MONOPOLE DESIGN & TEST

1. BACKGROUND:

This tender is only for the Supply, Manufacture and Delivery of Steel Monopoles required
by the PEC team for the construction of a new Marib 33kV Transmission line.

The following type of tubular towers for 220kV, 132 kV and 66kV transmission lines

suitable for ACSR Zebra are required:

a) Double circuit Suspension and Angle Tower.

b) Special Towers.

The towers are of self-supporting tubular pole (herein referred as Tower), designed to
carry the line conductors with necessary insulators, Earthwire/ OPGWs and all fittings under
all loading conditions.

2. SCOPE OF WORK:

1. Supply, Manufacture and Deliver Steel Monopoles to the Marib 33kV

construction site as outlined in the below BOQ.
2. Delivery of the Steel Monopoles shall commence within 4 weeks from the date of
placing the purchase order, with the last Steel Monopole being delivered
no later than the end of week 8 from the date of the purchase order being
placed.
3. All delivery vehicles shall comply with the relevant PEC specifications as well as
the latest Construction Regulations.
4. Supplier shall acquaint themselves with the delivery arrangement requirements by
PEC Power in cooperation with the Project Consultant or Site Manager.
5. Provide complete galvanized tower rate.
6. Provide duplex coating rate separately.
7. As part of the detailing design the client will advise based on the galvanizing
thickness that can be achieved if duplex coating maybe implemented or not.
8. The supplier must price for both options.
9. All towers must be galvanized prior to duplex coating.

3. CONDITION:

The monopoles are to be designed for 33KV double circuit lines with vertical formation &
one conductor of 400mm2 aluminum conductor steel reinforced 400mm2 ACSR as BS
215.2 standards Zebra and (5/3.22AL+7/3.22St) mm OPGW at the top. Monopoles shall
also be designed suitable for stringing single circuit on one side of the monopole.
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 The monopoles are to be designed conforming to reliability level 1 of ( IEC 60826 & ASCE
Manual No:72) for a ruling span of 300m for the details mentioned in following paras & as
per the general arrangement provided in the sketches enclosed (Drawing N02). The steel
sections considered for design should conform to EN 10025/1-6 Grade S355JO (Yield
Strength 350 MPa).

4. TYPE OF MONOPOLES
The two nos. monopole types proposed are as detailed below:-

A) Tangent Monopoles P-2

(To be designated as 'XP' type monopoles)
Suspension monopoles for use on straight run and also for line deviation upto 2° with
normal ruling span, the base width of this monopole is restricted to 1.2m.
B) 90° Angle Monopoles P-90
(To be designated as 'ZP' type monopoles)
Large angle monopoles with tension insulator strings for use on line deviation upto 90° with
normal span and for longer spans with smaller angles subject to adequate ground clearance.
These monopoles will also be used as dead end monopoles and at Switchyards with no angle
of deviation on the monopole on line side & up to 15° angle on slack span (gantry) side. The
base width be restricted to 2.2 meters.

5. WIND PRESSURE:
The wind load on structures shall be calculated based on basic wind speed between of 180 to
200 km/hr. at 1 Om height with importance factor of 1 .1 5.

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 5.1 Wind Span & Weight Span:
The following wind spans and weight spans shall be adopted for the design of all types of
monopole structures.

i) Normal span 150m

1.1 x150(Normal condition)

ii) Wind span:
0.6x1.1 x 150(Broken wire condition)

iii) Weight span: Normal condition Broken wire condition

Max.: 1.5 x 150 225 m

3.2 Broken Wire Condition:

The following broken wire conditions shall be assumed in the design of Monopoles:-

Suspension Anyone phase or ground wire broken, which

Monopole XP (0-2 )
Large Angle tension
monopoles/ dead
end monopoles ZP 0
(0-90 /DE)
ever is more stringent
Any 3 phases broken on the same side and
same span or any 2 of the phases & ground
wire broken on the same side & same span,
whichever combination constitutes the
most stringent condition

5.3 Strength Factors Related to Quality:

To account for the reduction in strength due to dimensional tolerance of the structural
sections and the steel used for fabrication will be of minimum
guaranteed yield strength. The estimated loads shall be increased by a factor of 1.02.
5.4 Loads on Monopoles:
5.4.1 Classification of Loads:
Transmission lines are subjected to various loads during their life time. These loads are
classified into three distinct categories, namely:
a) Climatic Loads: related to the reliability requirements.
b) Failure containment Loads: related to security requirements.
c) Construction & Maintenance Loads: related to safety requirements.

a) Climatic Loads:
These are random loads imposed on monopole, insulator string, conductor &
ground wire due to action of wind on transmission line & do not act continuously. Climatic
loads shall be determined under either of the following climatic conditions whichever is
more stringent:

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1) 100 percent design wind pressure at every day temperature (45° C) or
2) 36 percent design wind pressure at minimum temperature (-2.5°C).

b) Failure Containment Loads:

These loads comprise of:
1) Anti cascading Loads &
2) Torsional & Longitudinal Loads
c) Anti Cascading Loads:
Cascade failure may be caused by failure of items such as insulators, hardware, joints
failures of major components such as monopoles, foundations, conductor due to defective
material or workmanship or from climatic overloads sometimes from casual events such as
misdirected aircraft, avalanches, sabotage etc. The security measures adopted for containing
cascade failures in the line is to provide angle monopoles at specific intervals which shall be
checked for anti cascading loads

d) Torsional & Longitudinal Loads:

These loads are caused by breakage of conductors and/or ground wire. All the monopoles
shall be designed for these loads for the number of conductors and or ground wire
considered broken as per provisions of this specification.

NOTE: The mechanical tension of conductor/ground wire is the tension corresponding to

100 percent design wind pressure at everyday temperature
or 36% design wind pressure at minimum temperature after accounting for drag co-efficient
& gust response factor.
e) Construction & Maintenance Loads:
These are loads that are imposed on monopoles during constructions & maintenance of
transmission lines.
5.5 Slenderness Ratio :
Slenderness ratio for members shall be computed in accordance with EN 10025/1-6 Grade
S355JO .

5.6 Computation of Loads & loading combinations:

The computation of loads is to be done in line with relevant provisions/ sections of EN
10025/1-6 Grade S355JO (latest amendment)
5.7 Anti Cascading checks.
i) Suspension monopoles shall be checked for narrow front wind with a wind speed of 1.5 of
basic wind speed.
ii) Angle monopoles shall be checked for the following anti cascading conditions with all the

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 conductors & ground wire intact only on one side of the monopole.
a) Transverse load: These loads shall be taken under no wind condition.
b) Vertical Load: These loads shall be the sum of weight of conductor/ground wire as
per weight span of intact conductor/ground wire, weight of insulator strings and accessories.

c) Longitudinal Loads : These loads shall be the pull of conductor/ground wire at every
day temperature & no wind applied simultaneously at all points on one side with zero degree
line deviation.

5.8 Tension Limits:

Conductor/ground wire tension at everyday temperature & without external load should not
exceed the following percentage of the ultimate tensile strength of the conductor:
Initial unloaded tension 35 percent.
Final unloaded tension 25 percent.
Provided that the ultimate tension under everyday temperature & 100 percent design wind
pressure or minimum temperature & 36 percent design, wind pressure does not exceed 70
percent of the ultimate tensile strength of the conductor/ground wire.
6. Foundation Design:
The detailed foundation design will be evolved by the bidder and submitted to PEC with the
bid. PEC reserves the right to get the same checked by

PEC Engineer/ Consultant. Since the monopoles are proposed to be provided on the road
divider having approx. Width of 3 meter, the width of the foundations above ground level
shall not exceed one (0.6) meter for tangent/ straight poles & (1.0) m for the angle poles.
Further, the dimensions of the base pad of the foundations may also be kept as minimum as
possible. The bearing capacity of soil shall be taken as 15 T/Sqm.

7. Monopole Configuration:
The monopole configuration shall be conforming in general to the out line diagrams
enclosed (Drawing N02).

8. Electrical Clearances:
i) Ground Clearances:
The minimum ground clearance from the bottom of the conductor shall not be less than 12
M for 33KV Monopoles at the maximum sag condition at maximum temperature and still
air. The total height upto X-arm shall be equal to ground clearance (+) Max. Sag of 2.5 m
( as the poles are to be designed for low tension) (+) Length of Suspension String and for

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angle monopoles ground clearance (+) max. sag of 2.5 m (as the poles are to be designed for
low tension) (+) 4% of Max sag to cover Creepage & stringing errors.
ii) Live Metal Clearance:
The following minimum clearances between the live parts, monopole & cross arm members
shall be as under:

Clearance
Swing
mm
Nil 1400
1 Single Suspension Insulator String 15 1400
45 610

2 Tension String (Single/Double) Nil 1400

Nil 1400
3 Jumpers 15 1400
20 610

Vertical 2000
4 Between conductors
Horizontal 3500

Length & weight of a string insulator to be considered for design purposes

A) For 33KV Suspension Monopoles:

Single suspension Length in mm 2270mm

B) For 33 KV Tension Monopoles:
Approx. Wt. 25Kg
Single tension
Length in mm 2270mm
Approx. Wt. 32 Kg
All the clearances are to be maintained as per EN 50341-1 :2001, latest amendment.
Clearance shall be checked for both single suspension & double suspension string

iii) Angle of Protection:

The angle of shield by the line joining the center line of the earth wire & top power
conductor in still air at monopole supports to the vertical line shall be
iv) Mid Span Clearance between Earth wire & Power Conductor is to be kept more than the
clearance at monopole. The earth wire sag shall be not more than 90 percent of the
corresponding sag of power conductor under minimum temperature condition for normal
span for the entire specified. The mid span clearance shall be reckoned as direct distance
between earth wire & top power conductor.

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9. Design Temperature:
The following temperature range for the conductors & ground wires shall be adopted for the
line design.

Min. temperature = ( - ) 2.5Cْº

Max. temperature for conductor 85Cº
For ground wire max. Temperature exposed to sun = 53Cْ Every day temperature = 32Cْ

10. Sag & Tension:

Sag & Tension for conductor and earthwire shall be made in accordance with
the relevant provision of relevant To IEC publication for following combinations:
i. At- 2.5 Cْ with 36% Full Wind pressure after accounting for drag and gust
response factor.
ii. At 32 Cْ with Full Wind pressure after accounting for drag co-efficient and
gust response factor.

11. Structure Design: Structures shall be designed so that member unit stress does
not exceed the yield point stress of the material. The ratio of major axis of tubular diameter
to wall thickness shall be such that local buckling does not govern member design.

12. Deflection: Structure deflection under maximum load condition including over
load factors shall be no more than 5 % of the structure height.
13. Pole Shape : Cross section of the pole shall be 12 sided polygon and
shall be tapered from top to the base of minimum three sections shaft. Cross arm member
shall be of polygonal cross section with taper and shall conform to PEC's general
arrangement drawings. The strength of the attachment of cross arms to the columns shall be
sufficient to develop the full capability of the cross arm. Members requiring more than one
length of tubular section shall be constructed by telescoping the sections together with
sufficient overlap to develop the full strength of the member. Minimum overlap shall be 1.5
times the maximum inside diameter of outer section at the telescopic joint. Rigging
accessories, insulator attachment plates, ladder, lugs for bolted steps and lighting brackets,
and hand line attachment shall be welded to the structure.
14. Structural Analysis.
Elastic methods of analysis shall be used. Stability shall be provided for the structure as a
whole and for each structural element. The load effects resulting from the deflected shape of
the structure and individual elements shall be considered during design.
The analysis shall include all structural members in their actual manufactured geometry and
sizes.

The structural design of the pole shall be done using proper design software.

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15. TESTING OF MONOPOLES

15.1 General: All standard tests, including quality control tests in accordance with relevant
ASTM / ASCE shall be carried out. The black monopole of each type shall be subjected to
design and destruction tests by applying tests equivalent to the specified maximum, in
manner approved by the purchaser (i.e PEC). The monopoles shall withstand these tests
without showing any sign of failure or permanent distortion in any part. Thereafter the
monopoles may be subjected to destruction by increasing the loads further in an approved
manner till they fail. No part of any monopole subject to test shall be allowed to be used in
the work. The price will be quoted after allowing rebate for the scrap value for the
monopole material which will be retained by the supplier.
In case of premature failure, the monopoles shall be retested. The supplier shall
provide facilities to the owner or their representatives for inspection of materials during
manufacturing stage and also during testing of the same.

The supplier shall submit to the owner for approval, his detailed program and
proposal for testing monopoles showing the methods of carrying out the tests and manner of
applying the test loads. After the owner has approved the test procedures and programs, the
contractor will intimate the owner about carrying out of the tests at least 10 day in advance
of the scheduled date of tests during which the owner will arrange to depute his
representative to be present at the time of carrying out the tests. Six copies of the test reports
shall be supplied.

15.2 MONOPOLE TESTING PROCEDURE

All measuring instruments shall be calibrated in systematic manner with the help of
Universal Testing Machine or by standard weights. In case the calibration is done with the
use of UTM, the UTM shall be periodically (once in every six months) calibrated by an
external third party. The calibration shall, before commencing the test on each monopole be
done up to the maximum anticipated load to be applied during testing. Calibration curves for
the instruments shall be drawn and the test load be corrected accordingly.

15.3 LOAD AND DEFLECTION MEASUREMENTS

All loads shall be measured through a suitable arrangement of strain devices or by using
weights. Positioning of strain devices shall be such that the effect of pulley friction is
eliminated. In case the pulley friction cannot be avoided, the same shall be measured by
means of standards weights and accounted for in the test loads.
Monopole deflections under load shall be measured by suitable procedure at the top cross
arm level on the front sides of the transverse faces. Deflection readings shall be recorded for

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the before load, 'load on' and 'load off' conditions.
15.4 TESTING PROCEDURE DETAILS:
The testing procedures shall be in accordance with the relevant ASTM / ASCE codes &
standards.
15.4.1 SEQUENCE OF TEST LOADING CASES:
Sequence of test loading cases shall be pre-determined. The choice of the test sequence shall
largely depend upon simplification of the operations necessary for carrying out the test
program.
15.4.2 DETAILS OF TESTS:
Test 1 :(Broken wire Condition) Security and Safety Conditions as well as Ant cascade
condition.
A) Each type of monopole to be tested shall be a full scale proto type black monopole and
shall be erected vertically on rigid. The monopole erected on test bed shall not be out of
plumb by more than 1 in 360.
B) CALIBRATION OF MEASURING INSTRUMENTS

Under these conditions (all conditions involving longitudinal loads in addition to the
transverse and vertical loads) all the transverse and vertical loads are first increased to about
100%. Longitudinal loads are then increased in steps of 50%- 75%90%-95% of the ultimate
loads. At all stages of loading it shall be ensured that the transverse and vertical loads are not
less than the values for corresponding step of the longitudinal load. At each step the loads
are maintained for two minute and the deflections are noted. All loads are then increased to
100%. At this final 100% loading stage, monopole is observed for 5 minutes and deflections
are noted. the monopole is required to withstand these loads without showing any failure.
After every test the loads are brought down and deflection readings are taken for no load
condition.

Test 2: (Normal Condition) Reliability Condition:

These loads are applied as far as possible simultaneously at all points in steps of 50-75-90-
95%. The waiting period of two minute shall be maintained at each step.
The waiting period at the final 100% loading stage shall be 5 minute. Throughout the
process of loading under all tests, the monopole shall be closely observed for any visual sign
of deformation. Whenever, such deformation is observed, the loads shall be brought down
and remedial measures shall be taken.
Test 3: Destruction Test:
In continuation to test 2, after the final waiting period, the transverse loads only are increase

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in step of 5% till the failure occurs. The point of failure is detected from the sudden drop of
load indication in the instrument dials in the Control Room.

15.4.3 SPECIAL REQUIREMENTS

i) The test monopole shall be black made up of steel conforming to EN 10027-1 S355JO.
(Grade E-350 80) (Latest amendment).
ii) During the process of monopole test, when a number of tests have been completed
satisfactorily and a failure occurs as a subsequent test, the design reviewed will be and
monopole will be reinforced with a member of higher strength as required. The reinforced
monopole will be put to test again and subjected to balance tests, unless the failure is of
major nature, which will require all the tests to be repeated, or as mutually agreed between
the Purchaser and the Supplier.
i) Application of Loads on test monopole As considered in design.

15.4.4 CHECK FOR MECHANICAL STENGTH OF MONOPOLE

The structure is considered to be satisfactory if it is able to support the specified ultimate
loads for 5 minutes as stipulated in 4.4.3 with no visible local deformation after unloading
(such as bowing, buckling) and no breakages of elements of constituent parts.
15.5 TEST REPORT
The report shall include the following:
a) The type of tested monopole
b) The name and address of the monopole manufacturer
c) The name and address of the client.
d) The dates and location of testing.
e) The name of persons present during the tests.
f) A list of various assembly and shop drawings relating to the monopole tested, including
any modification of the drawings referred to.
g) A dimensioned line diagram of the monopole showing the various load points and
directions of loading to be applied and table with the specified load.
h) Diagram showing the rigging arrangement used to apply the test loads.
i) Brief description of the test facility including the number, location, range and calibration
charts or tables of every load transducer, as well as the accuracy of the equipment used to
measure the test loads.
j) One table per test, showing the loads required at the various points on the structure and for
the various loading steps.
k) One table per test, showing the various deflection values which may have been recorded.

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I) In the case of failure:
i) a table showing the maximum loads applied to the structure, just before the collapse.

ii) a brief description of the failure; and

iii) The dimensional and mechanical characteristics of the failed elements.

m) A certain number of photographs, showing the whole of the structure and, possibly,
details of the failure.

16.0 Drawings & Data

a) Drawings & Data to be submitted by the bidder:

i. Fully dimensioned line diagram along with electrical clearance of each
monopole including Dimensioned line diagrams of extension.
ii. Various loadings calculated for evolving monopole design in a tabulated form for NC &
BW condition for every condition of design. iii. Loading diagram Tree for all monopoles
under different working condition.
iv. Dimensioned drawing of Anti climb devices. v. Plate / rolled sheet sections to be used.
vi. Foundation design calculations & fully dimensioned line diagrams.
b) Drawings & Data to be submitted on award of contract:
i) Detailed design calculations based on the complete analysis by space
frame method along with analytical method.
ii) Tabulation of stresses under different conditions & calculations for maximum permissible
stresses for various members / sections employed in the monopoles & cross arms complete
with the following information:
a) Member reference for identification on diagrams and calculations.
b) Aggregate loads, compressive and tensile with factors of safety, based on loadings
specified under different conditions.

c) Permissible crippling load.

d) Number & size (s) of bolt(s) provided.
e) Net Area of section.
f) Permissible tensile load.
g) Aggregate cross-sectional area of bolts.
h) Shearing stress on bolts
i) Bearing stress on bolts.
j) Detailed design calculations & detailed drawings of the foundations.
iii) STRUCTURAL DRAWINGS:
Provisional Structural Drawings and bill of material of each type of monopole shall be

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furnished.
C) After Monopole Testing:
After the successful monopole testing the following details/drawings have to
be submitted for approval:

i) Erection drawing/structural Drawings:

Erection drawings shall be furnished in respect of each type of monopole and shall show
assembled diagram of structures, clearly indicating the position of each member and the
quantity and the size of bolt for each joint.
Foundation drawings shall be furnished in respect of each type of monopole giving all the
relevant details about steel, concrete, foundation bolts & base plate etc.
ii) Bill of material:
Complete B.O.M. for each type of monopole shall be submitted with the erection drawings
indicating each part number, quantities required for one monopole, section thickness, length,
calculated weight, fabrication process done on each member / section and relevant design
drawing reference. The BOM shall also include the list of accessories required to complete
the structure.
iii) Bolt & Washer schedule:
Bolts & washers schedule shall list the number of bolts and washers required per monopole,
along with the sizes and lengths of bolts and number, type of size of washers.

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Technical Particulars of Monopoles

1. Environmental & Site Conditions

Ambient Temperature 50°C maximum / 0°C minimum

Relative Humidity 93% maximum / 10% minimum
Altitude 1500m above MSL
Wind Speed
44.7 m/s maximum
Wind design
ASCE-7 and relevant EN
Seismic Zone
UBC Zone 2 B
Rain Load 10cm (max. in 12 hours)
Wind Pressure (velocity) at every day conditions 39 N/m2 (@ 8 m/s)
Minimum Wind No Wind
Max. wind pressure (velocity), q 1199 N/m2 (@44.7m/s)
Maximum Wind gust, v 44.7m/s
Minimum conductor temperature 0° C
Everyday conductor temperature 45° C
Maximum conductor temperature 75° C (for continuous current rating)
Maximum conductor temperature 90° C (for sag/tension calculations &
short time current rating)

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 2. GENERAL PARAMETERS

Nominal System Voltage 33 kV

System Frequency 50 Hz
Highest System Voltage 36 kV
Power Frequency Withstand Voltage (1 minute) 70 kV (RMS)
Lighting Impulse Withstand Voltage 170 kV (Peak)
System Fault Level at Rated Voltage 40kA / 3 Sec
(3 Phase Symmetrical)

Minimum Creepage Distance for Insulators 1440mm

Lines Data

Length 4 Km
Number of circuits Double
Number of conductors per phase 1
Number of OPGW
Number of earth wire
Monopoles
Surface treatment Hot dip galvanized as ASTM A 123
Standard
Number of Monopoles Min 28

Span 150 m

Thickness 18-22 mm

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Length 18 m

Octagonal, Polygonal
Shape
Joint with insert mode, flange mode
Joint
22mm
bolt diameter
3m Coated above ground
Painting
Concrete foundation pits
Foundation Not embedded
Against earthquake of 8 grade
Design of poles
High strength cross arms
Cross arms
2.0 – 2.5
Factor of safety

CONDUCTOR
400mm2
ACSR
Zebra
Designation
Standard BS 215.2

Material ACSR

Diameter of Conductor 28.62 mm

Steel Stranding and Wire diameter 7/3.18 mm

Aluminum Stranding and Wire diameter 54/3.18 mm

Area of conductor 484.5 mm²

Nominal Aluminum Area 428.9 mm²

Weight of conductor 1621 kg/km

Ultimate Tensile Strength (UTS) 130.32 KN

Modulus of elasticity 7034 N/cm²

Temperature co-efficient of linear expansion 19.30 X 10-6/°C

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Continuous current rating (80°C) A

Short time current rating (90°C) NA

Max. DC resistance at 20°C 0.068 Ohm/km

Maximum Conductor Tension , Initial Conditions,

5oC, w/900N/m2 wind force used for single NA
conductor in kgs

Maximum Conductor Tension, Initial Conditions, NA

5oC, w/900N/m2 wind force used for twin
conductor

OPGW
Voltage Level 33 KV

Stranding Aluminum alloy diameter 5/3.22 mm

Aluminum clad steel Wire diameter 7/3.22 mm

Overall diameter 6.72 mm

Sectional area -
Aluminum alloy 88.7 mm

Steel 57 mm

Total sectional area 45.7 mm

Approx. Weight 639 Kg/km

Calculate de resistance at 20 C 6.52 ohms/Km

Min. UTS - 9177 Kg

Modules of elasticity 14140 Kg/mm2

Co-efficient of linear expansion - 16.7x106 /C O 53 Co

Max. Allowable temperature

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