PRACTICAL APPROACHES AND EXPERIENCES Wilford Caulkins, IIT, Member, IEEE ‘Sherman & Reilly, Inc. Chattanooga, Tennessee Abstract - The purpose of this paper is to familiarize construction personnel and transmission engineers, so that the design erection of overhead transmission Lines can be more closely coordinated. Practices deseribed provide for positive control throughout the total operation. Procedures used vary from the basic techniques to che Latest ‘state of the arts’ methods, such as the use of helicopters “for stringing. Comparisons are made between uses” of “bullwheel” type versus “drum type” pullers, steel. versus. synthetic pulling” lines) grounding procedures, sagging and. clipping in the conductor. Tt is hoped that this paper will, through a very practical Approach and with the experience collected over many years of working with Design and Construction Engineers, fill a void in the availability of information on construction practices. INTRODUCTION Information herein” was derived from personal observation and “participation in the construction. -of overhead. transmission Ines for over 25 years. Detailed infor~ mation on the specifies of cools and equip ent have been. provided ‘previously and" ave available tn ANSE/TEEE Standard 32421980. The" purpose of this paper te to gives general overview of shat is necessary tn the Planning. and execution. of the construction SE a typical overhead transmission Line. The Significance is to give a nevconer to. the trade a general, fofmat_to follow and to Eeniliarize the ‘Transmission Design Enginee tov further hie underecanding ‘of how this Line, that he Ls" preparing fo desiga, will be" butte Stringing overhead conductors in trans— mission is a very specialized type of construction requiring years of experience by personnel as well as equipment and tools that have been designed, tried and proven, to do the work. Because transmission of electrical current is normally at higher BTIC-68 A paper recommended approved by the IEEE PES for present tion at the IEEE/CSEE Joint Conference on High Voltage transmission Systems in China, Beijing, October 17-22,1987. Manuscript submitted June 10,1987smade available for printing June 20, 1987. +380- voltages (69 KV and above) conductors would be larger in diameter and span lengths would be longer than in normal distribution. Al- though proximity co other energized lines may “be ‘limited on the right-of-way, extra care must be exercised to protect the con- ductor so that when energized, power loss and corona will not be a problem. ‘There are four (4) methods that can be sed co install overhead transmission con- juctor: 1. Slack Stringing 2. Semi-Tension 31 Full Tension 4) Helicopter Stringing Slack stringing can only be utilized if it is not necessary to keep the conductor off of the ground, and if no energized Lines lie benaath the line being strung. In this method the pulling lines are pulled out on the ground, threaded through the Stringing blocks, and the conductor is pulled in with legs tension than is required fo keep it off the ground, This 1s not considered to be an acceptable method under current demands of maximum utilization of transmission requirements. Semi-tension methods upgrading of slack stringing but do not necessarily provide for Keeping the con- ductor completely clear of the ground, or the Lines used to pull. Full tension stringing is a method of are merely an installing the conductors and overhead groundvire in which sufficient pulling Capabilities on one end and tension capabilities on the other, keep the wires clear of any obstacles during the movement of the conductor from the reel to their final sag position. By doing so it is insured that’ these current-carrying cables are "clipped" into the support clamps in the best possible. condition which is the ultimate goal of the work itself. Stringing with helicopters, although within itself is much more expensive per hour of work, can be much less expensive when extremely arduous terrain exists along the right-of-way and when proper pre- planning is utilized. Although pulling con- ductors themselves with @ helicopter can be done it is limited and normally not practical. Maximum utilization comes from Setting structures and pulling in pilot Lines with the helicopter and then’ the conductor stringing ie done in a con- ventional manner. Special tools (such as stringing blocks) are needed if helicopters are used~Single Helicopter Block Bunce Helicopter Block So that maximum protection of the con- ductor {s realized and maximum safety of personnel is attained, properly designed and Constructed tools and equipment are canca- mount to a successful job. Because the initial cost of these todle and. equipment represent such a small percentage of the overall cost of the project, the highest quality should be used, thus minimizing down tine’ and possible failure during the course of construction. (A)_ Tools Basic tools needed to construct over- head transmission lines are as follows (A) Conductor Blocks (8) Overhead Groundwire Blocks (Cc) Cateh-off Blocks (D) Sagging Blocks (£) Pulling Lines (F) Pulling Grips (G) Catch-off Grips () Swivers (1) Running Boards (J) Conductor Lifting Hooks (XK) Hold Down Blocks Conductor Blocks are made in diffrent configurations: (1) Single Conductor (2) Multiple Conductor (2, 3, 4) (3) Multiversal type (can be converted from bundle to single and vice versa). (4) Helfcopter Conductor blocks should be large enough to properly accommodate ‘the conductor ant be Mned with a resilient Liner such as neo- prene ‘or ‘poylurethane and. constructed of Light-weight, “nigh strength materials. Sheaves should ‘be mounted on anti-friction Dall ‘bearings co ‘reduce. tension vequired in Stringing and. facilitate proper ‘sagging. Conductor blocks are available for stringing Single ‘conductors or multiple conductores Sone “are ‘convertible thus enhancing their versatility. When “stringing. maltiple conductors it is" desireable’ to pull all Conductors with a ‘single pulling line so EE, (alE conductors “in the bundle have lentical tension history. The runing beaYd makes this possible: eee ‘ +381 ‘Two Conductor Bundle Block xunnang #oara Pulling lines are divided into, two categories (1) Steel cable (2) Synthetic Rope Because of the extra high tension required in transmission line construction, steel pulling lines and pilot linee are the most practical to use. Torque-resistant, stranded, and svsgged cables are used so that bali bearing swivels can be utilized to prevent torque build up being transferred to the conductor. Sone braided or woven steel cables are also used.If synthetie ropes are most important features shoul utilized, the Include No Torque Very minimm elongation No. "kinking" Easily spliced High strength / small diameter Excellent dielectric properties Stringing overhead groundwires normally do not require the care of current carrying conductors. ' Most overhead groundwires are stranded steel construction and the use of steel wire with a@ fiber optic core for Communication, has become a common practice. Special care ‘should be taken to insure that excessive bending does. not occur when erecting overhead) ground wires “with optic centers. fiber (8)_Bquips Pullers t are used to bring in the main pulling lime. Multi-drum pullers, called Pilot Line winders, are used to’ tension string the heavy pulling cable. Primary pullers are used to tension string the conductors. These pullers are either drum type or bullwheel type. The drum type is used more extensively in many areas ©f North America because the puller and pulling cable are stored on one piece of equipment, but is not practical fn other areas because it is tog heavy. Thue the bullwheel type is used allowing the puller and pulling cable to be separated onto two (2) pieces “of equipment. Also the pulling cable can be separated into shorter lengths to allow easier handling, especially” if manual labor 1s preferred Drum-Type Puller Tensioners should be bullwheel type using muLti-groove wheels for more control. Although V Groove machines are used on some lighter, smaller conductors, they are not reconmended in transmission work because of fhe crushing effect on the conductor. Tensioners are either mounted on a truck oF trailer mounted. Reel Stands are used to carry the heavy reels of conductor and are equipped with brakes to hold “tailing tension” on ‘the conductor as it is fed into the bullwheel tensioner. These stands are usually mounted on a trailer separate from the tensioner. Helicopters are used normally to fly in a light line which can be used co pull in the heavier cable. ‘Three-Bundle Tensioner 1382+COMPOSITE, FOR THE INSTALLATION OF OVERNEAD. TRANSMSSON LINE CONDUCTORS ra ne none ra Race tne meassson i Flor UNE WER Die suai ce Ruins cn A TER FES Ie 1 re aenaion PAP Cn WI ICT Spacer cars are used to install spacers and spacer danpers. Spacer Cart (c)_ Procedures, once the right-of-way has been cleared the following are normal steps taken in construction: + Framing 2) pulling overhead groundwire and pilot Lines. 3. Pulling overhead groundwire up to sag and installation. 4. PULL in main line with pilot line. 5. Stringing conductors. 6 Sagging conductors 7. Clipping in conductors. 8. Installing spacers | or spacer Ganpers where applicable. Framing normally consists of erecting poles, towers, or other structures including Foundations and anchors on guyed structures. ie is desireable for the stringing blocks to be installed, with finger lines, on the ground before " structures are’ set to Eliminate an extra climb later. Helicopters are used to set structures especially where rough terrain exists or right-of-way Clearances are restricted. 383.Once structures are secure, overhead ground wire and pilot lines are pulled in Eogether with a piece of equipment such as a caterpillar or ‘other track vehicle. A helicopter is also used to fly in these lines. Once the overhead ground wires are in place they are sagged and secured, thus giving the structures more stability for the Stringing of the “conductors. This is especially imporcant for guyad structures. Normally the three pilot lines (typically 3/8" diameter swaged steel cable) Pull in the heavier pulling line (typically 3/W diameter or 7/8” diameter swaged steel) under tension. ‘The main pulling line is then attachecd ko the conductor which is strung under tull tension. Once the conductor is "caught off", the main pulling line is returned pulling of the next phase. Once the conductors are in place they are then brought up to final sag and clipped into the conductor clamps provided. Tf the conductor is part of a bundle per phase, the Spacers or spacer dampers are installed, using a spacer cart which is either pulled along from the ground or self-propelled. ‘Coordination between design engineers and construction personnel is very important in the planning and design of transmission Lines. “Although it 1s sonetines impossible to accommodate the most. efficient capabil~ ities of the construction department (or Line contractor) much tine and money can be conserved if pre-design meetings are held to discuss such items as yclearances needed for installing overhead ground wire blocks, hardware equipped with "work" holes to secure lifting hooks or blocks, conductor reel. sizes compatible with existing reel stands, length of pull most desireable, towers equipped to facilitate climbing. For maximum safety of personnel con— structing transmission lines, proper and effective grounding procedures ‘should be utilized. Grounding can be accomplished by: A. Adequate grounding of conductors being strung ~ and pulling cable being used, or B. Fully insulating the’ equipment and operator, oF C. Isolating ‘the equipment and personnel. CONCLUSION The message of this paper is general, but serves as an overview Under ost cireun Stances. it is Limited by the briewity of the "message, but provides enough information to. familiarize new construction personnel and Design Engineers aso the methods of the job a it appears in the field. Further work could ‘be one” to present, in more detatt, the specifics of the work itself for those who would want to learn more. Also a future” paper written from the Design Engineer's standpoint, would well serve the construction people 'in a better under~ Standing of the design problems involved REFERENCES [1] Guide _to The Installation of Overhead ‘cansaissfon jonductors, a 1980 Wilford Caulkins, ~ If was born in Ohattandoga, Tennessee on April 11, 1931. He received a B.A. degree in Economics from the University of Alabama, Tuscaloosa, Alabama. We has. been employed’ by Sherman '& Reilly, Inc. since 1961, serving as General Sales Manager, Marketing and Advertising Manager, and West Coast Representative. He is a member of the IEEE Power Engineering Society and currently serves as a member of the Working Group on The Con~ struction of Overhead Lines and is a member of the Towers, Poles, and Conductors sub- comittee and the subcommittee on Engineering in The Safety, Maintenance and Operation of Lines - ESMOL. 384.