8.

Field Work procedure

8.1 Pre Hand Checks

Ensure relevant approved drawings, Drum schedules and Stringing charts & Necessary NOC’s
are available at the site before commence the work.

 Ensure right Quantity and Quality of materials available.

 Prepare all equipment necessary for stringing and verify it is complete in all respects.
 Ensure protection such as grounding, anchoring etc including positioning of equipment.
 Ensure safety PPE’s are available.
 Ensure necessary stringing tools & tackles are available at site.
 Ensure Test Inspection of erected towers is carried out for respective sections and
relevant ITP’s are submitted.
 Ensure towers are installed firmly and correctly and earth test are completed and earth
resistance value noted.

8.2 Patrolling the Route

This is to ensure that pulling stretch to be string is clear in respect of various aspects such as
tower earthing, all structures in position, cleared for loading Puller/ Tensioner locations suitably
chosen and crossings are provided with necessary protection etc. The site Engineer is In
charge of this responsibility.

8.3 Positioning of Stringing Equipments

In the proceeding activity of patrolling the route, location of main equipment, tensioner and
puller would have been selected and studied in detail taking in to consideration of all aspects
applicable. Important aspects of selecting these locations are as furnished below:

 Length of the Stringing section.

 Length of conductor/ reels available.
 Location of crossings and strategic importance of crossing points.
 Types of Structures available at machine locations and convenient working space
available around.
 Capacity of Equipments.
 Land Topography, accessibility etc.

Equipment will be positioned at sufficiently enough distance from the first structure
approximately 1.5 times of the structure height as far as possible. The criteria for selection of
Puller / Tensioner location will have equal consideration to minimize the movement of
equipment as much as possible.

8.3.1 Tensioner and Reel

Tensioner and Conductor Reel will be positioned at one end and Puller & Pilot Reels will be
positioned at the other end. Tensioner will be anchored by using pre cast concrete blocks
suitable to counter the pull force.

Reels will be placed on reel stands, facilitated with hydraulic or rigid reel stands. The Reel
stands will be normally positioned from 10 to 20 Mtrs behind tensioner on level grounds. In
case of sloppy grounds, necessary anchors need to be provided separately for reels. In case of
rigid reels stand without built in Jacks are used, conductor reels will be placed on reels by
means of lifting equipment. Wooden battens fixed around conductor spools will be removed and
conductor end taken out, checked and inserted in pulling grip attached with a swivel connector
and nylon rope passed around the grooves of Tensioner Bull Wheel.

Conductor creep shall be maintained for 72 hrs between stringing and clamp in as per the
specification.

The slope of the cable is 40 Degree from the Reel to Tensioner

8.3.2 Puller and Reel

Puller and Pilot Reel will be positioned at the other end of pulling section, as far as possible on
level ground. Two rear anchors will be provided using concrete blocks of appropriate cage as
substitute. However this will be governed by the type and position of exit towers.
.

8.4 Reinforcement of end supports

It is imperative that the end support structures of a stringing section are provided with
temporary guys. This will be achieved by means of steel ropes and anchor concrete blocks.
Anchor blocks have to position adequately away from tower base, so that it is not exceeding 45
Deg. With horizontal (ground) as far as the topography permits the same.

8.5 Insulator /Roller /Pilot wire pulling

Prior to this activity all the towers in respective section are checked for proper tightening with
torque wrenches and all the towers are connected with earth. This activity is apparently a
combination of fixing hardware fittings related to insulator string and hanging aerial roller. This
activity will be normally carried out using utility blocks, ropes, operator men etc. The insulators,
fittings will be cleaned thoroughly prior to installation. Workmen will not be allowed to climb on
insulators for access to conductors. If access required it will be done through ladders, platforms
etc. All aerial rollers to be checked properly for functioning and availability of neophryne rubber,
to avoid the damage of the conductor during stringing operation.

8.6 Crossings of Road & Power lines etc.

Wherever the OHL crosses the road, power lines, etc scaffolding will be used to prevent the
conductor and OPGW from coming within 5 meters of roads and 1.5 meters from
telecommunication lines during stringing. Efficient temporary grounding shall be installed in
case metal scaffoldings are used for power line crossings. The scaffoldings shall be sufficiently
long to cater for any conductor side-swing which may occur during stringing and shall be of
sufficient strength to withstand wind pressure, vertical loads and all other loads which may be
anticipated.

Required notice to the appropriate authorities will be issued indicating the date / time of work.

8.7 Laying of Pilot Wires

Pilot wire shall be braided, non – rotating type of wire. Pilot wires, winding in reels, in varying
lengths will be made available to suit the normal installation requirements. Pilot wire reels with
individual lengths can be joined together using pilot wire connectors to achieve requisite length
to pull full section length.
Pass lines (pieces of nylon ropes) provided along with rollers will avoid the lineman climbing up
and down the towers every time. Pulling of pilot wire will continue until it reaches the tension (i.e
reel stand) end, where the pilot wire will be connected with swivel and pulling grip already
attached with conductor end.

At this stage it is very important to ensure that the end support is adequately reinforced with
temporary guys if prescribed by the designer to withstand erection pull force unless the
structure is designed to string without temporary guys. Same check should be adopted in
respect of extended cross arms, if these are not designed to carry out such forces; for instance
machines kept very close to the structures result in higher magnitude vertical down pull.

Precautions are taken wherever the distribution lines crossing are in route. Proper outages to
be obtained for stringing activity.

8.8 Conductor paying out

Walkie-talkie will be provided at both ends and middle during paying out of conductor,
preferably for pilot wire paying out also. Engineer will once again confirm all pilot wire
connectors are properly secured and pilot wires well in position in roller grooves. Conductor
drum shall be closely examined before pulling commences and all nails/external materials
which could damage the conductor shall be removed. Conductor drums of same stranding
machine shall be used for sub conductors of each phase. Anti twisting headboard will be
connected to the conductor to avoid possible twisting. A lineman will use the walkie-talkie to
give the precautions to tensioner and puller operator for every crossing of conductor into the
aerial roller. Pulling will continue until the conductor end reaches other end, Hold down blocks
or similar devices will be used at uplift locations. The joint protectors will be used above the mid
span joint, to avoid any possible damages while mid span joint passing the aerial rollers.

The Conductor will reach to the puller point, then the rough sag arrangement to be done by
using conductor clamps, long slings and anchoring spikes or blocks. Now conductor, will be
dead end compression joint pressed and will be attached with the insulator string on tower
cross arm. This operation is called tie in or make up.

Normally make up of conductor tension joints are made on tension tower and rough sag of
conductor by temporary anchor blocks at puller end with proper come along clamps and wire
ropes.

Physical checking / testing of full tension splices after compression shall be done for all joints.
The Mid span joints shall be minimum distance of 30 Mtrs. from the nearest conductor clamps
and no joints will be allowed in spans crossing power lines, buildings, main roads, and single
span sections.

8.9 Final Sagging

Final Sagging will be done on other end of the section. Before taking up real sagging operation
following need to be checked:
 Approved Sag tension Tables available.
 Thermometer to read conductor temperature.
 All Sagging tools available.
 Temporary grounding is provided at required points.
 Temporary back guys are well in position.
Measurement of Sag will be carried out to the following methods.
1. Sag boards and sag scope method.
2. Using dynamometer.

Sagging will be done by using double sheave pullies with wire rope arrangement, Winches and
conductor clamps. Each conductor will be secured by a clamp, attached to pull line fastened to
the cross arm by means of short slings. Erection sag will be read from sag table. Winches will
be pulling the conductor up, keeping watch on the sag to coincide the correct value of sag. At
this stage markings will be made on the conductor accordingly and conductor will be secured
by additional clamp and sling temporarily. Subsequently, conductor will be lowered for dead
end compression joint and again raised and attached to the tension insulator string.
During pulling of conductor of final sag, all the aerial rollers in the section are to be checked for
movement with communication through walkie-talkie.

Once above sagging procedure gets over, all tools temporarily secured will be removed and
line cleared for clipping & Jumpering work.
When sag tension completed, tension reading to be recorded. If deviated, corrections shall be
made to get required sag.

8.10 Clipping, Installation of Vibration Dampers & spacers

It is the procedure in which conductor will be fixed in clamps at final erection position. Prior to
taking up this activity, conductors will be grounded using temporary drain earth connected to
tower cross arms. In order to release the rollers, conductors will be lifted from the roller grooves
using pull lift. Armour rods and vibration dampers will be fixed in position during the clipping
operation and Jumper operation. Sagged conductor will be grounded to tower body at
convenient locations to provide protection during clipping /jumper. Clipping will be followed by
installation of Spacers and Vibration dampers.

8.11 Jumpers

All angle towers will be provided with Jumper connections. Similar to clipping activities, working
section/points will be sufficiently grounded to protect from possible static current. Jumper loops
shall be pressed with jumper lugs and bolted with main dead end. Due care should be given to
maintain length and shape of jumper loops as far as accurate to ensure swing clearances as
per specification.

8.12 Shut Down/OHL Crossings

Permits required for work across road, to cross existing lines or near sub stations, shutdown
permits / clearances etc, shall be arranged by contractor and all the supports shall be done by
client/consultant. Existing lines will be grounded at disconnection point immediately after de
activating the lines by Electricity Authorities and temporary grounding shall be removed before
returning the power outage.

8.13 Bundle Conductor:

The stringing work procedures for Bundle Conductor will be same as per the Single conductor
method statement.
9. Methodology for OPGW

OPGW also will be pulled in the same manner as that of conductor, however considering the
down lead clamp along the tower leg from peak to joint box, this method shall slightly modified
in such a way that the running out cable from tensioner is routed inside the tower frame and the
manufacturers recommendations will be strictly followed.

9.1 Protection

 Pre-installation tests will complete to ensure the healthiness of OPGW prior to stringing.
 The Machines will be anchored to ensure stability through pulling.
 The Machines and running cable shall be grounded.
 Posses necessary permit wherever applicable.
 To maintain bending radius of OPGW as per manufactures recommendation in order to
avoid any damage to OPGW Fibres.
 Running Earth will be provided for Conductor and Equipment, also tower earth will be
provided for Towers during the stringing period.
 Ground Roller Protection will be provided for Conductor ground protection.

9.2 Important Check Points

9.2.1 Sheaves (Rollers)

 To ensure the grooves are free from nicks and scratches.

 To ensure free running wheels (suitably well greased bearings) & precision of
neophryne rubber.
 To ensure all locking pins, nuts etc in order and perfect.
 The rollers will be used for installation minimum 25 times of OPGW conductor diameter.

9.2.2 Puller

 To ensure dynamometer in order and functions.

 To ensure it is positioned as far as possible i.e. line with pulling axis or to a maximum
deviation of 10° or so to avoid any bird caging of exit tail of cable.
 Equipment will be positioned at sufficiently enough distance from the first structure
approximately 1.5 times of the structure height as far as possible.

9.2.3 Tensioner
 To ensure the machine is positioned in opposite end of puller machine.
 To ensure the used groove are free of nicks, cuts and soil etc.
 To ensure minimum distance of 10 to 20 Mtrs maintained between tensioner and
OPGW Drums.
 To ensure the cable is received in right direction around the bull level.
 Equipment will be positioned at sufficiently enough distance from the first structure
approximately 1.5 times of the structure height as far as possible.
 To ensure bull wheel dia should be 70 times of OPGW.
9.2.4 Entry & Exit Running Points

Specific care should be given to ensure sheaves are suitably attached at entry and exit points a
top towers and run through angle towers to avoid bird caging.

9.2.5 Documents
To ensure following documents are available with Stringing Engineer/Supervisor:

 Approved Stringing Chart for OPGW.

 OPGW Drum Schedule.
 Maximum permissible pulling value of OPGW.

9.2.6 Communication

Walkie Talkies are provided to stringing activity for Communication.

9.2.7 Step-by-Step Procedure of Installation

 Anti rotational devices and pilot wires will be used for pulling of the OPGW.

 Maximum permissible pulling tension will be preset in the puller, the maximum pulling
tension will be 20% rated breaking strength of OPGW.

 Anti rotational device will be connected between the OPGW and pilot wire to ensure the
OPGW is not being twisted while pulling.

 Once Communication is established between Puller and Tensioner ends and clearance
given by tensioner end pulling shall start a very low speed and gradually increase up to 3 to
3.5 KM/hour until the required length is pulled. Subject to the provision in Drum Schedule,
the remaining length can be pulled out and cut away so that the most stressed part of the
cable is excluded from permanent installation.

 Once pulling is completed, sagging, clipping etc shall be done in similar way of conductor
installation. Self-gripping or bolted conductor clamps shall be used in conjunction with pull
lift to accomplish sagging.

 OPGW shall be guided along the tower leg as per approved drawings and clamped up to
joint box, leaving approximately 10-15 Mtrs. cable and end to facilitate splicing and testing.

 OPGW length before splicing joint box shall be kept as per specification drawing.

10. Safety

L&T HSE Policy is built on the philosophy that all accidents are preventable; and no work is so
important that injury to people or damage to property is justified.

11. HSE REQUIREMENT

All HSE activities related to the project shall be based on the NGSA Engineer’s issued
HSE Management System Guidelines and NGSA Engineer’s approved Project Specific
HSE Plan.

Personal Protective Equipment

All PPE shall be used during the stringing works.

Special Safety Requirements / Precaution

Enclosed Risk Assessment in Appendix – 1 with clear identification to potential HSE

hazards and proposed controlled measures including responsibility to implement the
same.