stallation delivering 440 psi.

Several trial installations with

a compressor pressure of 3,000 to 4,500 psi have been in service

for several years. This innovation gives manufacturers coInsiderably miore freedomi of chioice as regards the breaking

chanmber pressure.

Isolating switches comprise, in principle, two rotating insulator colimns upon which the contact arms are mounted.
The latter rotate in a horizontal plane. The modern tendency is towvard isolators of the pantograph type.
Originally the busbars complrised twin conductors of copper,
but this material was later replace(l by aluminum. In recent
lyears tubular busbars have been introduced, wrhieh in coinbination with pantograph-type isolating switches appear to

*yield economnies.
Transmission lines are protecte(l by distance relays, supplemented by special ground-fault relays, necessitated by the
long sections, which result in low fault currents in the event

Fig. 12. 400-kv air-blast circuit breaker

dividers, on the line side of the by-pass isolating switches for

the line circuit blreakers. Tran.sformer current transformers
are located either in the transformer bushings, or in the end
boxes of the associate(l cables.
Anmaini and( a transfer bus bar are used in the 400-kv switechyards. I'he transfer breaker serves as a common reserve for
both the line and transformer breakers. Occasionally the
breaker for a short line is omitted, the transfer breaker being
used for this line, whei niot otherwise occupied.
WVe demanid that circuit breakers shall be restrike-free on
line-dropping at 550 kv. Initially only air-blast breakers
with many serics-conneeted breaking chainbers could meet
this requirement. However, minimum oil breakers are now
built on the satie principle, thus giving us more choice.
The earlier types of air-blast circuit breakers were litted
withl synchronized isolating switelses, whichi however gave
(luite a few mechanical difliculties, and occasionally failed to
co-operate witlh the bheaking chamber. MIanufacturers lhave
IIow dispensed with the isolator, thus improving ami(I simlplifying the design; see Fig. 12. I'he working plressure in the
breaker has usually been 220 psi, the central compressor in-

of remote faults. Iligh-fre(luency links betweeni the en(ls of

the faulted line ensure immediate tripp)ing for all fault locations. Three-phase high-speed reclosure is general, but
single-phase reclosure is sometimes employed. Transformer
protection includes differential protection and 1Buchholz relays. Only exceptionally do busbars have relay protection.

Conclusion
The service experience obtainied from the Swve(isli 400-kv
network has exceeded our expectations. 'Ihe introduction of
400 kv resulte(d in a reduction of specific transmission costs by
about 40%, compared with those at 230 kv. We can, however, never be satisfied, and arc continually searching for better solutions to problems. In this connection it shoul(l be
noted that consumption in Sweden, just as in most other
countries, is doubling about every 10 years. The solutions
whllich were ideal 10 years ago can scarcely represent an optimum in the futuire, when many timles the present loads must
be expected. Therefore, it can be said of power engincerimig,
plerhaps to a greater degree than of other branches, thatt a
stationary condition is, in reality, the same as retrogressiomi.
Simultaneously, a power network requires the investimient
of considerable suimis of money. A small country such as
Sweden can scarcely by its owII efforts find the solutioni to all
its problems. A.n intimiiate co-operation across national
boundaries is therefore in the best interests of all.

Construction Aspects of the Pinard-Hanmer

500-Kv Transmission Line
G. A. IacAkie IV. A. R?. Leire S,nior Mlebser IEEE
Summary: This paper describes (onstruction aspects of the
northern 228 miles of Ontario Hydro's new 437-mile 500-kv EHV
(extra-high-voltage) bundle conductor transmission line. Because of rigid specificationis and new designi features, new construetion practices had to be developed in many areas, particularly
foundation construction, tower erection, atd the tension stringing of a 4-conduchtor bundle.

Ontario hlydro's decision to enter the EHV transmission field

with a single-circuit 500-kv transmission line confronted its
construction (division with a coml)lete reassessment of existing
MARCH 1964

methods and equipment to mect the rigid specification and

prototype designs proposed by Hydro's transmission engrtpr
gieers.'
Four-conductor bundle construction and V-towers, supported by guyed anchorages, were all new to the HydroElectric Power Commission of Ontario. Hence, background
was lacking, and construction methods had to be developed.
To minimize radio interference and corona loss due to
conductor abrasion,2i it was (lecided that all conductors
would be strung under tension. To ensure that all cables

Mackie, Lemire-Construction of Pinard-Hanmer 600-Kv T7ansmission Line

205

A Fig. 1. Map of 500kv transmission

line between Pinard and Hanmer

in each bundle retain their relative sags in the future, it was

also necessary that all four be pulled and tensioned simultaneously. The basic methods for doing this were not new, but
they were not sufficiently advanced to provide the trouble-free
high production necessary to build the line to the specifications and schedule required. Therefore, a complete sequence,
involving suitable equipment and methods, was developed.

The support of V-towers by means of guyed anchorages presented problems at some tower sites where difficulty was encountered in obtaining anchors strong enough to hold specified
loads.
That portion of the line from Pinard to Hanmer traverses
228 miles of terrain, as seen in Fig. 1, varying from razorbacked ridges, between 100 feet and 150 feet high, to locations
where 80 feet of pile had to be driven to secure bearing. Access is limited along the line to the terminal areas and three
other points, as shown in Fig. 1, at mileages of 46, 98, and
156.

\5NPINARD-X

The northern 100 miles of line are almost impassable as they

I) \ \ 5 \

\ \
:A

Ml

IT)MIpMlNSr / E 7 /

are flat muskeg swamps. The next 70 miles provide the

transition from muskeg through swamp to gravel terrain, all
without access. The last 58 miles is rough, rocky terrain,
interspersed with some swamp. Throughout its length, the
OGHRANEright of way was heavily forested with growth indigenous to

<'

the area.
Road construction, camp erection, and material supply to
such a right of way was a major consideration in building the
line, as was the direct selection of equipment for performing
various construction operations. Terrain also dictated the
season for economic construction. This limitation complicated a schedule that required the line's completion in 20
working months.
Planning and Scheduling

PRELIMINARY PLANNING
560

X t

ol

(n( ^t

<\MILEAGE 156

CAPREOL

MILEAGE 228 HANMER

_ _ t (S ~/

=A

Paper 63-1038, recommended by the IEEE Transmission and Dis-

tribution Committee and approved by the IEEE Technical Opera-

tions Committee for presentation at the IEEE Summer General

planning for the line was formulated by the

sePreliminary
planning, line, and station departments of Ontario Hydro's

construction division, starting nmore than a year in advance

of actual work commencement. The plan was based on 228
miles of line being completed between November 1961 and
October of 1963. Because the completion date was firm,
being predicated on servicing of the Mattagami River plants,
the rate of progress was varied denending upon terrain and
experience.
The preliminary schedule, Fig. 2, indicates that 30 miles of
foundations and towers and 15 miles of stringing would be
completed in the first winter. This original assignment, while
minimal from a construction standpoint, would provide the
basis for completing the entire program on schedule and would
highlight any problems that had not been foreseen when first
deciding upon work methods. As terrain was a governing factor, muskeg areas were put on the winter calendar whenever
possible because access and transportation in such areas are
more economical ovter frozen ground. All four major construction divisions are tied to the terrain, and their mlost
suitable construction season is shown.
DETAILED FIELD PLANNING

To complete the broad 4-part construction program within

the stipulated time, each phase had to be broken into its
1963.components and the components scheduled on an individual

Meeting and Nuclear Radiation Effects Conference, Toronto, Ont.,

Canada, June 16-21, 1963. Manuscript submitted March 18, 1963;
made avilablefor
prnting Aril

23

Th*prto

G. A. MACKIE and W. A. R. LEMIRE are with The Hydro-Electric

bais
bss

of Ontario Hydro's Research Division.

progress rates achieved on the previous line section, an over-

Power Commission of Ontario, Toronto, Oat., Canada.

The authors gratefully acknowledge the assistance of various members
206

mngmn

prto

a
a

odce
odce

ru,wihi

Mackie, Lemire-Con8tructiern of Pinard-Hanmer 500-Ky Transmission Line

ytecntuto
ytecntuto

il-oae.Bsdo

MARCH 1964

all rate was established for clearing, roads, camps, founda-

come too extended. If camps have to be erected ahead of

schedule, this will result in the overcapitalization of camp
equipment and precludes the scheduled reuse of the camp
facilities.
To minimize costs of work equipment, construction schedules were reviewed with regard to terrain, and purchases were
based on a 100% load factor for all types of machines under
average conditions. Rented equipment is utilized to relieve
peak demands. Under the worst ground conditions, the fleet
was increased 45% of capitalized value by the use of rented
equipment. Daily scheduling of aircraft and specialized
muskeg equipment is part of the program designed to ensure
the minimal rental and the maximum usage of all special
equipment.

tions, towers, and stringing such as would assure on-time com-

pletion of each division. The over-all period was divided into

20-day targets, and if all crews achieved their goals, this would
maintain the required rate for the section of line under construction.
Results from each group are collated weekly and charted
against the target rate. Fig. 3 illustrates a typical target
schedule for tower construction. It is a simple matter then to
detect declining progress and to take necessary corrective steps
or, if the converse is true, to compensate for an increased production rate by reducing the staff. All supervisors are required to be aware of progress in the over-all field as well as
in their own area of responsibility. Senior staff meetings,
therefore, are held weekly or daily as necessary to discuss
critical areas and plan such action as will keep the job on the
move and up to date.
Tension stringing of bundle conductors will pace all phases
of the schedule. Since dead-ending structures are as much
as 100 miles apart, the difficulties of jointing the bundles in
mid-span, if strung from opposite directions, means stringing
has to be unidirectional. Once the required rate for over-all
job completion has been established, all operations are keyed
to it. It is, therefore, essential that tower erection and foundation construction precede stringing with sufficient lead that
neither of these two operations hold up the other and ultimately impede the conductor crews. Another essential is
that the leads required for economic construction do not be-

10

CLEARING

20

30

40

CAMP

LROADS

ROADS

I 1 11 11

4 5

6 78 9
NO

~~~~~NOV.9 1962_

PRODUCTION RATE

2.5

99 WORKING

DAYS

FOOTING

)~0

EREGTlOaiN|

cW

CD

CD

CD

CD

I_

MCONDUC1TOR
|

I I
.~~~~~~~~~L

D|

1<

40

60

50

70

80

11

N
,

N|

*D

COMPLETE
JULY 18

120 130

DEC. 30 1962

AS OF JULY 18, 1962

JULY 19 1962

|-|
D

110

17 18 19

PRODUCTION RATE 2.5

FOUNDATION / WKG. DAY

I100

34 WORKING DAYS-

100

90

l1
I
T ZIIXI

12 13 14 15 16

COMPLETE AS WKOGJUYD1/62FDN./
Z OF JULY 18/62 PRODONWKG.RATEDAY3.8
COPLEE/A

PRODUCTION RT
0.6 MILES
/ WKG. DAY
130 WORKING- eDAYS

0..
0

/WKG. DAY
115 WORKING DAYS
|N GN4

30

20

COMPLETE AS OF JULY 18,1962SEPT. 1.1962I

10

TOWERS
~~-CD

ERECTION

10

AUG.3.1962-

CD2.5

PRODUCTION RATE

TOWEUCTOR

90 98 0

-COMPLETE

ROAD

SEPT.T,1962

FOUNDATIONS

-,

80

|SEPT?1|AL3;962III

|C O N STRN|DN|

70

-COMPLETE JULY 18,1962

C-ONTRACT
NOV. 30,1962

CONSTR'N
CONSTR'N F_

60

50

STRINGING EQUIPMENT, GENERAL

The line conductors are bundled, four per phase, 0.9-inch
diameter, 18 by 7 ACSR (aluminum cable, steel-reinforced),
clamped in an 18-inch square configuration. Stringent
conductor handling specifications, to minimize scratches or
abrasions to the conductor and ensure similar treatment of all
conductors during the stringing operation, were the basis for
deciding to tension-string the bundle of four conductors
simultaneously, with one pulling line. To assist in the selection and development of stringing blocks, running board, and
pulling line, a 1-mile test line was constructed.

MILEAGE
SCHEDULE
L E A G E

E.H.VM

OPERATION

Equipment Selection

AS OF

O /62

{D0
CDC,

t
6
6z
D a

PROD'N RATE
D

|)

ND

O*W

Ct to

/WKG DAY
105 WORKING DAYS

C-iCDC
O

AS OF

D
R'ATE

0.8 MILES
DAY
85 WORKING DAYS

PRODUCTION

JULYIF8 g /62

-,

n)
PRODUCTION
RATE D 2.3

TOWERS

PROD'N RATE MILE

/ WKG. DAY P
r_
o50 WORKING DAYS
<
S|~OD|co

COMPLETE

a
4

U.
Q

TOWERS/WKG. DAY
WORKING DAYS
_56
N N
{C)

0.

WORKING DAYS

ofW

1<I0.

'1'D'
.~
4

Fig. 3. Target schedule

200

150

50

DEC

_SEpy -4/ QCT.

12

24

36

48

WORKING

72

60

84

STRINGING BLOCKS
Five-sheave 21-inch-root-diamiieter stringing blocks are
usLed to string the line. The sheaves are mounted on a
commnon horizontal axle and rotate independently. The
piulling line rides in the flame-hardened groove of the ductile
iron center shcave. Tle four conduietors ride in polyurethanecoate(l magnesium-alloy sheaves, two each sile of center,
See Fig. 4.
'lThe importance of designing the equipment associated
with the stringing blocks so that it performs as an integrated
Unlit is illustrated in Fig. 5. C(uIve A indicates that a poorly
designed running board can impose large load fluctuations on
the tower arm. Curve B illustrates how improvements to
the running board can reduce these loads. These curves
were obtained by instrumenting the suspension insulators on
the test tower and( pulling the bundle through the stringing
block. Deflection of this instrumented string of insulators
lends a definite measure of efficiency to the equipment when
passing the stringing block--as can be seen from the deflection notation on the graph.
To eliminate tIhe possibility of conductor abrasion, the
sheav (es mu.st be suitably lined. Polished stainles steel was
inivestigated but proved too expensive. Existing neopre-nes,
tested for wear an(d cold-weather performance, were found
unsatisfactory since crystallization occurred at a relatively
higlh teml)erature and the brittle points were in the vicinity of
-25 F (degrees Flahrenheit) to-44 F. Refer to Table I.
Investigation resulted in the selection of a polyurethane
formulation of the poly-ether toliene di-isocyanate type. It
is oil-resistant and noncrystallizing. It has a brittle point of
-90 F. As may be seen from Table I, its tear- and abrasionresistance characteristics are excellent, and general operation
with this material in a temperature range from -50 F to
+100 F has been satisfactory. It should be noted that the
choice of polyurethane fornmulation is vital in obtaining proper
characteristics.
Sheave bearings were specified to be free-running at -50 F
and yet to be shielded against dirt penetration. All prototype
equipment was laboratory and field tested to ensure specification performance. Sheave spacing, of course, determines
horizontal conductor spacing during stringing. Price, weight,
208

96

108

117

DAYS

and manageability dictated that sheaves be placed as closely

together as possible, consistent with minimal conductor damage inflicted by clashing during stringing.
Tests were performed to determine the extent and frequency
of this damage. Conductors spaced 35/i6 inches apart, center-to-center, made up to 42,000 contacts in two spans of line
during a 24-hour perio(l. Conductors separated by 16 inches,
center-to-center, made ap)proximately 10,000 contacts in the
same length of time. However, by varying the sags of the
individual conductors of a bundle so that they were not all in
one plane, the number of contacts was reduced to 1% or less of
the test figures just quoted. From observation, it was established that conductors shadowing one another were attracted
to contact under light, steady wind conditions. It should be
noted that single isolate(d conductors would not move under
the same conditions.
Conductors were removed after a wvck of such contacts for
laboratory examination. Some flattening of strands was

Fig. 4. Multiple-sheave stringing block

Mlackie, Lemire-Construction of Pinard-Hanmer 600-Kv Transmission Line

MARCH 1964

6,000

CURVEI
' 1l C(URVE
[

Fig. 5. Fluctuations in load applied to

insulator string by passage of:

A-Prototype running board

B-Same board after improvements in
design

4,000

,0C L___v_

__

0. 2 000;Cq

10.0

____

0.20.4

S ECONOS

0.6

0.8

visible to the eye, but corona tests indicated a voltage gradient

of 21-ky rms/cm (per centimeter), which was satisfactory
for our purpose. No change, therefore, was considered necessary in stringing procedure, and final minimum sheave spacing
was established at 43/4 inches center-to-center.
Selection of the stringing block,v Selection
per se, did not solve
the stringing and shock load problem. Selection of the block
depended on the supplier designing a running board that
complemented the block and worked in unison with it. Consequently, the contract was awarded to a supplier who was
found capable of both the designing and the fabricating of the
two units.

I.0

TENSIONING AND PULLING EQUIPMENT

Tension stringing can be defined as the application of power
to the leading end of a conductor or group of conductors
while braking the trailing ends. This can be achieved with

man cobntosadtyev
oftesriningblok,prs,ddnThe
decision is simplified by thefeupet
capacities available and the
v v

PULLING LINES
Pulling lines utilized in tension stringing require minimal
weight, maximum strength, and antispin characteristics to insure that the rope remains stable, regardless of abuse, during
the operation. To hold the conductors 10 feet above ground
at all times, a minimum stringing tension of 2,200 pounds per
conductor is required. It was established that the conductor
tension at the tensioners and pullers differed due to flexing,
friction, and diameter of the sheaves. For this job, a pullerto-tensioner ratio of 3 to 1 was assumed. The pulling line
would, therefore, have to be capable of handling at least a
25,000-pound load. A 3/4-inch wire rope was selected, and
tests were conducted on various strandings to determine a
type most suitable for the job.
Spin-resistant-type ropes were shown to be superior to
standard ropes having all strands layed one way. Spinresistant ropes, having a 50-50
ratio perhaving outer-layer-to-core
outer-layer-to-core ratio
formed very well; see Fig. 6. As the percentage of outer
strands increased, the spin-resistant effects decreased. However, ropes having the 50-to-SO ratio were very unstable and

difficult to handle and it was found that a compromise had

to
be
reached~~~~
bewe
~stblt annclsplnresstace.lne
spi rstac.Th
to b reche
beweenCstbllty
final selection was an 8 by 19 Seale construction with an in-

dependent wire rope core, having a ratio of approximately

75 to 25; 180,000 feet of' this
type of rope was purchased in
'
7,500-foot leng,ths. To date,
one failure havs occurred for
which there is no explanation. Present experience would indicate a minimulm life expectancy of 25 uses per rope when
operat,ed
witha
safety
facto

MARCH 1964

of

Mackie,

to

liiAtin
upocase,
qimn hog nweg n
th a completely
In this
experience. plce
hydraulic system was
selected. See Fig. 7.
v
The puller was chosen for capacity, pulling line take-up
system, and control. As in the selection of pulling lines, the
puller-to-tensioner ratio of 3 to 1 was considered in draw-bar
horsepower (hp) calculations. The pullers selected are powered by hydraulic motors. Pressure is obtained through a
pump operated by a 250-hp gasoline engine. To move the 4conductor bundle, two of these pullers are reaved in tandem.
The bull wheels of four of the five pullers selected for the job
are neoprene lined. The fifth unit has bull wheel rims of
stainless steel. To date, there has been insufficient experience
to state conclusively which material is superior for this purpose.
The tensioners selected werehydraulically actuated through
a 36-hp gasoline-engine-driven pump. The braking capacity
was calculated from the stringing tension and required line

Table I. Comparative Physical Characteristics of Elastomers

Used as Liners for Stringing Sheaves

Durometer Hardness(Shore A)
Tensil Strength,Psi

Wear Resistan;ce, Milligram Loss

Compressive
70 Hours @ -7 F
Per-Cent SetSet,
Remaining
Brittle Temperature

Neoprene
Sample
~~~~~~~~Sample
A
B

83

2,1470

526
74%
-25 F

Crsalzn eprtr
1
Coefficient
of
Friction
1.5
in Hardness, 24 Hours t@ 32 F
~~~~~~~~~~~~~~~Increase
+ 72 Hours@-10 F
8
Note: All values obtained by American Society

Polyurethane

84

2,525

-44 F

(PolyEther
Type)

90
4,8430

112
45%
-90 F

1
ocytl-zn
0.7
13
4
for Testing Materials
methods. Neoprene materials were those supplied by two string

3l/2.Polyurethane was material used to line sheaves for this job.

Lemire-Construcotion

of Pinard-Hanmer 500-Ku Transmission Line

209

Fig. 6. Rotation characteristics of wire

ropes
Curve C-Spin-resistant rope with ratio
of steel in outer-layer strands to corestrands of 50 to 50
Curve D-Spin-resistant rope with ratio
of steel in outer-layer strands to core-

strands of67to33

-YPETYPE C

30

TYPE
-TYPE D_

25

l
m.g 20 t___
/
.

Curve E-Spin-resistant rope with ratio

of steel in outer-layer strands to corestrands of 74 to 26
Curve F-Regular wire-rope stranding,
all one way

//

./ ^/_

7//
/ _

_-_ _-_ _ - _ _ _ =_ _

10
12
ROTATION

--_-_

__-TYPE F

is
20
14
16
(NO. 360 TURNS)

22

24

26

28

30

used, is a normal operation in any line construction project.

Muskegs deeper than 2 feet require a ground pressure of less
than 3 psi for access. Excavation and piling problems in this
terrain were solved by using 1/2-yard shovels with 48-inch
swamp pads. See Fig. 8. These machines were equipped
with augers and 1/2-yard backhoes and could be adapted to
pile driving by adding 40-foot aluminum-alloy driving leads.
This machine could dig 17 feet when rigged as a backhoe and
was satisfactory for all purposes.
For shallower excavations and the same ground pressures,
a 3/8-yard backhoe and auger were mounted on a muskeg
tractor. This machine has a ground pressure of 2 psi and is
versatile where access takes precedence over production.

speed. The four units, each tensioning one of the conductors

in the bundle, are controlled by one operator through a control console.
Four features were considered and verified in practice when
selecting tensioning equipment:
1. Flat control must be maintained on the bundle to
minimize oscillation.
2. Postive tension on the pulling-line take-up is necessary
to prevent kinking and, on the conductor, in payout to keep it
clear of the ground.
3. Level wind control is needed to prevent conductor damage and simplify pulling-line take-up.
4. Adequate cooling is required in both tensioners and
pullers.

MATERIAL

EXCAVATING
Foundation excavation, where standard tracked equipment
of 6 to 7 psi (pounds per square inch) ground pressure can be

Ground pressure was the governing factor in selecting

equipment for delivery over muskeg. One special piece of
equipment was developed for handling the 6-ton cable reels.

Fig. 7. Hydraulic tensioning machines

for one bundle of four conductors
210

Mac7cie, Lemire-Conetruction of P;nard-Hanmer 500-Kv Tranamisaon Line

MARCH 1964

GENERIAL FACTS

The foregoing discussion indicates that the backbone of the

fleet is the lowv-ground-pressure 11,000-pound payloadcapacity muskeg tractor. Twenty-two muskeg tractors are
attached to the job, 16 of nwhich are 11,000-pound capacity
units.
Also important and equally versatile through areas other
than inuskeg are the conventional types of equipment for
this work; that is, the class 3 tractor, 4-wheel-drive truck, and
5-ton line body truck.
The fleet is capitalized at approximately 2-million dollars
for this job, exclusive of rentals which amount to an additional
3/4 of a million. The job must be equipped to handle maintenance and overhauls. A rigid routine maintenance program
was established and portable garages were built as work progressed down the line. This work is supecrvised by a mechanical superintendent with a staff of 15 mechanics.

__

Fig. 8. Pile driver with aluminum-alloy leads mounted on

shovel with 48-inch-wide tracks for muskeg travel

See Fig. 9. This machine can load and unload reels with minimal help and traverse muskeg terrain with a full reel of conductor. The cable-handling device was developed to minimize
rough reel handling during delivery.
For taking 6- to 10-ton loads to muskeg areas, a dual-drive
48-inch-pad tracked transporter was obtained. This equipment carries tensioning and pulling equipment where terrain
dictates.

Clearing
Five-thousand acres of mixed bush were cleared in preparation for the construction of the transmission line. This work
was performed by individual contractors for 72% of the acreage cleared, and the balance was cleared by two major

lumbering organizations.
Strict specifications controlled the piling of timber and burning of slash or debris. All tops, limbs, and trunks down to 4
inches were burned, the balance retained in situ for corduroy

or later sale, depending on the species and market. Piling

fire break from the edge of the bush and the foundation areas
clear.
Production was forecast on the basis of one man clearing,
piling, and burning 3/4 of an acre per week. Gang strength
was maintained to complete 10 miles per month. Gangs were
provisioned and moved by truck, canoe, fixed wing aircraft,
and helicopter. Work progressed through all seasons including the summer months of high fire hazard. The clearing was
conducted under the fire regulations of the Provincial Department of Lands and Forests. During the complete clearing
operation, there was no loss by uncontrolled forest fire resulting from our work program.
was restricted to four sections of the right of way, leaving a

Fig. 9. Wide-tracked muskeg vehicle for

transporting cable

MARCH 1964

Mfackie, Lemire-Construction of Pinard-Hanmer 500-Kv Transmission Line

211

Roads and Camps

Rloads arc required on the right of way for actual construction and off the right of way to connect with tote roads, trails,
anrlcamp sites. Roads vary from .a simple bulldozed trail
to triple-corduroyed brush-based gravel-top roads in muskegs.
In wintcr, ice roads are constructed.
All roads constructed were minimal, providing a future
base for maintenance of the line, but designed for 4 to 6
months' access only. The roads are located from aerial
mosaics, combined with ground and air surveys. Heavy cuts,
fills, and bridging are eliminated where possible by balancing
against the cost of additional road miles. Our experience
indicates a ratio of 1.4 miles of road to 1 mile of right of way
in this part of the country.
CAMPS

Camps were locatedi every 10 miles alonig the righit of way.

An all-year construcetion program. required all-wveathier caimp
facilities, and a sandlwich-type sectional building used extensively in the Arctic was selected. These units are16 by 28feet
and sleep) 8 mien. The basic camip houises 64 meni anid utilizes
13 of these structures combined as follows: 8 dormitories,
a combination of 2 buildings for cooking, 1 wash hut, 1
office, and 1 recreation hut. Sufficient buildings were purchased for four suchl camps, but these were supplemented
with canvas camps in the suimmer weather and, as necessary,
lined canvas for winter.
Camp hcating is accomplished by oil andl lighting by 25-kw
diesel generator sets.

Fig. 10. Tower erection method for rough terrain, building

from top down

Material Handling

In addition to the specialized equipment already discussed, conventional cquipment is utilized for material
delivery where access permits. The bulk of material for 228
miles of line was delivered to 6 locations by the suppliers and
rehandled to camp locations or tower sites, depending on
the material to be delivered.
Specialized material gangs deliver towers, hardware, conductors, and insulators directly to the tower sites. Foundation
material is sent from the main receiving depots to the camp
yards. Since the specific type of anchorage to be used frequently cannot be determined until the hole is opened, final
delivery of foundation material is left to the footing crews.
A helicopter was employed for camp and tower delivery as
an experiment in handling and to obtain cost data. These
machines were excellent for dropping camps in impassable
terrain, but the cost for tower handling averaged three times
more than by conventional methods. This machine was
abandoned, therefore, except for use in regions where access
could not be gained with ground equipment.
The prototype design of the line slowed delivery from
manufacturers. This complicated the work of the material
handling section. At the outset of the job, the rate of
delivery from the manufacturer of hardware, fittings, and
footing material was hardlv sufficient to keep ahead of installation. Continuous rehandling to keep crews active was ex-

pensive and time consuming.

Communications
Work on a long transmission line cannot be confined to any
50-mile stretch at one time. Radio communication from the
base of operations to every camp, between camps, and
between gangs is essential.
Base-to-camp and camp-to-camp communication is
212

achievedbyAM (amplitude-modulated)single-side-baud trais

mitted
il)tllations
and receivers. Terrain,l
Terrain, pooraerial installations due
mitters
to temporary locations, and inherent faults in
t
aithcllinmyen)
resulted inipooroservice from this communication sysemi.
For communication over distances of less than 15 miles
between gangs, superinttendenits, or aircraft, mobile and( portable FM (frequency modulated) equipment is utilized . Seventy-fivc of these units are on the job and the results within
their range is generally satisfactory.
r

Foundations
Installation of 800 tower foundations of the
o 800 versatieeq ofeth ityc
Instalatin
in reference 1 required versatile e(uil)ment
flotation characteristics to permit using any combination of
the described anchorages at any one location. Low ground
pressure requirements and equipmentsclection have already
been discussed and, from these discussions, it is obvious that
the major problem in foundation setting is manoeuverability of
equipment, both between tower locations and between
anchorage locations. This, however, is only one difficulty.
Soil borings prior to excavation, while providing valuable
indications, did not provide conclusive evidence of the type
of footing required at any one place. It was, therefore, not
always possible to determine with certainty the proper
anchor material to transport to each site before
started. Since many excavations were unstable, itexcavation
was mandatory that anchorage material be on hand for immediate use.
This necessitated transporting, under difficult conditions, a
surfeit of various types of anchorage material in order to
perform a specification job.
The average rate of progress to date under muskeg conditions is about 1/2 an anchorage per day per gang. Between
8 and 9 footing gangs are usually engaged, the production

Mackie, Lemire-Construction of Pinard-Hanmer 500-Kv Transmission Line

rescrlibed
withnrcasontable

MARCH 1964

being about 3 towers per day for the complete footing strength.
Considerable time is expended relocating to new camps and
moving pile-driving equipment.
Each anchor is required to be load checked with a dynamometer, and the anchorage test pulled by the hydraulic
system of the digging equipment, to assure specification installation.
Tower Erection

V-guyed tower erection had been accomplished in various

ways in North America, prior to erection of the EHV line.
Towers had been carried in their entirety to tower sites by
helicopter, set on the footin-g, and tied off temporarily. In
other locations, towers were tipped into position, using mobile
or crawler-crane equipment. Due to the size and weight of
the V-guyed tower, the helicopter was ruled out. Difficulty
of access ruled out the mobile crane as well.
The first 15 aluminum V-guyed structures were built,
utilizing two conventional gin poles, the tower being constructed from the bridge down; that is, the completely assembled bridge was carried by the gin poles, the V-leg sections
being added as the bridge went up. See Fig. 10. This
method was slow and was developed only for locations where
the methods next described were deemed impractical because
of ground conditions.
Tipping the tower was recognized as the simplest method of
erecting a V-structure. Due to the design criteria, with the
tower footing being a straight compression member, it could
not be used as a fulcrum. Lifting thrust was obtained by

the hydraulic system of the tractor blade and set down on the
footing. On poor bearing, the tower is lifted to its footing by
utilizing front-mounted winches located on the swamp
tractor. Low ground .pressure and light angle towers required two such units for tower lifting.
Erection crews, under ideal conditions, can erect two towers
per day. Normal progress is about 11/4 towers per day per
crew. Each erection crew consists of a foreman, 2 linemen,
and 8 groundmen. Separate tower-assembly crews, consisting of 12 men each, can assemble one tower per working day.

Equipment for these operations varies with terrain.

For erecting the towers by tipping, sectional 80-foot
aluminum-alloy gin poles with special open sheaves at the
top were fabricated of the same extruded sections as the
aluminum towers. This made their construction and purchase less expensive and spare parts easily obtainable. The
poles are in 20-foot sections and have a 30-inch face, and will
safely lift an axial load of 45,000 pounds when vertical.
They were designed especially for the job by the tower manufacturer in conjunction with Ontario Hydro's construction
methods engineers. Two 140-foot gin poles were obtained for
tower erection where steel towers were to be erected by the
conventional lift method. These gin poles have a 36-inch
face and are capable of Awithstanding an axial load of 25,000
pounds when vertical.

Stringing
A tension-strung 4-conductor bundle can be put in the air
i av
o w s
in a variety of ways. It can be strung singly,, in pairs, or four
open .sheave
passing the pulling lines of drum winches over an~~~~~~~at
gghas been
b
.
a time. Bundled conductor stringing
done elsewhr b u
at the top of an 80-foot aluminum gin pole. The first towers
all
the
.
.
.
~~~~~~~where
of
with
some
by utlizing
foregoing methods,
erected by this method utilized two gin poles with two tractors
more
success
than
others.
providing the winch power. Later this was changed to
Economic studies were prepared on all known methods insingle gin and two part line with single tractor as shown in
bundled
conductors. As a result,
Fig.11.Thismetod
eimiate the
theeretionanddis
volving
erection
Fig.l This methodeliminate
anwas
decided to pull the bundle of four simultaneously. Thisit
mantling of one gin pole, as well as the necessity for using
decision having been made, the considerations outlined earlier
one of the two tractors.
in
the paper concerning equipment selection were applied,
As previously mentioned, the footing does not permit side
peiuerating
blcs and plng line.
tower is held back a tractor as a
thrust, so the base of- the
and pulling line.
' . natural anchorbv<when
stringing blocks,
~~~~~~~~~~~~~~pullers,
dead man or by a convenient
available.
. .
T s
o
c
The same problem exists with temporarv side-guy anchors.
per month. Based on experience, it was felt that, using a
.
or muskeg
Under difficult swamp conditions, four <tractors
configuration of 4 tensioners with 2 pulling units in tandem,
tractors must be used to bring the towa-er to an erect position.
t would be possible to cornplete about 11 miles per month.
toe
erceits tipping base ..
inpsto
isshl
n position
The erected tower
on
held
.
~~~~~~~~~~~~Twso
.
sets of equipment,
therefore, were ordered.
Subsequent
qimn,teeor,wr
ree.Sbeun
initially by its two permanent back guys and is stabilized by
delay
of
specifications
and
materials,
and
difficulty
of access,
the addition of the remaining permanent guys, left slack.
a rescheduling to 20 miles of line strung per month.
required
Lifting onto the tower footing is accomplished in a variety
The two sets proved adequate for this rate of progress.
of ways, depending on the tower type-whether it is aluminum
or steel--and the terrain where the tower is located. On firm
PROCEDURE
footing, an aluminum or steel suspension tower can be lifted by
The orders for conductor called for 14,000-foot reels so the
stringing program was based on 14,000-foot conductor settings. Experience proved that the equipment was adequate
for 28,000-foot pulls, so the method was readjusted accordingly. For purposes of this paper, procedures and methods
are based on 28,000-foot conductor pulls.
total stringing crew of 90 men is broken down into in~~~~~~~
>
~~~~~The
_
sulator-hanging crew, pulling-line crew, tension, sagging, and
-- RAISING BLOCK-< '\~~~~~~~~~~~~clamping crew, and a spacing crew.
<--.
~~~~~~~~~Sufficient
~~~~ 3/4-inch nonspinning pulling line and stringing
~~~~~~~~~~blocks
are carried to work continuously on two 28,000-foot
>
~~~~- ~~~~~settings. Each setting consists of 20 towers, required 60
blocks, and 90,000 feet cf rope. To allow for a continuity of
~~~XX ~~~work, a total job stock of 120 stringing blocks and 180,000
feet of pulling line is needed.
Fig. 11. Tilt-up method of erecting towers
The insulator crew moves ahead and hangs a string of in-

.a

tension-strungr

The~~~~~~~~~~~~~~~~
onistpilbs

MIARCH 1964

MIacicie, Lemire-Construction

Tw.eso

of Pinard-Hanmer 500-Ks Transmission Liine

213

sulators complete with stringing block at each of the three

conductor positions on the tower. A finger line is hung on the
center sheave of the stringing block.
The pulling-line crew follows, and the finger line and a
lighter lead line draw the 3/4-inch nonspinning pulling line
through the center sheave of the block. As explained in the
section dealing with pulling-line selection, a positive tension is
always maintained on the pulling line. This is achieved by
paying it off braked reel stands. Each pulling line is 7,500
feet long, and lengths are connected by a swivel having a
working load of 15 tons.
Tension and pulling machines are located, the pulling line
secured to the running board by a 15-ton swivel, and, in turn,
the four conductors are connected to the trailing end of the
running board by basket-weave pulling grips and 5-ton
swivels. Two reels of conductor are paid out for each tensioner in the setting. The construction joint, going around
the bull wheels of the tensioner, consists of two cable grips,
back-to-back. The permanent joint is made after this
temporary splice clears the tensioner, the leading conductor
Fig. 12. Motor-driven aerial car, used to install spacer
being maintained at stringing tension by means of a front winch
dampers
mounted on each tensioner.
from
varies
tension
To date in this operation, stringing
8,000 pounds--4 by 2,000 pounds at the tensioners-to 16,000
and carrying them one setting ahead. In such an operation,
pounds at the pullers for an approximate ratio of 2 to 1. It
avearryndthe owe setting gangs sue at leation
we have found the tower building gangs should be at least 60
is conceivable that this ratio will increase with rougher
g
ato
terrain and numerous angles. For convenience in maintainiinevitor
gperform
tesg
Tension stringing is performed to minimize conductor
ing equal tension on all conductors, tensions for each condamage. The conductor itself must, therefore, be handled
ductor of the bundle are controlled through a console by one
great care at all times. When conductor is laid on the
operator. This feature was specified in buying the machinery.
wgith
for splicing, it is placed on lagging and, if necessary,
ground
and
line
pulling
the
in
reels
machine
The pulling or winching
sheets are placed between the conductor and
rewinds it on its reels in preparation for the span ahead.
plagethylene
lagging. Minimum acceptance standards for joints and reThis equipment maintains a positive tension on the pulling
pairs have been established by our research groul, and the
line between the bull wheels and the take-up reels. As
crews gage their performance accordingly.
splicing
of
kinking
prevent
to
a
requirement
is
this
earlier,
mentioned
the pulling lines. The 15-ton swivels previously mentioned
Conclusions
are not passed around the bull wheels. When a swivel apSimultaneous stringing of four conductors in a bundle is
1
proaches the bull wheels of the pullers, the pulling line is held,
ngically foundd
feaSibltaneo
feasible and economically sound.
and the swivel is removed and replaced by short double2. For successful stringing, running board and associated fitended clevis. Thiis s passed through the bull wheels of the
tings must be designed for and work with stringing block.
pullers, and the completed reel is then removed from the take3. A definite ratio of tension exists between plullers and
up stand and replaced by an empty one. up stand and
replcedtensioners. To date on this job, measurements indicated
It is felt that conductor speed is not too significant in tenthat this ratio has never been more than 2 to 1.
sion stringing. A pulling speed of 11/2 to 2 miles per hour was
4. Prior to construction of a prototype line with prototype
found adequate. Under difficult terrain, the scheduling probequipment, the expense involved in developing mpethods,
lem is moving and setting up, not the actual stringing time.
testing equipment, and training of men through a test line
It has been noted, however, that line speeds under 3/4 of a
is jtstified if the capital expenditure is great enoughli
mile per hour cause poor control and conductor oscillations.
5. On this line, helicopter transportation of 500-kv
Following stringing, the conductors are sagged, one conductowers, regardless of material and yard location, could be
tor at a time. One conductor is brought up to sag by means
t
onle.
wnereimpossible.
economethods
of sighting telescopes on the tower legs. The remaining three
were
tion
methods
are sagged to it, using a ground-located transit. Adjust6. A stockpile of all material, consisting of 21/2 times the
ments are then made for decreased sag in the top two conducrate of progress, should be available for maximum ecnnomic
tors, and clamping proceeds. In stringing, sagging, and
production.
clamping, many special devices such as helper clamps, hangers
References
for the transition from the flat to square configuration, grips,
1. ENGINEERING D)ESIGN FEATURES OF THE PINARD-HANMER 500etc., were designed and developed.
KV
TRANSMIssioN LINE, N. J. McMurtrie, B. R. Murphy, M. MarSpacer-dampers are installed from a motor-driven aerial
pt. III (Power Apparatus and SysTransactions,
kowsky,
span, the
span toosa,te
In
moving from
cart
shown in Fig. 12.
rmsa
2
nmvn
cart
shw
1964, pp. 54-62.
83, Jan.
tems), vol.IEEE
nFg
2. CORONA Loss RESFARCH AT THE ONTARIO IIYDRO COLDWATER
carts are swung around the insulator string by a davit arrangement clamped to the insulator string. Difficulty was had in
PROJECT, 0. Nigol, J. G. Cassan. Ibid.. vol. 80, June 1961, pp.
304-12.
finding a motor that would withstand the work and weather.
3. ONTARIO IIYDRO'S Eq1V SYSTEM-SELFECTION OF VOLTAGE,
While spacing and clamping is progressing in one setting,
SIZE AND BUNDLE ARRANGEMENTS, H. P. Smith, J. G.
CONDUCTOR
pulling is proceeding in the next setting, and the insulator
Cassan, N. J. McMurtrie. Paper No. 415, CIGRE, Paris, France,
1962.
crews are picking up the blocks released by the clamping crews
s

V-type

214

Mackie, Lemire-Construction of Pinard-Hanmer 500-Kv Transmission Line

MARCH 1964