EMIT Unit-7

Unit-7: Installation Ghatal Govt.
Polytechnic
Installation
Inspection procedure of Machine Installation:
It often happens that the motors are stored by factories or stockists for long periods and in some
cases store houses are having dampness and may become wet during carriage. When anything
happends the insulation is lowered and it may be dangerous to connect the motor up until it has
been dried out. The inspection of the motor should be carried out as follows.
1. External inspection of motors for conditions.
2. Inspection of terminals by opening the terminals lid.
3. Blowing of the motor with clean, dry air to remove dust.
4. Checking of the rotor for easy rotation when turned by hand.
5. Rectification of defects observed during inspection.
6. Particular attention should be given towards antifriction bearings of the motor.
7. Insulation resistance between winding and frame tested by means of a 'Megger' and compared
with the data supplied by the manufacturer for the insulation resistance. It should always be
above 0.5 mega ohm.
Supply voltage as stamped Minimum Insulation

of Motor Name Plate resistance on setting to work
Below 2000 volts 1.0 mega ohm
2000 V to 3000 V 1.5 mega ohm
3000 V to 4000 V 2.0 mega ohm
4000 V to 5000 V 2.5 mega ohm
5000 V to 6000 V 3.0 mega ohm
TABLE: Minimum Insulation resistances for Industrial Type Motor of 1 H.p. and above
Insulation resistance should be checked before a motor is put to work. Note that one connection
from the Megger is held in contact with one of the winding terminals, while the other connection
is placed upon the motor frame.
If the reading obtained is lower than given in the table, the motor should be dried out.
When the electrical motor is kept idle for longer period, then they shall be stored in dry, clean
and well ventilated store room and under no circumstances should a motor be enclosed by any
covering because ventilating air is restricted. The exposed metal surface of the motor shall be
coated with anticorrosive grease and wrapped in moisture resistant material such as wax paper.
The temperature in the store room shall not be lower than 15°C.
The machine foundation:
The part of a structure which provides a base or support for the machinery is called a foundation.
The size and strength of foundation depends upon the size and nature of supported machine and
surrounding soil condition. The qualities of good foundation are rigidity and freedom from
vibrations.
Prepared by Sanjoy Pondit, Lecturer, Department of Electrical Engineering, Ghatal Govt. Polytechnic
Unit-7: Installation Ghatal Govt. Polytechnic
Objects of Foundation
The following are the main objects of foundation
(i) It carries and supports the weight of machine in order to prevent any settlement or crushing.
(ii) It maintains the alignment of machine.
(iii) It gives a level and firm surface for the machine.
(iv) It absorbs the vibration produced by the unbalanced forces created by reciprocating and
rotary means of the machining elements.
Foundation serves the purpose to protect the machine from externa vibrations and to lower
down the frequency of natural vibration by increasing its total mass. The shape and size of the
foundation differs according to the type and size of the electric machine. They are also dependent
on the property of the soil and the dynamic loads of the machine during operation and also
dependent on the maximum output of horse power of motor.
If the foundation is not properly made i.e., if the foundation is made too high and is not extended
to a sufficient depth, this will cause continuous source of trouble. For machines, where vibrations
occur, a concrete foundation must be prepared. The depth of concrete foundation will depend
on:
(i) the weight of machine
(ii) amount of vibrations involved and
(iii) character of the subsoil
Cheaper foundations should be given preference (if they are able t give the required service) but
it should not be at the cost of stability and permanency Transportation facilities of materials also
need consideration
If all machines are to be placed in a line, a common foundation is preferable specially in power
station leaving ample space between them.
The width and the length of the foundation can be suitably calculated considering the foundation
drawing, its height and weight. Provision for cable ducts, required pipe lines etc. should be made
along with the foundation.
Factors involved in designing the machine foundation:
(i) Planning the Foundations
The static load and dynamic load of running machine is transmitted to the ground via the machine
foundation. The foundations should be firm solid and level, and the motor, its bed plate should
be securely bolted down. The best material for the foundations is concrete because the concrete
bases are so easy to shape, they are almost universally used.
The dimensions of the foundation block may be determined by finding out the weight of the
foundation with the following empirical formula 𝑊𝐹 = 𝐾𝐹 𝑊𝑀 . Where K, is the factor commonly
taken 2, 3 for the machine with dynamic load and W is the weight of machine.
The height of the foundation
Weight of the foundation (𝑊𝐹 )
=
Area of the base of foundation × specific wt. of material
Of course, the height so calculated should be sufficient enough to accommodate the foundation
bolts etc.
(ii) Ground Condition:

For a hard soil or for a normal soil, the construction of a concrete bed is most suitable. But for a
soft and loose soil, a large surface area with proper depth is needed for the foundation of a
machine.
Figure 1: (a) Sand-filled trench around foundation. (b) Soft insert below foundation block
(iii) Vibration Consideration:
To avoid transmission of vibration to adjoining parts of buildings or other foundation, it is
necessary to provide a suitable isolation between the equipment foundation and the ad joining
structure. Usually a gap is maintained all around the foundation and is filled by sand to avoid such
transmission of vibration. The foundation for the equipment shall not be allowed to serve as a
support for other structures. Two typical foundation blocks are shown in figure-1 (a) & (b).
(iv) Size of Concrete Foundation

A concrete foundation should be carried down to solid and it should be sufficiently large to
prevent vibrations and give a good grip to the holding down bolts. It can generally be said that a
concrete base should be about 15 cms larger in both length and breadth than the motor feet,
bed plate or slide rails.
As regards the depth of foundation, for motors up to 10 H.P., an ordinary concrete workshop
floor or a good brick floor about 7.5 cms to 10 cms thick and bedded on well-rammed earth is
quite adequate. Above this size the depth of foundation should be as follows:
10 to 25 H.P. 15 to 20 cms deep
25 to 50 H.P. 20 to 25 cms deep
50 to 75 H.P. 25 to 37.5 cms deep
75 to 100 H.P. 37.5 to 60 cms deep
It should also be noted that figures given above refer to the depth of concrete below the ground
level. The height of plinth etc. must be added to the depth given.
Installation of rotating machines as per I.S. 900-1992:

Installation rotating electrical machines is given in the following parts.
(i) Acceptance and storage at site.
(ii) Shape and size of foundation.
(iii) Laying of supply and control cables.

(iv) Making the motor/machine ready for installation.
(v) Installation of the motor/machine on foundation and alignment of shaft.
(vi) Checking of air gap between stator and rotor.
(vii) Coupling
(viii) Trial run, no load run under close supervision.
(ix) Installation of cooling system of large machine.
(x) Installation of fitting of other parts, accessories, piping etc.
(xi) Installation of motor with gear drive.
(xii) Drying out the wet parts.
(xiii) Setting/adjusting of protection relay.
(xiv) Tests on motor/machine starter and associated equipments.
(xv) Final commissioning and handling over to customers operating staff.
(i) Acceptance and Storage at Site:
After getting the machine from the manufacturer or supplier, it should be stored temporarily
before the installation date. But before the machine is stored, it should be inspected. The main
purpose of the inspection is to check that the received machine should be in good condition and
also according to our requirements.
Therefore, before the installation of electric machine, it is necessary to check it very carefully.
This inspection work should be carried out by some competent persons who have got the through
knowledge regarding the inspection of particular machine. During the inspection of electrical
machine, the instructions given by the manufacturer must be followed.
Following procedure should be followed while inspection on arrival of machine.
The wooden crate containing motors should be unloaded by using crane sliding the motor down,
an inclined plane using pipes or bars should be avoided. However, where use of inclined plane is
unavoidable, care should be taken to reinforce plane by boxes under them. Ropes and wedges
should be employed in bringing the crates down in a steady manner to avoid injury to the
machine or personnels.
On arrival of machine at site, the packing case should be checked carefully against the dispatch
particulars. Any loss of packages in the transmit should be intimated to the machine. The
manufacturer or supplier and insurance company. The packing case contains a part hat, a
duplicate of advice note and check tag which should be taken out of case as soon as it is open.
The packing case have some marking indicating the sender and receiver. The warning
instructions, such as "Do not turn over", "Handle with care" etc., must be followed strictly.
Storage of Machine at Site: The machine should be stored in a clean and dry place. The machine
parts have a protective coat antirust preservative which should not be taken off during normal
storage periods but for long storage, periodic inspections should be carried out and fresh
preservative be applied if required. During the storage period or during installation or their
working life, motor should be protected from moisture, acid, alkali, oil, gas, dust, dirt and other
injurious substances. There should be proper pest control. No rats, vermins and other
troublesome pests such as rodents should be allowed in the store room. Machine should not be
kept on mud floor. The floor of store should not be subjected to vibrations. In case of vibrations,
the machine should be placed on rubber blocks. There should be "No smoking" sign in the store
room.
(ii) Shape and size of Foundation and Construction Work:
The part of a structure which provides a base or support for machinery is called a foundation.
The size and strength of foundation depends upon the size and nature of supported machine and
surrounding soil condition. The qualities of good foundation are rigidity and free from vibrations.
The following are the main objects of foundation:
(a) It carries and supports the weight of machine in order to prevent any settlement or crushing.
(b) It maintains the alignment of machine.
(c) It gives a level and firm surface for the machine.
(d) It absorbs the vibrations produced by the unbalanced forces created by reciprocating and
rotary means of the machinery elements.
Foundation serves the purpose to protect the machine from external vibrations. The shape and
size of the foundation differs according to the type and size of the electric machine. Foundation
are also dependent on the property of the soil and the dynamic loads of the machine during
operation and also depend on the maximum output or horse power of motor.
If the foundation is not properly made i.e., the foundation is made too high and is not extended
to a sufficient depth, this will cause a continuous source of trouble. For machine where vibrations
occur, a concrete foundation must be prepared. The height or depth of the foundation depend
on the weight of machine, amount of vibrations involved and character of the sub-soil.
Cheaper foundation should be given preference but it should not be at the cost of stability of
permanency. The width and length of the foundation can be suitably calculated considering the
foundation drawing, its height and weight, provisions for cable ducts, required pipe lines etc.,
should be made along with the foundation.
Proper place should be searched for construction of foundation. Construction work of foundation
should be searched and construct according to the following.
(a) After the installation of machine if any fault occur then it should be disassembled carefully.
An empty space should be provided which should be according to the area covered by the shaft.
(b) Foundation should be made 60 to 85 cm below the earth and 45 cm above the earth.
(c) Before constructing the foundation a pit of 15 cm is dugged out. It is then filled with brick
pieces and cement layer of sand is then spread which is then beaten with heavy hammer.
(d) 24 Hours after the construction of base of foundation, it is sprinkled with water continuously
for 3 days.
(e) Foundation should be flat
(f) Machine is installed on it after confirming whether the foundation has moisture or not.
Foundation bolts are kept in cement concrete when this cement concrete is settled then the
machine is to be installed on it.
(iii) Laying of supply and Control Cables:

Every manufacturer or firm sends out a terminal diagram with his motors and this generally
shows how the internal windings are arranged and how the terminals are connected. This
diagram should be frequently consulted during connecting up. The machine body should be
effectively earthed using the earthing provision on the machine body. All cables should be of
large size to carry current which is stamped on the motor name plate and size of the cable should
be followed. The size of cables used should be capable of carrying full load current corresponding
to the rating of the motor.
The size of the cable shall be so chosen as to take care of the starting or accelerating current and
also the short circuit current. In motor circuits the sizes of the conductors are chosen in such a
way that the voltage at the motor terminals, when running under full load conditions, is not less
than 95 percent of the declared voltage at the consumer's supply terminals.
To read the name plate current and then select appropriate cable for a short run is perfectly
simple, but it is not easy to decide what cable to use when voltage drop question enters into the
choice.
The wiring of cable is done for electrical supply. The cables are spread under the ground.
Generally, the trench of 25 cm width and 1 meter depth is dugged. The base of this trench is
covered with 15 cm thick dry sand. The wiring is done in the middle of this sand layer. The cable
area is covered with bricks along the length of the cable. The remained space is than filled with
the soil.
(iv) Making the Motor/Machine Ready for Installation:
Motor/machine should be carefully remove from the packing case. Then dust and dirt on the
machine is to be clean then machine is to be inspected carefully. If any nut, bolt found loose,
then tighten it immediately. If any part of the machine found broken, then remove it. Machine is
to be inspected by turning the shaft through hand. If the alignment of shaft is not found proper,
then make it properly align. When shaft start rotates freely by turning it through hands, then
measure the insulation resistance of stator, rotor winding. In case of three phase induction
motor, insulation resistance is to be measure in between phase winding, between windings and
earth and in case of slip ring motor, insulation resistance is be measure in rotor winding and core.
The minimum insulation resistance for machine upto 600 V should be at least one mega ohm.
(v) Installation of the Motor/Machine on Foundation and the Alignment of Shaft:
Small electric motors and generators can be installed on the same bed-plate. But large motors,
generators and compressors are installed on 'U' channel constructed frame.
After having the machine on the foundation, the important job is to level and align it with other
accessories. The levelling is performed with the levelling wedge, shoe etc. The levelling is to be
checked in both, longitudinal and traverse direction. When levelling is completed, the foundation
bolt, cavity along with the bolt may be made of concrete.
When carrying final alignment, it is necessary, in the case of all types of drive, to ensure that
packing pieces placed between bed plates or slide rails and the top of the foundation block are
positioned correctly, that is, they shall be at the position of the foundation bolt holes and not in
between those positions, and there shall be enough of these supports to ensure that where
foundation bolts are tightened down the bed plate will not be bent.
After alignment of any motor, it is always essential that the motor be turned over slowly by hand,
if possible. Feel for any increase of any jerkiness. If it is not possible to turn the motor by hand,
the motor should be used at low speed watching the ammeter for any sudden increase of load.
The final check should always be done after the bolts have been finally tightened down.
(vi) Checking the Air Gap between the Stator and Rotor:
Air gap between the stator and rotor depends upon the size of machine and is much less in case
of ac motors as compared with de motors. The air gap is measured by inserting long steel feeler
gauge leaves in the air gap between the rotor and stator and as certaining the maximum thickness
of the feelers that can be passed. It should be measured at least at four places i.e., say top,
bottom, front and back. These values should be checked with previous record. If much vibrations
are observed in the readings it indicates
(vii) Coupling:
Various methods can be used to couple the motor to its rod or the generator to its prime mover.
The coupling can be provided by means of a belt running over the pullies fitted to the motor to
load. The advantage of this method is that the motor speed can be matched with that of using
pullies of different diameters.
Motor speed x Diameter of motor pulley
Load speed =
Diameter of load pulley
(viii) Trial Run, No Load Run under Close Supervision:
It is a common practice to have trial start on the medium and large size de motor, ac motors and
generators. For motors having the driven machine on a common bed-plate supplied by the
manufacturer, the trial start of the motor is with the driven machine to avoid dismantling of
coupling.
The first trial start is made with voltage applied for one or two seconds, check the rotation of
motor, condition of rotating parts, starting currents, functioning of contractor/circuit breaker,
thermal relay. Observe closely for sound, smoke and other unhealthy sign if any.
(ix) Installation of Cooling System for Large Machine:
For medium size machine, water can be used as cooling agent. But for large size machine instead
of water, hydrogen gas is used for cooling purpose. Cooling water or gas ducts are provided
around the windings of the machine. The water or gas when circulated through the ducts, it
absorbs heat of the machine and then radiates the heat to the atmosphere or in the radiator
partially by a fan. The cooled water or gas is again recirculated through the cooling ducts.
For large machine, the radiators are generally dispatched in separate packings. Before erection,
they should be cleaned properly and washed with oil and then mounted as per layout.
(x) Installation of Fitting of other parts Accessories, Piping etc:

When finally erected, the other accessories may be joined accordingly. While laying out the
foundation plan, overall requirement should be kept in mind, thus minimise the problem arising
later on.
(xi) Installation of Motor with gear Drive:
The installation of motor with gear drive is quite straight forward, but great care must be taken
to see that the shafts are parallel and teeth are fully in mesh. Lack of attention to this will result
in violent vibration and breakage of gear teeth. There are many types of gear, but spur gear
reduction are common and it gives speed reduction six to one. Before deciding on the type of
gear drive to be used must consult a gearing manufactures.
(xii) Drying-out the Wet Parts:
In all drying out of electrical winding the regulation of the temperature should be controlled
carefully. Maximum drying temperatures on windings should not exceed 194°F i.e., 90°C as
measured by thermometer. This will prevent not only the rapid thermal deterioration of the
insulation but damage from the high vapour pressures that would be obtained if steam was
produced.
Several methods are available for drying machine. Probably the most satisfactory solution to the
problem is when the windings can be placed in an oven with suitable temperature control and
proper air circulation. Banks of infrared lamps may be used when this is not possible, or a suitable
housing may be built around the machine using steam coils or electric resistance type units for
source of heat. Openings should be provided for the free circulation of air. Blowers may be used
to increase the air movement. Vacuum drying has also been effectively used to expedite the
return of machine to service. Certain precautions are necessary if this method is used and it
should be carried out by experienced personnel.
Another method often used is to circulate low-voltage current through the windings. This should
not be done however, until the insulation resistance has reached a value of at least 1,00,000
ohms.
On ac generators, drying current may be provided by driving the units at less than rated speed
with the terminals short-circuited and excited with very low values of fixed current. Here again,
this should be done only by those with experience in such methods. During drying operations,
when insulation resistance values are used as an indicator of the suitability of windings for service
or for application of test potential, the drying must be continued for a sufficient time to make
sure that the values are reliable. Often the resistance curve will be taken one or more sharp dips
before levelling off or continuing to increase in a positive direction. This is due to moisture
working out of the windings. When the machine is completely dried out, further work is required
to remove any remaining dust. This may be done through the use of dry compressed air at
pressure not exceeding 40 psi.
(xiii) Setting/Adjusting of Protection Relay:

First the contacts of starter and control gear if any are checked. If they are in good condition they
should be cleaned with fine sand paper and treated with a fine coating of vaseline. If they are
burnt, pitted, resurfacing of them is carried out with a smooth file. If badly pitted they are
replaced by new ones. Special care is to be taken of contacts of a over load relay in DC motor
starter and contacts of off button. It should be checked that the overload relay operates at the
set value. Oil in control gear should be checked and replaced or added if required.
(xiv) Test on Motor/Machine Starter and Associated Equipments:

Different parts of motor/machine such as stator, rotor and field winding, starter connected with
static and dynamic parts etc. should be checked from time to time. There is a possibility of earth
fault, open circuit fault. These faults can be tested through megger while open circuit faults can
be tested through continuity test.
(xv) Installation of the Stator:
After through inspection, the rotor is mounted on the bed plate with reference to the factory
marks or to the holes for bolts and check pins.
(xvi) Installation of Rotor in the Stator:
This is very difficult process and requires particular care, as the gap between the stator is very
small. Therefore rough handling may cause damage the stator and rotor stocks and windings.
Drying-Out of an Electric Rotating Machines and Its Necessity

All the motors should be dried out before the full voltage is applied to terminals. To decide
whether drying out is necessary, the insulation resistance should be measured. If it is found that
the resistance when measured with 'Megger' between any terminal and frame is less, then the
motor should be moved to warm and dry place where the air is free from dust and where the
temperature does not exceed 90°C..
The insulation of motors and generators have a tendency to absorb moisture when not carrying
currents and kept idle. This moisture reduces the insulation resistance and electrical withstand
values of the windings. Before commissioning a motor/generator/transformer the drying out is
essential, particularly for high voltage machines (above 1000 V rating) and for machines kept is
damp/flooded condition. Drying out i also necessary prior to recornmissioning after a prolonged
idle period.
Step in Drying-out of a Motor or a Generator
1. Preliminary preparation of the machine, source of heat, measurements etc.
2. Arrange the set-up.
3. Apply heat by one of the suitable means gradually.
4. Take periodic readings of
 Clock-time
 Temperatures of windings, body and air,
 Insulation Resistance values of 15 second Megger Reading and 60 second Megger Reading
 Winding Resistance (At the beginning and at the end) and during decreasing
temperatures.
Megger (Insulation Resistance Tests) is used for measuring the Insulation Resistance between
windings, winding and earth. Temperature Measurement is by thermometer or thermocouples
or self resistance method.
5. Measure periodically of the Insulation Resistance values.
6. Initially, during the first few hours (for medium motors), the values of insulation resistance
reduces even though the heat is being applied for Drying-out. During initial heating period, the
moisture trapped in the insulation in form of small globes gets released within the insulation.
Hence the insulation resistance value starts reducing.
7. Intermediate Stage: After a span of a few hours or a few days the insulation resistance reaches
a steady value. This indicates that the moisture has spread all over the insulation.
8. Rising Stage. After a few hours of steady value, the insulation resistance starts rising.
9. The drying-out process is stopped when the desired value of Insulation resistance (hot) is
reached. In case of large machine the insulation resistance is important. The input power is
switched off.
10. The winding resistances are measured for various temperatures as the temperatures start
falling.
Methods of drying out an electrical machine
(a) By using chamber and resistor heaters
The machine to be dried is placed in a drying chamber. The drying chamber should be of volume
about 4 times the volume of motor. The air is circulated by means of fans and air circulation
system. The air temperature is periodically measured by means of thermometers. The moisture
expelled from the machine letout of the drying chamber with outlet air.
Figure 2: Drying by hot air

(b) By radiating lamp. (Infrared Lamps)
This is a most convenient and simple method used for medium and small motors. The infrared
lamps are used. The lamps are located in the chamber opposite to the motor winding. (The rotor
is removed). The heating should be continuous and carefully controlled so that it does not rise
too high, thus scroching and damaging the insulation. In order to ascertain how drying out is
proceeding, "Megger" reading should be taken every 12 hours and drying should be continued
until figures obtained are constant for four successive readings.
Figure 3: Drying by radiating lamps.

(c) By circulating short-circuit current
This is most convenient method of drying any electrical machine such as generator, slip-ring
motor, synchronous motor, d.c. motor, field windings etc.
The machine is connected to low voltage source. The input voltage, current, power, the
temperature of winding temperature of body, temperature of air are periodically measured. The
end shields of the machine are removed. The machine body is covered with trapaulin. No cool air
below shall come over hot winding.
The increase in temperature should be very gradual up to the value of not exceeding 70°C. The
cooling down is also gradual.
During the drying out period, readings of temperature and insulation resistance shall be taken at
short interval of time in order to see how the drying out is progressing.
Figure 4: Short Circuit Current Method

After drying out, air drying varnish should be applied by brush on the winding surface only. This
should be only applied when this is in hot condition to prevent absorption of moisture. The motor
should be watched constantly during drying period.
Transmission Tower:
Towers are used for extra high tension for very great height overhead line Supports and are made
of fabricated steel of angle-irons or channels [Figure 5(a)]. Towers can be built up to any desired
height and to withstand all the full of the conductors which they hold. Broad based type of design
of towers are adopted at points where they are subjected to greater pull viz. at terminal and at
angle points etc. But narrow based towers are used at intermediate points. Various angle iron
sections are used to form a close cage to form tower as shown in Figure 5 (b) & (c).
Towers used for transmission include single circuit and double circuit towers. Towers are either
self-supporting or guyed towers in following types:
Figure 5(a) E.H.T. Tower
Figure 5(b) Single Circuit Tower
Figure 5(c) Double Circuit Towers

Classification of Transmission Tower
The following the main towers used in transmission of electric power.
a. Tangent towers
b. Anchored towers
c. Angle towers
d. Dead-end towers
e. Transposition towers
a. Tangent Towers (Self-supporting):
These are used for norm span and straight line. About 85% of towers in a transmission line are
of this type. This towers support the conductors and are not designed for load. Under normal
condition the tangent supports take up load caused by the mass of conductors, insulators, and
wind pressure exerted on the conductors and supports.
b. Anchored towers :
The anchor towers are erected in straight sections of the router to pass over highways,
communication lines and small rivers. The anchor tower must be of robust and strong design with
anchor and guy for additional strength.
c. Angle towers:
Angle towers are erected at the corners of the overhead line route turns. They are erected
where the conductors supported change direction slightly and the resultant loads are small. At
large angles of turn, use is made of anchor angle towers which are of a more robust design.
d. Dead-end towers:
The dead-end towers are a type of anchor tower erected at the end or beginning of a
transmission line. Under normal conditions they take up the entire pull of conductors which
terminate on them.
e. Transposition towers:
In electrical power transmission, a transposition tower is a transmission tower that changes
the relative physical positions of the conductors of a transmission line in a Poly-phase system. A
transposition tower allows these sections to be connected together, while maintaining adequate
clearance for the conductors. This is important since it distributes electrical impedances between
phases of a circuit over time, reducing the problem of one conductor carrying more current than
others.
Installation of Transmission Tower:
There are four main methods of the erection of steel transmission towers which are described
below:
1. Build-up method or piecemeal method.
2. Section method.
3. Ground assembly method.
4. Helicopter method.
1. Build Up Method of Transmission Tower Erection
This method is most commonly used in India for the erection of 6.6 kV, 132 kV, 220 kV, and 400
kV transmission line towers due to the following advantages:
1. Tower materials can be supplied to the site in a knocked down conditions which facilitates
easier and cheaper transportation.
2. It does not require any heavy machinery such as cranes etc.
3. Tower erection activity can be done in any kind of terrain and mostly throughout the year.
4. Availability of workmen at cheap rates.
This method consists of erecting the towers, member by member. The tower members are kept
on the ground serially according to the erection sequence to avoid search or time loss. The
erection progresses from the bottom upwards.
The four main corner leg members of the first section of the tower are first erected and guard
off. Sometimes more than one contiguous leg section of each corner leg is bolted together at the
ground and erected.
The cross braces of the first section which are already assembled on the ground are raised one
by one as a unit and bolted to the already erected corner leg angles. First section of the lower
thus built and horizontal struts (belt members) if any, are bolted in position. For assembling the
second section of the tower, two gin poles are placed one each on the top of diagonally opposite
corner legs.
These two poles are used, for raising parts of the second section. The leg members and braces of
this section are then hoisted and assembled. The gin poles are then shifted to the corner leg
members on the top of the second section to raise the parts of the third section of the lower in
position for assembly. Gin poles are thus moved up as the tower grows.
This process is continued until the complete tower is erected. Cross-arm members are assembled
on the ground and raised up and fixed to the main body of the tower. For heavier towers, a small
boom is rigged on one of the tower legs for hoisting purposes. The members/sections are hoisted
either manually or by winch machines operated from the ground.
For smaller base towers/vertical configuration towers one gin pole is used instead of two gin
poles. In order to maintain speed and efficiency, a small assembly party goes ahead of the main
erection gang and its purpose is to sort out the tower members, keeping the member’s incorrect
position on the ground and assembling the panels on the ground which can be erected as a
complete unit.
2. Section Method of Transmission Tower Erection
In the section method, major sections of the tower are assembled on the ground and the same
are erected as units. Either a mobile crane or a gin pole is used. The gin pole used is approximately
10 m long and is held in place by means of guys by the side of the tower to be erected.
The two opposite sides of the tower section of the tower are assembled on the ground. Each
assembled side is then lifted clear of the ground with the gin or derrick and is lowered into
position on bolts to stubs or anchor bolts.
One side is h held in place with props while the other side is being erected. The two opposite
sides are then laced together with cross members and diagonals; and the assembled section is
lined up, made square to the line. After completing the first section, the gin pole is set on the top
of the first section. The gin rests on a strut of the tower immediately below the leg joint. The gin
pole then has to be properly guyed into position.
The first face of the second section is raised. To raise the second face of this section it is necessary
to slide the foot of the gin on the strut of the opposite face of the tower. After the two opposite
faces are raised, the lacing on the other two sides is bolted up. The last lift raises the top of the
towers.
After the tower, the top is placed and all side lacing has been bolted up all the guyed are thrown
off except one which is used to lower the gin pole. Sometimes whole one face of the tower is
assembled on the ground, hoisted, and supported in position. The opposite face is similarly
assembled and hoisted and then the bracing angles connecting these two faces are fitted.
3. Ground Assembly Method of Tower Erection
This method consists of assembling the tower on the ground and erecting it as a complete unit.
The complete tower is assembled in a horizontal position on even ground. The tower is
assembled along the direction of the line to allow the cross arms to be fitted. One slopping
ground, however, elaborate packing of the low side is essential before assembly commences.
After the assembly is complete the tower is picked up from the ground with the help of a crane
and carried to its location, and set on its foundation. For this method of erection, a level piece of
ground close to footing is chosen from the tower assembly.
This method is not useful when the towers are large and heavy and the foundations are located
in arable land where building and erecting complete towers would cause damage to large areas
or in hilly terrain where the assembly of the complete tower on the sloping ground may not be
possible and it may be difficult to get the crane into position to raise the complete tower.
In India, this method is not generally adopted because of the prohibitive cost of mobile crane,
and the non-availability of good approach roads to tower locations.
4. Helicopter Method of Transmission Tower Erection

In the helicopter method, the transmission tower is erected in section. For example, the bottom
section is first lifted on to the stubs and then the upper section is lifted and bolted to the first
section and the process is repeated till the complete tower is erected.
Sometimes a completely assembled tower is raised with the help of a helicopter. Helicopters are
also used for lifting completely assembled towers with guys from the marshaling yards where
these are fabricated and then transported one by one to line locations. A helicopter hovers over
the line location while the tower is securely guyed.
The ground crewmen connect and tighten the tower guys. As soon as the guy wires are
adequately tensioned the helicopter disengages and files to the marshaling yard. This method is
adopted where the approach is very difficult or to speed up the construction of the transmission
line.
Tightening of Nuts and Punching of Threads and Tack Welding of Nuts of Transmission Towers
All nuts shall be tightened properly using correct sized spanners. Before tightening it is ensured
that filter washers and plates are placed in relevant gaps between members, a bolt of proper size
and length are inserted and one spring washer is inserted under each nut.
In the case of step bolts, the spring washer shall be placed under the outer nut. The tightening
shall be carried on progressively from the top downwards, care being taken that all bolts at every
level are tightened simultaneously. It may be better to employ four persons, each covering one
leg and the face to his right.
The threads of bolts shall be projected outside the nuts by one to two threads and shall be
punched at three positions on the top inner periphery of the nut and bolt to ensure that the nuts
are not loosened in course of time. If during tightening a nut is found to be slipping or running
over the bolt threads, the bolt together with the nut shall be changed outright.
Painting of Joints of Transmission Tower
For galvanized towers is coastal or highly polluted areas, the joints shall be painted with zinc paint
on all contact surfaces during the course of erection.
Checking the Verticality of Erected Transmission Towers
The finally erected tower shall be truly vertical after erection and no straining is permitted to
bring it in alignment. The tolerance limit for vertical shall be one in 360 of the tower height.

EMIT Unit-7

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Unit-7: Installation Ghatal Govt.

Supply voltage as stamped Minimum Insulation

(ii) Ground Condition:

(iv) Size of Concrete Foundation

Installation of rotating machines as per I.S. 900-1992:

(iii) Laying of supply and control cables.

(iii) Laying of supply and Control Cables:

(x) Installation of Fitting of other parts Accessories, Piping etc:

(xiii) Setting/Adjusting of Protection Relay:

(xiv) Test on Motor/Machine Starter and Associated Equipments:

Drying-Out of an Electric Rotating Machines and Its Necessity

Figure 2: Drying by hot air

Figure 3: Drying by radiating lamps.

Figure 4: Short Circuit Current Method

Figure 5(a) E.H.T. Tower

Figure 5(b) Single Circuit Tower

Figure 5(c) Double Circuit Towers

4. Helicopter Method of Transmission Tower Erection

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