27) 1
19 Lifting coupling link 6
20 Screw pin shackle 4,75 t 65
21 Screw pin shackle 8,5 t 10
22 Steel grinder 2
23 Earhing rope with connection clamp 2
24 Snatch Block 4 t 3
25 Snatch Block 1 t 6
26 Lever Hoist 1,6 t - Elephant 6
27 Lever Hoist 3 t - Elephant ili Kito 10
28 Lever Hoist 6 t 10
29 Lever Hoist 2,3 t 10
30 Lever Hoist 9 t 8
31 Lever hoist 3 t 3
32 Plastic bucket 3
33 Eye hook 3 t 3
34 Stationary Radio Station 2
35 Hand-handle Radio Station 10
36 Bicycle for 2 or 3 conductors 3
37 Drum for puling rope 56
38 Anti-twisting steel rope, diameter 24 Lr=800 m 40
39 Anti-twisting steel rope, diameter 8 Lr=1600 m 12
40 Polypropylene rope, diameter 10 Lr = 1000 m 6
41 Swivel joint for phase conductor 3
42 Swivel joint for ground wire 3
43 Double head sock joints for phase conductors 3
44 Double head sock joints for ground wire 3
45 Single head socket joint for phase conductors 3
46 Single head socket joint for ground wire 3
47 Cardle reel elevators for anti-twisting steel rope 3
48 Polypropylene rope, diameter 14 Lr = 100 m 3
49 Polypropylene rope, diameter 16 Lr = 100 m 3
50 Dynamometar with hook 3
51 Steel bar, diameter 30 Lr=1,5 m 20
52 Self Gripping clamps , diameter 16 mm 3
53 Self Gripping clamps , diameter 8 mm 3
54 Self Gripping clamps for phase conductors 24
55 Self Gripping clamps for ground wire 3
56 Anchor steel rope, dimeter 16,8 mm; 15 t; L 15m 15
57 Anchor steel rope, dimeter 16,8 mm; 15 t; L 30m 15
58 Anchor steel rope, dimeter 16,8 mm, 15 t; L 40 m 15
59 Anchor steel rope, dimeter 16,8 mm;15 t; L 50 m 15
60 Fixed joint for ropes 24 mm 3
61 Fixed joint for ropes 8 mm 3
62 Binocular 1
63 Zoom sag-scope 1
64 Hammer 2
65 Shovel 2
66 Pickaxe 2
67 Thermometer 1
68 Tirfor 1,6 t 27
69 Hydraulic compressor 1
70 Hydraulic Cable Cutter Tools 1
71 Hydraulic power units 1
72 Total station with accessories 1
73 Grounding devices for pulleys 40
74 Grounding devices for Machines 2
75 Grounding device for work on towers 15
76 Running grounding device 6
77 Generator 6,5 kW 1
78 Drilling Machine 1
79 Tension Ladder 6 m 6
80 Suspension Ladder 6 m 8
81 Welding Machine 1
82 Portable Winch with engine drive 4
83 Pulling ropes for winches 100 m 4
84 Instrument for meausurement of ressistance Metrel 1
85 Voltage Indicator 5
86 French spaner 36 - 55 mm 6
87 Torque wrench spaner 2 - 22 kg 10

TOOLS, EQUIPMENT AND MACHINES

Quantities
No Scaffoldings
Vehicles and working machines
2 Tractor with crane 16 t 2
3 Pick-up Mitshubishi L200 1
Tools
1 Tool box 1
2 Steel rope L=4m, diameter 14 4
3 Steel rope L=50, diameter 14 2
4 Steel bar 1,5 6
5 Wire rope sling, dimeter 14, L 10 m 6
6 Two legs wire rope sling, dimeter 14, L 3 m 1
7 Roundsling 2 t, L=2 m 3
8 Rope transfer rifle 1
9 Axe 1
10 Hammer 1
11 Shovel 2
12 Pickaxe 2
13 Snatch Block 1 t 2
14 Snatch Block 1.5 t 2
15 Hand-handle Radio Station 1
8 Appendix 4 – Check Lists

1 2

10

7 8
7
9

Tower number: Team leader signature:

Numbers of isolator strings: Approved by:
Bolt torque/Split inserted
1 6 Technician signature:
2 7 Installed by:
3 (90 Nm) 8
4 (18 Nm) 9
Date:
5 (90 Nm)

Split pin facing (1) Split pin facing (2) Nut locked (3) Nut locked (4) Nut locked (5)
Nut Nut Nut
Towards Towards facing facing facing
South: tower: South: tower: South:
Split pin facing (6) Split pin facing (7) Split pin facing (8) Split pin facing (9)
Towards Towards Towards Towards
South: tower: South: tower:
(10)Arcing ring facing away
from tower:
 1

2 3

10 10

4
2
5

7
9 7
8

Tower number: Team leader signature:

Numbers of isolator strings: Approved by:
Bolt torque/Split inserted
1 6 Technician signature:
2 7 Installed by:
3 (90 Nm) 8
4 (18 Nm) 9
Date:
5 (90 Nm)
Split pin facing (1) Split pin facing (2) NutNut locked (3) NutNut locked (4) NutNut locked (5)
Towards Towards facing facing facing
South: tower: South: tower: South:
Split pin facing (6) Split pin facing (7) Split pin facing (8) Split pin facing (9)
Towards Towards Towards Towards
South: tower: South: tower:
Arcing ring facing away from
tower(10):
 12

5 6
4 8
1

1
7
9

11

2 3

Tower number: Team leader signature:

Numbers of isolator strings: Approved by:
Bolt torque/Split inserted
1 7 Technician signature:
2 8 Installed by:
3 9
4 (90 Nm) 10
Date:
5 (18 Nm) 11
6 (90 Nm) Arcing ring facing up(12):
Split pin facing (1) Split pin facing (2) Split pin facing (3) Nut locked (4) Nut locked (5)
Towards Towards Towards Towards Towards
ground: tower: ground: tower: ground:
Nut locked (6) Split pin facing (7) Split pin facing (8) Split pin facing (9) Split pin facing (10)
Towards Towards Towards Towards Towards
tower: ground: tower: ground: tower:
Split pin facing (11)
Towards
tower:
 1

4 5 6 8
1

7 9 10

2
3

Tower number: Team leader signature:

Numbers of isolator strings: Approved by:
Bolt torque/Split inserted
1 6 (90 Nm) Technician signature:
2 7 Installed by:
3 8
4 (90 Nm) 9
Date:
5 (18 Nm) 10
Split pin facing (1) Split pin facing (2) Split pin facing (3) Nut locked (4) Nut locked (5)
Towards Towards Towards Towards Towards
ground: South: ground: ground: ground:
Nut locked (6) Split pin facing (7) Split pin facing (8) Split pin facing (9) Split pin facing (10)
Towards Towards Towards Towards Towards
ground: ground: South: ground: South:

Arcing ring facing up(11):

 1

2
3

5
1
4

1
7

8 9 8

8
Tower number: Team leader signature:
Numbers of isolator strings: Approved by:
Bolt torque/Split inserted
1 6 (75 Nm) Technician signature:
2 7 Installed by:
3 (75 Nm) 8
4 9
Date:
5 (75 Nm)
Split pin facing (1) Split pin facing (2) Nut locked (3) Split pin facing (4) Nut locked (5)
Nut
Towards Towards Towards Towards facing
tower: south: tower: south: up:
Nut locked (6) Split pin facing (7) Split pin facing (8) Split pin facing (9) Split pin facing (10)
Facing
like Towards Towards Towards Towards
drawing: south: tower: tower: south:
Arcing ring facing like
drawing(11):
 1 2

2 1

4
3
5

5 6

Tower number: Team leader signature:

Numbers of isolator strings: Approved by:
Bolt torque/Split inserted
1 6 Technician signature:
2 (70Nm) Installed by:
3 (70Nm)
4
Date:
5
Split pin facing (1) Nut locked (2) Nut locked (3) Split pin facing (4) Split pin facing (5)
Towards Towards Towards Towards Towards
South: tower: South: South: South:
Split pin facing (6)
Towards
tower:
Arcing ring facing like
drawing(7):
 1

Numbers of spacers: Team leader signature:

Installed between Approved by:
towers:
Span length (m) Technician signature:
System 1 Installed by:
Systen 2
Spacer no. Length between spacers:
Date:
1
2
Tightened until break of breakaway 1 [45 Nm]
3
4 Breakaway cap removed
5
6
7
Spacer no.1 (2) Spacer no.2 (2) Spacer no.3 (2) Spacer no.4 (2) Spacer no.5 (2)
Away Away
Towards from Towards from Towards
line: line: line: line: line:
Spacer no.6 (2) Spacer no.7 (2)
Away
from Towards
line: line:
Installed between towers: Team leader signature:
Numbers of joints:
Approved by:
All compressions overlapping:

Lengthafter compression for Technician signature:

joint Phase 1 System 1: Installed by:
Mark placed for correct
position of joint:
Date:

Photo documentation showing mark on conductor on both

Phase: 1 System: 1
sides of joint:
Installed at tower: Team leader signature:
Numbers of joints: Approved by:
All compressions
Length after compression for Technician signature:
Phase 1 System 1: Installed by:
Mark placed for correct
position of joint:
Date:

Photo documentation showing mark on conductor on both

Phase: 1 System: 1
sides of joint:
 1

Tower number: Team leader signature:

Numbers of dampers: Approved by:
Installed on span towards
tower no.: Technician signature:
L1 (mm) Installed by:
Installed at length:
L2 (mm)
Tightened until 1 [30 Nm]
Date:
break of breakaway
(2)Big weight block facing Breakaway cap removed from
away from tower bolt
 1
1

Tower number: Team leader signature:

Numbers of counterweights: Approved by:
Distance from 1 (mm)
middle 2 (mm) Technician signature:
counterweight: Installed by:
Straight side away from tower (2)
Tightened 1 [40 Nm]
Date:
 Team leader signature:
Installed between tower nos.:
Approved by:
All compressions overlapping:
Length Technician signature:
after compression: Installed by:
Mark placed for correct
position of joint:
Date:

Photo documentation showing mark on GW on both sides of

GW: 1
joint:
 4

1
3
2

Tower number: Team leader signature:

Number of GW: Approved by:
Bolt torque/Split inserted
1 Technician signature:
2 Installed by:
3 (44 Nm)
4
Date:

Split pin facing (1) Split pin facing (2) Nut locked (3) Nut locked (4)
Nut Facing as
Towards Towards
facing in
tower: tower:
tower: drawing:
 3 3

4
2 2 4
1

Tower number: Team leader signature:

Number of GW: Approved by:
Bolt torque/Split inserted
1 Technician signature:
2 Installed by:
3

Date:

Split pin facing (1) Split pin facing (2) Nut locked (3)
Facing as
Towards Towards
in
tower: tower:
drawing:

(4)Distance between sides

after compression:
 3
4
2 1

Tower number: Team leader signature:

Number of GW: Approved by:
Bolt torque/Split inserted
1 Technician signature:
2 Installed by:
3
4
Date:

Split pin facing (1) Split pin facing (2) Nut locked (3) Split pin facing (4)
Facing as
Towards Towards Towards
in
tower: tower: tower:
drawing:
 4

5
6

Tower number: Team leader signature:

Number of GW: Approved by:
Bolt torque/Split inserted
1 6 (44 Nm) Technician signature:
2 Installed by:
3
4
Date:
5
Split pin facing (1) Split pin facing (2) Split pin facing (3) Split pin facing (4) Nut locked (5)

Towards Towards Towards Towards Facing as

ground: tower: tower: tower: drawing:
Nut locked (6)
Facing as
in
drawing:
 5
1

4
2
3

Tower number: Team leader signature:

Number of OPGW: Approved by:
Bolt torque/Split inserted
1 Technician signature:
2 Installed by:
3
4 (44 Nm)
Date:
5
Split pin facing (1) Split pin facing (2) Split pin facing (3) Nut locked (4) Nut locked (5)
Towards Towards Towards Towards Towards
South: tower: tower: tower: ground:
 2

5
3

Tower number: Team leader signature:

Number of OPGW: Approved by:
Bolt torque/Split inserted
1 Technician signature:
2 Installed by:

Date:

Split pin facing (1) Split pin facing (2)

Towards Towards
tower: tower:

(3)Distance "X": (4)Distance "Y":

Minimum bending radius for

(5)Distance:
OPGW:
 4
7 3 7

1 5
5 1 2

6 6

Tower number: Team leader signature:

Number of OPGW: Approved by:
Bolt torque/Split inserted
1 Technician signature:
2 Installed by:

Date:

Split pin facing (1) Split pin facing (2) Split pin facing (3) Split pin facing (4)
Towards Towards Towards Towards
tower: tower: tower: South:

(5)Distance "X": (6)Distance "Y":

Minimum bending radius for

(7)Distance:
OPGW:
 5 5

2 1
3 1
4 3
4

Tower number: Team leader signature:

Number of OPGW: Approved by:
Bolt torque/Split inserted
1 Technician signature:
2 Installed by:

Date:

Split pin facing (1) Split pin facing (2)

Towards Towards
tower: tower:

(3)Distance "X": (4)Distance "Y":

Minimum bending radius for

(5)Distance:
OPGW:
Afstand mellem tromle og bremse/Distance between drum and brake:
Afstand mellem bremse og mast/Distance between brake and tower:

Vinkel mellem tromle og bremse/Angle between drum and brake:

Vinkel mellem bremse og fasehjul/Angle between brake and tower:
Section:
Mast nummer start/from tower:
Mast nummer ende/to tower:
Fase: Tromle/Drum #
System: Trækstyrke/Tension: kN Trækhastighed/Speed: km/t
Nedhæng / Sag
Dato/date Klokkeslæt/time Temp. Mellem/Between Nedhæng/Sag Træk/Ten.

Fase: Tromle/Drum #
System: Trækstyrke/Tension: kN Trækhastighed/Speed: km/t
Nedhæng / Sag
Dato/date Klokkeslæt/time Temp. Mellem/Between Nedhæng/Sag Træk/Ten.

Fase: Tromle/Drum #
System: Trækstyrke/Tension: kN Trækhastighed/Speed: km/t
Nedhæng / Sag
Dato/date Klokkeslæt/time Temp. Mellem/Between Nedhæng/Sag Træk/Ten.
9 Appendix 5 – COMPOSITE INSULATOR HANDLING

9.1 RECEIPT AND STORAGE

On Receipt ...

• Examine the crate for signs of damage.

• Open the crate carefully, ensuring that all tools used are kept well away from the
insulators.

• On removal of the lid and any internal battens, remove or flatten all exposed nails.

• Check that the type numbers on the insulators agree with those on the order and the
packing lists.

• Undertake an examination of a sample or all of the insulators as defined on the

Inspection Check List given on Sheet 2.

• Return the insulators to their original crates and re-seal.

If Crates are Damaged ...

• Advise the supplier immediately.

• Visually examine each insulator in the crate in the presence of the supplier, his
insurance agent and the project engineer.

• Reject any insulator with damage to the housing or end seals.

Storage ...

• If possible, store insulators in their original crates.

• Crates should be raised off the ground and stored in an area free of standing water
and contaminants such as oils and petroleum derivatives.

• Crates must be sealed to prevent the entry of rodents.

• If the insulators must be un-crated, they must be hung from suitable racks or provided
with adequate temporary protection such as plastic tubes.
9.1.1 CHECK LIST - STORES RECEIPT

ORDER No : PROJECT :

TYPE No : SUPPLIER : QTY :

TYPE No. ON INSULATOR :

CRATE IN SOUND CONDITION : Yes / No

NUMBER OF SHEDS :

LIVE-END FITTING TYPE :

LIVE-END FITTING SIZE : mm

ALL PINS, NUTS, ETC. INCLUDED? Yes / No

EARTH-END FITTING TYPE :

EARTH-END FITTING SIZE : mm

ALL PINS, NUTS, ETC. INCLUDED? Yes / No

CORONA RINGS INCLUDED? Yes / No

CONNECTING LENGTH : mm
ALTERNATING SHEDS ? Yes / No

SHED DIAMETER 1 : mm

SHED DIAMETER 2 : mm

SHANK DIAMETER : mm

GALVANIZING THICKNESS : µm

SHED MATERIAL TYPE :

IF CRATE DAMAGED :

ALL UNITS EXAMINED ? Yes / No

No. OF UNITS REJECTED :

CRATE APPROVED FOR RELEASE TO SITE

INSPECTED BY :

DATE : SIGNATURE :
9.2 TRANSPORT

• Wherever possible, insulators must be transported in their original crate with the lid in
place.

• Once the insulators are removed from the crate, temporary protective packaging
should be provided.

• Insulators must never be transported loosely or tied together or tied down with chains,
ropes, etc.

• Other material and equipment must never placed on top of insulators in transit.

• On arrival at site, undertake an examination of a sample or all of the insulators as

defined on the Inspection Check List given on Sheet 4.

• If packaging damage is evident, visually examine each insulator.

• Reject any insulator with housing or end-seal damage.

• Transport insulators to the structure position only when immediately required

9.2.1 CHECK LIST - SITE RECEIPT

ORDER No : PROJECT :

TYPE No : SUPPLIER : QTY :

TYPE No. ON INSULATOR :

CRATE IN SOUND CONDITION : Yes / No

NUMBER OF SHEDS :

LIVE-END FITTING TYPE :

LIVE-END FITTING SIZE : mm

ALL PINS, NUTS, ETC. INCLUDED ? Yes / No

EARTH-END FITTING TYPE :

EARTH-END FITTING SIZE : mm

ALL PINS, NUTS, ETC. INCLUDED ? Yes / No

CORONA RINGS INCLUDED ? Yes / No

CONNECTING LENGTH : mm

ALTERNATING SHEDS ? Yes / No

SHED DIAMETER 1 : mm

SHED DIAMETER 2 : mm

SHANK DIAMETER : mm

GALVANIZING THICKNESS : µm

SHED MATERIAL TYPE :

IF CRATE DAMAGED :

ALL UNITS EXAMINED ? Yes / No

No. OF UNITS REJECTED :

CRATE APPROVED FOR RELEASE TO SITE

INSPECTED BY :

DATE : SIGNATURE :
9.3 ON-SITE HANDLING

On Arrival at the Pole Position ...

• Open the crate carefully and remove or flatten all exposed nails that could damage the
insulator housings or cause injury.

• Once removed from the crate, the insulators should be provided with some temporary
protective packaging.

• Insulators must not be left lying where they are in danger of being driven over, stood
on or struck by other components and equipment.

Assembling ...

• Do not place the insulator directly on the ground. Use a protective cover or, at least,
lay the unit on a plastic or canvas sheet.

• Insulators exhibiting damage to the housing or end seals must be rejected and
removed from the site.

• Check that the type number marked on the insulator agrees with that given on the
assembly drawing.

• Check that the insulator is the right way around and that all metal fittings are in the
correct order.

• Check that the fitting sizes and dimensions of adjacent metalware are compatible and
that all components can be coupled without undue force.

• Ensure that all split pins, cotter pins and W-clips are fully inserted and that nuts and
bolts are properly tightened.

Figure 1: Protection devices for insulator storage and installation.

9.4 INSTALLATION

Installing ...

• Lifting lines must be attached to the caps of composite insulators only and never to the
sheds or housing.

• Where poles are dressed with line posts before being positioned, it must be ensured
that, on the lifting of the pole, the insulators do not make contact with the ground.

• All line post mounting bolts must be tightened to the recommended torque.

• Do not step, sit or crawl on the insulators - climbing ladders and work platforms must
be used.

• Where buckets or cages are employed, it must be ensured that at no stage they come
into contact with, or rest on, the insulators.

• Ladders, tools, blocks, and other equipment must be kept away from the
insulator sheds and housings.

• Lifting lines must not be thrown over the insulators.

• Ensure that line post trunnion clamp keeper pieces are installed the right way up.

• No bending or torsional loads must be applied to long rod insulators.

• When attached to the pole or crossarm, it must be checked that long rod insulators are
free to swing in all directions.

• Corona rings and arcing horns must be properly fitted and the bolts tightened to the
recommended torque.
9.5 CONDUCTOR STRINGING

• Do not use any equipment or stringing procedure that may subject the long rod
insulators to bending or torsional loads.

• When stringing, a proper conductor swivel fitting must be used.

• The conductor must be carefully run out and handled to avoid the formation of loops
and twists.

• Under no circumstances must attempts be made to align or un-twist conductor

bundles by rotating the insulator or the string hardware.

• Ensure that all tensioning equipment is kept well clear of the insulators.

• Long rod insulators must be held and prevented from rotating when turnbuckles in the
string assembly are adjusted.

• Ensure that long rod suspension strings are free to swing and follow the movement of the
running-out blocks without bending.

• To prevent potential damage to line post insulators, all running-out blocks must be
checked and, if necessary, serviced, prior to use.

The appropriate stringing charts, sighting boards, and dynamometers must be employed to
ensure that insulators are not over-stressed.