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Transmission Lines: User's Manual of Construction
Transmission Lines: User's Manual of Construction
Transmission Lines: User's Manual of Construction
users manual
of
Construction
(part one)
Transmission Lines
Volume-4
Tower Erection
Construction Management
Power Grid Corporation of India Limited
(A Government of India Enterprise)
DOCUMENT CODE NO. : CM/TL/TOWER ERECTION/96 JUNE,
1996
FROM THE DESK
OF
DIRECTOR (PERSONNEL)
Four Ms viz. men, material, machine & money are vital to run an organization.
However the key to success of the organization lies the way our employees
structure and manage the construction, operation and maintenance activities of
transmission system. Construction activitiy in transmission system is an important
aspect and time, quality and cost are its critical parameters.
These manuals for transmission lines (Vol. 1 2 & 4) alongwith SFQP (Vol. 1) will be
of immense help to our line staff to manage their resources in a more efficient and
systematic way to achieve high quality and reduced time.
I find sincere efforts have gone into preparation of these manuals for which I
congratulate Construction Management team and I am sure the authors will
continue their efforts to bring out more and more such manuals.
(R.P. SINGH)
CONTENTS
CHAPTER-I
TOWER CONFIGURATION
CHAPTER-2
TYPES OF TOWERS
2.1 CLASSIFICATION ACCORDING TO NUMBER OF CIRCUITS
CHAPTER-3
TOWER FABRICATION
3.1 GENERAL
3.2 BOLTING
3.3 WASHERS
CHAPTER-4
METHODS OF ERECTION
4.1 GENERAL
4.1.1 BUILT UP METHOD
4.2 EARTHING
ERECTION GANG
ERECTION GANG
CHAPTER-5
GL-5 EARTHING
CHAPTER-6
CHAPTER-7
CHAPTER
ONE
_________________________________________________________
TOWER CONFIGURATION
(d) Vertical clearance between ground wire and top conductor (H4).
H = H1 + H2 + H3 + H4
The size and type of conductor, wind and climatic Conditions of the
region and span length determine the conductor sag and tensions. Span
length is fixed from economic considerations. The maximum sag for
conductor span occurs at the maximum temperature and still wind
conditions. This maximum value of sag is taken into consideration in
fixing the overall height of the steel structures. In snow regions, the
maximum sag may occur even at 0OC with conductors loaded with ice in
still wind conditions. While working out tension in arriving at the
maximum sag, the following stipulations laid down, in I.E. Rules (1956)
are to be satisfied.
(ii) The conductor tension at 32OC (90OF) without external load shall
not exceed the following percentages of the ultimate tensile
strength of the conductor.
This is governed by the angle of shielding i.e. the angle which the line
joining the ground wire and the outermost conductor makes with the
vertical, required for the interruption of direct lightning strokes at the
ground and the minimum mid span clearance between the ground wire
and the top power conductor. The shield angle varies from about 20
degrees 30 degrees, depending on the configuration of conductors and
the number of ground wires (one or two) provided.
The wind load constitutes an important and major component of the total
loading on towers and so a basic understanding of the computation of
wind pressures is useful.
The country has been divided inot six wind zones of different wind
speeds. The basic wind speeds for the six wind zones are:
1 33
2 39
3 44
4 47
5 50
6 55
Fig. 1.2 shows basic wind speed map of India as applicable at 10m
height above mean ground level for the six wind zones.
In case the line traverses on the border of different wind zones, the
higher wind speed may be considered.
At ground level, the wind intensity is lower and air flow is turbulent
because of friction with the rough surfaces of the ground. After a certain
height, the frictional influence of the ground becomes negligible and
wind velocity increases with height.
These are :
(a) Reliability
(b) Security:-
(c) Safety:-
Transmission lines are subjected to various loads during their life time.
These are classified into three distinct categories, namely:
Transverse load
Longitudinal load
Vertical load
Torsional shear
Weight of structure
The conductor and ground wire support point loads are made up
of the following components:
The wind span is the sum of the two half spans adjacent
to the support under consideration. The governing
direction of wind on conductors for an angle conditions is
assumed to be parallel to the longitudinal axis of the
cross-arms (Fig.1.8). Since the wind is blowing on
reduced front, it could be argued that this reduced span
should be used for the wind span. In practice, however,
since the reduction in load would be relatively small, it is
usual to employ the full span.
(b) Transverse load due to line deviation
Vertical load is applied to the ends of the cross-arms and on the found
wire peak (Fig.1.6C) and consists of the following vertical downward
components:
(iii) Arbitrary load to provide for the weight of a man with tools.
1.6.3.4 Weight of structure
The weight of the structure like the wind on the structure, is an unknown
quantity until the actual design is complete. However in the design of
towers, an assumption has to be made regarding the dead weight of
towers. The weight will no doubt depend on the bracing arrangement to
be adopted, the strut formula used and the quality or qualities of steel
used, whether the design is a composite one comprising both mild steel
and high tensile steel or make use of mild steel only. However, as a
rough approximation, it is possible to estimate the probable tower weight
from knowledge of the positions of conductors and ground wire above
ground level and the overturning moment.
TYPES OF TOWERS
support.
types as follows.
lines :
structural member.
arms.
phase to phase.
The latticed parts are fully galvanised.
washers.
as detailed below :-
15 degrees deviation.
angle.
in Fig.2.9.
shielding angle.
Like single circuit towers, these towers are also
accessories.
without angle.
Railway Authorities.
transposition.
at suitable intervals.
in Fig.2.11.
Fig. 2.12
different levels.
Standard designs can be made for 1.5, 2.5 and 3.5 M
leg extensions.
Tower
Weight of towers for 279 202 135 126 76 2 48
a 10-km line
weights.
--------------------------------------------------------------------------
CHAPTER
THREE
Chapter-3
--------------------------------------------------------------------------
TOWER FABRICATION
Tower Fabrication
3.1 General
fabrication.
galvanised.
eccentricity is avoided.
facilitate repairs.
3.2 Bolting
3.2.2 The length of the bolt should be such that the threaded
bolt threads.
3.2.3 Table 3.1 gives the minimum cover to free edge and bolt
---------------------------------------------------------
Size of bolted Maximum edge
Bolt dia. leg of angle distance that
section and its can be
thickness actually
obtained
--------------------------------------------------------
12 40x6 17
16 45x6 18
20 60x8 25
--------------------------------------------------------
indication method.
preferred.
3.3 Washers
galvanising.
(mm)
------------------------------------------------------------
Bolt dia. Thickness of spring washer
------------------------------------------------------------
12 2.5
16 3.5
20 4.0
------------------------------------------------------------
of the thread.
generally specified.
outside angle.
bolt.
Figure 3.6.
awkward.
as wear.
Figure 3.13.
respectively.
Fig.3.17.
No. 3.14.
3.15.1 Packing :
contents.
marked.
3.15.2 Transportation.
damaged.
3.15.3 Storage.
Highways.
power.
approach.
g. Communication facilities.
stores.
easy identification.
stores.
c. Proper lighting.
METHODS OF ERECTION
4.1 GENERAL
advantages.
as cranes etc.
complete unit.
Figure 4.7.
in position.
of the lacings have been bolted up, all the guys are
complete tower.
difficult.
4.2 Earthing
II/Section 1)-1976.
described below.
a) Soil Resistivity
in contact.
following expression.
2x22 x AxR
P = -----------
7
Where
resistance in ohms.
4.3 Tack welding :-
members.
(CONSTRUCTION MANAGEMENT)
LINE CONSTRUCTION
ERECTION ACTIVITY
19mm dia.1000 m.
Hammers,Slings,(16mm dia.and
9. Safety equipments :
(CONSTRUCTION MANAGEMENT)
CONSTRUCTION ACTIVITY
MANPOWER REQUIREMENT
FOR
1) Supervisor 1 No.
2) Fitter 8 Nos.
requirements
Chapter-5
Guide Lines
--------------------------------------------------------------------------
CHAPTER
FIVE
--------------------------------------------------------------------------
GUIDELINES
need to be made.
erection.
later date.
1.3.1 All the tools and plants required for safe and
at Annexure-E/1.
be worked out.
1.5 Manpower
1.6 Miscellaneous
line.
erec-tion site.
at erection site.
ruled out.
to ensure safety.
anchoring force.
Material.
Bill of Material.
2.2.3 All Bolts shall have their nuts facing outside the
connections.
step bolt.
during erection.
3.1 Tightening
at Para 1.2.1.
step bolt.
new ones.
size of bolt/nut.
3.2 Punching
3.3 Verticality
direction.
in 360.
3.4 Earthing
GL-5.
is 10 Ohm.
GUIDELINES
requirement.
manufacturer.
paint.
GL- 5. EARTHING
5.1 General
Ohm.
possible by auguring.
feasible.
of different types.
as under :-
- 1 No.
d) Coke-150 Kgs.
e) Salt-15 Kgs.
5.2.5 G.S. Pipe and flat are placed and tightened firmly
shall be 15 m.
ohm.
sufficient tightness.
size member.
Chapter-6
Standardisation of Tower Design
--------------------------------------------------------------------------
CHAPTER
SIX
--------------------------------------------------------------------------
6.1 Introduction :
transmission lines.
Sl. Type of Standard Design Design Wind Zone Name of the Adopted Trans. Lines
No. towers
1. 400 kV Single Ckt. Suspension Medium wind zone tower 45 400 kV S/C Agra-Chatta TL (By Dodsal)
A type tower M/Sec. As per IS : 802-1977 400 kV S/C Chatta-Ballabgarh TC (BY TSL)
2. 400 kV Single Ckt. Tension -do- 400 kV S/C Dadri-Panipat Line (Only D
Tower type B.C. and D/DE type tower used by M/s Dodsal)
3. 400 kV Double Ckt. Suspension -do- a) 400 kV D/C Jamshedpur-Rourkela TL
DA type tower
b) 400 kV D/C Misa-Balipara TL
4. 400 kV Double Ckt. Tension -do- a) 400 kV D/C Jamshedpur-Rourkela TL
tower type DB, DC and DD/DDE
b) 400 kV D/C Misa-Balipara TL
Notes :
1. Standardisation of tower design presently done on the highest wind velocity basis by clubbing 33.39 and
44 m/sec. Similarly, wind velocity of 47 m/sec. And 50 m/sec. Have been clubbed to 50 m/sec.
2. The basis wind speed at 10 M height for some important Cities/Towns of India as given below.
City/Town Basic Wind City/Town Basic Wind
Speed (m/s) Speed (m/s)
Agra 47 Jhansi 47
Ahmadabad 39 Jodhpur 47
Ajmer 47 Kanpur 47
Almora 47 Kohima 44
Amritsar 47 Kurnool 39
Asansol 47 Lakshadweep 39
Aurangabad 39 Lucknow 47
Bahraich 47 Ludhiana 47
Bangalore 33 Madras 50
Barauni 47 Madurai 39
Bareilly 47 Mandi 39
Bhatinda 47 Mangalore 39
Bhilai 39 Moradabad 47
Bhubaneshwar 50 Nagpur 44
Bhuj 50 Nainital 47
Bikaner 47 Nasik 39
Bokaro 47 Nellore 50
Bombay 44 Panjim 39
Calcutta 50 Patiala 47
Calicut 39 Patna 47
Chandigarh 47 Nellore 50
Coimbatore 39 Port Blair 44
Cuttack 50 Puna 39
Darbhanga 55 Raipur 39
Darjeeling 47 Rajkot 39
Dehra Dun 47 Ranchi 39
Delhi 47 Roorkee 39
Durgapur 47 Rourkela 39
Gangtok 47 Simla 39
Gauhati 50 Srinagar 39
Gaya 39 Surat 44
Gorakhpur 47 Tiruchchirrapalli 47
Hyderabad 44 Trivandrum 39
Imphal 47 Udaipur 47
Jabalpur 47 Vadodara 44
Jaipur 47 Varanasi 47
Jamshedpur 47 Vijaywada 50
Visakhapatnam 50
Chapter-7
Check Format
--------------------------------------------------------------------------
CHAPTER
SEVEN
--------------------------------------------------------------------------
Check Format
(CONSTRUCTION MANAGEMENT)
LINE CONSTRUCTION
Check Format
--------------------------------------------------------------
ITEM CHECKED RESULT OBSERVATION
--------------------------------------------------------------
1) Setting period of foundation is allowed
for atleast 14 days as per
specn. Back filling is O.K. Yes/No
2) All tested tools and plants
and safety equipments in
working conditions are availa-
ble at site. Yes/No
3) All tower members, Nuts/Bolts
are available at site without
any damage, bent or rusting. Yes/No
4) Benching/Revetment,if any,
completed. If not, then
programme of completion. Yes/No
5) Shutdown of powerline, if
required, is arranged. Yes/No
6) Reqd. no. of safety helmets,
safety belts & safety shoes
are being used. Yes/No
7) First section is completely
braced and all plane diagonals
are placed in proper position. Yes/No
8) Guying of tower provided as
per approved drawings and
norms. Guying to be termi-
nated on firm ground. Yes/No
9) All Nuts/Bolts, flat/spring
washers are provided as per
approved drawings. Yes/No
10) All horizontal Bolt heads
are facing inside and verti-
cal Bolt head facing upwards. Yes/No
11) Subsequent section are erected
only after complete erection and
bracing of previous section. Yes/No
12) Any undue stress, bending or
damage of member during erec-
tion noticed. Yes/No
13) Any filing of holes or cutting
of members during erection
observed. Yes/No
14) Any heavy hammering of bolt
causing damage of threads
noticed. Yes/No
15) Any substitute of tower member
erected. If yes, member nos. Yes/No
16) Tightening is done progressively
from top to bottom. Yes/No
17) All bolts at the same level are
tightned simultaneously. Yes/No
18) Slipping/running over nut/bolts
are replaced by new ones. Yes/No
19) Threaded portion of bolts
projected outside of nut is
not less than 3mm. Yes/No
20) Punching of threads projected
outside is done at three posi-
tions on dia. Yes/No
21) All left over holes are filled
with correct size of bolt/nut. Yes/No
22) Verticality of tower is checked
with help of the odolite for both
longitudinal & transverse direc-
tion. This is with in specified
limits. Yes/No
23) Details of missing members, nut,
bolts etc. Yes/No
24) Tower Accessories
All the following tower access-
ories are fixed as per specn/
apprd. drg.
a) Number plate. Yes/No
b) Danger plate. Yes/No
c) Phase plate. Yes/No
d) Anti-climbing devices/
barbed wires. Yes/No
e) Aviation signals/paints as
per requirement/specn. Yes/No
25) Tack welding is done as per specn.
using standard quality of welding
rods. Yes/No
26) Zinc Rich (90%) cold galvanising
paint applied over tack welding. Yes/No
27) Earthing
i. Tower footing resistance Ohm
ii. Type of earthing Pipe Type/
approved Counter Poise
A. Pipe Type Earthing
i. Earthing provided on Leg `A' Yes/No
ii. G.S. Pipe, flat tightened
with Nut & Bolt and placed
as per apprd. drg. Yes/No
iii. There is no sharp bent/
damage in earthing strips/
flat. Yes/No
iv. Finely broken coke (max.
size 25mm) and salt in Ratio
10:1 filled in bore holes. Yes/No
v. Backfilling done, properly. Yes/No
(B) Counter Poise Earthing
i. Excavation done upto reqd.
depth (min. 1m) and length
(min. 15m) in four radial
direction. Yes/No
ii. G.S. Wire placed in
excavation and lugs firmly
tightened with Nut and Bolt. Yes/No
iii. Backfilling done as per Yes/No
specn.
(C) Value of tower footing resist-
ance after earthing in dry
season (permissible limit
- 10 ohm). ..Ohm
Certificate : Tower erection is complete in all respects and
footing resistance is within permissible limit.
SIGNATURE SIGNATURE
NAME NAME
DATE DATE
SIGNATURE
NAME
DATE
__________________________________________________________________________
_
RESUMES
1. Sh. V.C. Agarwal, AGM, is B.E. (Civil) and M.E. (Hons.) in Soil Mech. and Fndns.
Engg. From Univ. of Roorkee, Roorkee.
2. Sh. D.K. Valecha, Sr. Manager, is B.Sc. Engg. (Electrical) from Reg. Engg. College,
Kurukshetra.
3. Sh. J.K. Parihar, Manager, is B.E. Elect. (Hons.) from Univ. of Jodhpur, Jodhpur.
4. Sh. R. Nagpal, Manager, is B.E. Elect. (Hons.) from Punjab Engg. College,
Chandigarh and MBA from Indira Gandhi National Open Univ., New Delhi.
5. Sh. B.K. Jana, Dy. Manager, is B.E. (Civil) from Regional Engineering College
Durgapur and M. Tech. In Applied Mechanics from I.I.T. Delhi.