GIN POLE-SOP Tower Erection - Transmission Line

KEC INTERNATIONAL LIMITED
Document Name Work Instructions
Document Title SOP on Erection using Gin Pole in Transmission Line

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Document No. KEC_PE_0017 VERSION: - 1 Date 15 September 2020
SOP on Tower Erection Using Gin Pole
Gaurav Bhaskar Dhiraj Rajinder

Chugh Sarathy Vashisth Gupta
Name Sign Name Sign Name Sign Name Sign
Prepared By Reviewed By Approved By


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Contents
1. Objective: ...................................................................................................................................... 3
2. Scope: ............................................................................................................................................ 3
3. References: .................................................................................................................................... 3
4. Acronyms: ..................................................................................................................................... 4
5. Roles and Responsibilities: ........................................................................................................... 5
6. Standard Machines and Tools Used: ............................................................................................. 5
7. Tower Erection: Standard T&P List .............................................................................................. 6
8. Tower Erection: PPE Matrix .......................................................................................................... 6
9. Flow Chart: Tower Erection Operation: ........................................................................................ 7
10. Flow Chart: Selection of Manpower and Tools & Tackles ............................................................. 8
11. Pre Operational Checks: ............................................................................................................... 9
A. At Site ......................................................................................................................................................................... 9
B. In Stores.................................................................................................................................................................... 11
C. Working on Hilly Region .......................................................................................................................................... 13
12. Operational Procedure: .............................................................................................................. 13

A. Common Checks ......................................................................................................................................................... 13
B. Tower Erection Using Gin Pole (Option 1: Modular Assembly) ................................................................................... 15
I. Planning................................................................................................................ 15
II. Pre- Execution Work ............................................................................................. 16
III. Ground Assembly .............................................................................................. 16
IV. Gin Pole Assembly ............................................................................................ 17
V. Erection of Gin Pole .............................................................................................. 17
VI. Lifting of Assembled Modules (Tower Parts) ..................................................... 18
C. Tower Erection by Gin Pole (Option 2 : Panel Wise).................................................................................................... 19
I. Panel Lifting Sequence ......................................................................................... 19
II. Second Panel Lifting Sequence ............................................................................ 19
III. Earth Peak and Cross Arm Lifting...................................................................... 20
IV. Box Cross Arm Lifting Sequence ....................................................................... 20
D. Tightening and Punching of Nuts and Bolts: .............................................................................................................. 21
E. Tack Welding ............................................................................................................................................................. 21
F. Working During Adverse Weather Conditions............................................................................................................ 22
G. Electrical Clearance for Storing Tower Material at Store ........................................................................................... 23
13. Post Operational Checks: ............................................................................................................ 23

14. Safety:......................................................................................................................................... 24
15. Checklists, Records, Permits and Other Requirements: ............................................................. 25

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1. Objective:
To understand the Procedure of Tower Erection using Gin Poles in Transmission Lines
2. Scope:
A. This SOP is applicable in all KEC projects and shall be followed by all KEC Employees,
Sub-contractors and their employees.
B. Modular assembly method of Tower Erection by Gin pole has been considered
while preparing this SOP.
C. SOP is applicable to the following sequence of activities:
a) Collection and loading of tower members from store
b) Transporting Unloading and Segregation of tower members at site
c) Planning of modular ground assembly to be done using Tower Erection drawing
and BOM by project team.
d) Assembly of the tower members at ground level as per drawings
e) Erecting the tower in sequential manner including fixing of diagonal members
f) Interlinked tower members to be tightened fully at the time of ground assembly
to save time for tightening after Tower Erection.
g) Non linked tower members to be tightened finally after connecting with erected
members
3. References:
A. QMS Work Procedure
B. HSE Manual
C. Tower Erection Safety Checklist
D. Erection Standard Operating Procedure
E. Electricity Act 2003 and Electricity Rule 2005
F. IS 5216-1 (1982): Recommendations on safety procedures and practices in Electrical
work Part 1

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4. Acronyms:
ACRONYMS FULL FORM

SOP Safe Operating Procedure
QMS Quality Management System
PTW Permit to Work
KV Kilo Volt
PTP Pre-Task Plan
LOTO Lock out Tag out
P&M Plant & Machinery
EHS Environment, Health & Safety
T&P Tools and Plants
SLI Safe Load Indicator
BOCW Act Building and Other Construction Workers Act
HVDC High Voltage Direct Current
DC Direct Current
HP Horse Power
ISMC Indian Standard Medium channel
HT High Tension
LT Low Tension
SWL Safe Working Load
MT Metric Ton
PP Poly Propylene
S/C Single Circuit
D/C Double Circuit
M/C Multi Circuit
IS International Standard
PPE Personal Protective Equipment

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5. Roles and Responsibilities:


A. Primary Responsibility: Site Supervisor, Site Engineer, Section Incharge and Safety
Officers
B. Secondary Responsibility: Project Manager
6. Standard Machines and Tools Used:
Truck 10-12 MT Aluminum Gin Pole Hydraulic Winch
Pulley – Open/Close Two Sheave Pulley Trifor 5/7 MT
Steel Wire Rope (12mm) D-Shackles (6/8 MT) PP Ropes (22mm)


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7. Tower Erection: Standard T&P List

Standard List of T&P for Tower Erection
Sl. Using Gin
Particulars UOM
No. Pole
1 Hydraulic Power Winch-3.5T No 1
2 GIN Pole-20M-LW Set 1
3 Trifor-5/8T No 8
4 Double sheave Pulley-5 MT No 10
5 Three bolted clamp-Earthwire No 8
6 Single sh. pulley-8/9.5MT-Close No 12
7 Single sh. pulley-8/9.5MT-Open No 10
8 Wire Rope -12 MM Mtr 2000
9 D Shackle- 6.5 MT No 30
10 D Shackle- 8.5 MT No 24
11 PP Rope 22mm Bdl 14
12 Crow Bar No 40
8. Tower Erection: PPE Matrix
PPE MATRIX
Safety Erection Safety Gang Height Helper
PPE List Welder Helper
Supervisor Supervisor Steward Leader Work Fitter Fitter
Safety Helmet - Green
Safety Helmet - White
Safety Helmet - Yellow
Safety Helmet - Red
Safety Shoe - Leather
Canvas Shoe
Full Body Harness
Horizontal Life Line
Reflective Jacket
Fall Arrestor Rope
Grab Type Fall Arrestor
Thermo Latex Hand Gloves
Shoulder Pad
Goggles
Fire Extinguisher
Welding Shield
Welding Apron
Chrome Hand Gloves
Pen Type Induction Tester

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9. Flow Chart: Tower Erection Operation:
TRANSMISSION LINE TOWER ERECTION
SEGREGATE THE TOWER PARTS AT LOCATION
ASSEMBLE TOWER PARTS IN MODULAR SECTIONS ON GROUND WITH

COMPLETE TIGHTENING & PUNCHING
SELECT THE POSITION OF GIN POLE ON GROUND FOR OPTIMUM USE
ANCHOR BASE PLATE OF GIN POLE ON SELECTED POSITION
ASSEMBLE GIN POLE AT GROUND
ERECT GIN POLE USING HYDRAULIC WINCH
ERECT THE MODULAR SECTIONS USING GIN POLE
COMPLETE THE SECTION WITH TIGHTENING & PUNCHING
SHIFTING OF GIN POLE TO NEXT LEVEL
COMPLETE THE TOWER
EARTH PEAK LIFTING
LIFTING OF CROSS ARMS FROM TOP TO BOTTOM
WELDING OF BOLT AND NUTS
PAINTING OF WELDED BOLT AND NUTS


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10. Flow Chart: Selection of Manpower and Tools & Tackles
SELECTION OF MANPOWER
SUB CONTRACTOR WITH REQUISITE KNOWLEDGE AND EXPERIENCE
SCREENING OF WORKMEN
TL SAFETY INDUCTION TRAINING
VIRTUAL REALITY TRAINING
PREMEDICAL CHECK UP FOR WORKMEN
ISSUE OF HEIGHT PASS AND SAFETY INDUCTION CARD
ISSUE OF PPE AT STORE
ISSUE OF T&P AT STORE (THIRD PARTY CERTIFIED)
SHIFT THE MATERIAL FROM STORE TO SITE


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11. Pre Operational Checks:
A. At Site
a. Ensure that the Tower Erection crews are experienced and aware of the Tower
Erection work methodology using GIN Poles
b. Ensure that the availability of following manpower resources at site as a
minimum:
Typical Tower Erection Gang
Resource Detail
Fitters (Height Work) 8 senior fitters with atleast 5 yrs of experience in Erection gang
Asistant Fitters 4-6 Assistant fitters for assembling tower members at ground
Drawing Master 1 Person
Gang Leader/Supervisor 1 Person
Winch Operator 1 Person
Helpers 8 helpers in a Erection gang
c. Ensure screening and visual safety induction is done and safety induction card is
issued for everyone.
d. Access the fitter for the requisite minimum 5-year experience and the
knowledge on the work procedure of tower erection
e. Age limit based on minimum / maximum experience say not exceeding approximate
35 to 40 year maximum and minimum 20 Years.
f. Ensure that the fitters who are likely to be engaged on height works have gone
through premedical health check-up and issued with Height Pass
g. Ensure that the backfilling of foundation is completed as per specification
before starting the tower erection
h. Ensure level, diagonals & back to back of stub are as per drawings.

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i. Ensure that all erection tools tackles and power winches are inspected and
certified by the competent authority / P&M department and easily identifiable.
j.
k. Inspect the Gin pole before use and check for welding, bend, rust and tightening
of joints between the Gin Pole modules.
l. Inspect all pulleys, D shackle, slings on daily basis before starting the work.
m. Check the operator fitness and experience during screening process
n. Prepare a Pre-Task Plan when the works are carried out near existing energized
lines.
o. The PTP shall be circulated to section in-charge, EHSO & Project Manager.
p. Ensure that Cardinal Rule # 2 - LOTO is followed during shutdown
q. Ensure that the sectional weight of the tower members is available with the
drawing master / front line supervisor and the project team.
r. Ensure that all works near the power line are identified and permits are acquired.
s. Ensure that the tower works are carried at a safe distance from the existing
energized lines as prescribed in the Indian Electricity Rules, 2005. If the distances
cannot be maintained, a line clearance is required.
t. Ensure availability of at least one trained First aider in each shift
with each gang.
u. Ensure the availability of a fully equipped First Aid box at each
erection location as per the BOCW Act, 1996.
v. Display Do’s and Don’ts and Cardinal Rule 1 & 2 posters at tower
erection location.

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w. Check the medical condition of workmen before commencing the work. If found
unfit to work at height, the fitter should be permitted to work at ground level only.
x. Ensure that the Cardinal Rule #1 “Harness the HOOK ALWAYS”, while working at
height is followed by all workmen.
y. Ensure shifting of tower parts from stores to site locations by using trucks only.
B. In Stores
a. Ensure to check the functioning of SLI, over hoist limit

switch, swing horn and reverse horn.
b. Ensure Third party examination report as per Form No 29 is
checked.
c. Ensure tower parts are unloaded before sunset.

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d. Ensure that full body harness and lanyards are stored in an area free from rain
and direct exposure to sunlight.
e. Ensure proper stacking of PPE at store.
 Knotting of lanyards are prohibited.

f. Cordon the erection area with warning tape to prevent entry of unauthorized
person’s and post warning signs.
g. Use shoulder pad on shoulders while shifting the tower members.
h. Ensure that workmen are not allowed to travel along with the tower members
placed on the truck.
i. Ensure presence of a competent person during the entire erection work.
j. Ensure that special care is taken while working near canals, river beds etc.
k. Ensure the availability of at least one trained swimmer in every erection gang,
while working on river crossing towers.
l. Check the swimming competency of workmen during the screening process,
before deployment in that area
m. Ensure the availability of lifesaving equipment such as lifebuoy, life jacket in
each gang.
n. Check the water current and engage boats if necessary.
o. se Concrete Block / ISMC 400 as guy rope support (Deadman) in sandy and wet
conditioned soil.
p. Ensure that work is suspended during adverse weather conditions such as
thunder, lightning rainfall and floods

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C. Working on Hilly Region
a. Assess and record the depth of valley.

b. Use safety net near the edge to prevent the fall of material
on road or public house.
c. Check the pathway for any hindrances before shifting the
material to the top.
d. Mark the danger locations clearly with signage’s.
e. Wherever materials need to be shifted manually, use a
hand trucks or any suitable means.
f. Use the appropriate access path. Do not opt for shortcuts
while shifting manual method.
g. Ensure group coordination between the workmen while handling heavy tower
members.
h. Use motorized and gravitational rope method to transport required materials to
work locations.
i. Ensure double sheave pulley rigging arrangement is used while lifting heavy
members.
j. Look for the possibility of using the crane for erecting the heavy towers
12. Operational Procedure:

A. Common Checks
a. Pl. refer the flow chart for the sequence of operation.

b. Ensure the tower members are set out and kept on the ground according to
erection sequence. The location shall be not below the tower.
c. Ensure that the first section legs are lifted (max. up to 12 m) during initial stage. All
the leg joints are fully tightened and polyamide rope (14 mm) is fixed on it to fix the
rope grab type fall arrester.
d. All workmen should use rope grab type fall arrester system while ascending /
descending on legs. Vertical lifeline should be installed on 2 sides of step bolt legs
(A and C legs).

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e. Step bolts shall be provided on the legs and tightened as per the specification.
Temporary step bolt shall be fixed in B&D legs during erection to ensure safe access
for climbing / standing on tower leg.
f. Complete the first section panel members and diagonal bracing members in all
respect.
g. Ensure horizontal life line is used by fitters while fixing the redundant.
h. Assess the position of fitters on partly erected towers and during tower erection in
progress.
i. Ensure that the lanyard of the harness is anchored on a firm fixed members. Do not
anchor the belt on bracings.
j. Ensure tool kit is used to prevent the fall of tommy bar while working at height.
k. Depute one height watcher equipped with whistle, binocular and Signal flag for
effective monitoring.
l. Before proceeding to the next section, lower section must be completed in all
aspects.
m. Ensure that this sequence is followed till the completion of all sections up to earth
peak.
n. Ensure that all bolts and nuts are tightened from top to bottom.
o. No person shall be allowed underneath the suspended load.
p. No person shall be allowed to climb on Gin pole for any purpose.
q. Ensure the maximum permissible angle between the guy rope and horizontal plane
is 45°.
r. Ensure that one anchor supports one guy only.
s. Ensure that a double crow bar of 32 mm diameter is provided for anchoring the guy
ropes.
t. Ensure that one guy rope of Gin pole is connected to trifor which is in center
opposite to the lifting load.
u. No trees shall be used for tying the guy supports.
v. Inspect all tower erection supports such as back stay and Deadman block before
commencement of work daily and specifically after a rainy day.

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B. Tower Erection Using Gin Pole (Option 1: Modular Assembly)

 Ensure the maximum capacity of the Gin Pole being used for each lift. We propose
to go with modular assembly methodology.
 Process flow for Erection using Gin Pole is shown below:
1. Planning
2. Pre Execution Work
3. Ground Assembly
4. Gin Pole Assembly
5. Erection of Gin Pole
6. Lifting of Tower Parts
I. Planning
The following need to be planned:
i. Base width: If the Base width is <= 20

meters, then a single Gin Pole should
be used at the center
ii. Height of the Tower and No. of Lifts
(no. of times the Gin Pole needs to be
lifted up for erecting the tower). The
objective should be to minimize the
no. of lifts to, maximize the efficiency
iii. Ground Assembly of the Tower based
on the above 2 inputs
iv. Load Capacity of the Gin Pole ,i.e., the
maximum tonnage that the Gin Pole
can take in one lift under different
tilting conditions
v. Movement of the Gin Pole on the ground for every leg erection, with respect
to the center point. This movement needs to be minimized for higher
efficiency

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vi. The weight of the assembled parts of the tower should be confirmed with
their respective BOMs ( Bill of Materials) to verify the load on the Gin Pole for
every lift. This weight should be within the Load Capacity of the Gin Pole.
Perfect
vii. Gin Pole can be tilted by a maximum 20
Vertical
degrees, but tilting reduces its loading Tilting
capacity. To use the full load capacity
of the Gin Pole, it should be positioned
perfect vertical.
II. Pre- Execution Work

i. Level of Stubs: All the 4 stubs must be at the same level
ii. Back to Back: The base width must be checked to ensure they are as per the
planned value
iii. Diagonal of Tower should be as according to the planned value
iv. Backfilling must be properly done, up to the ground level
v. Housekeeping of the ground (by removing stones, pebbles, etc.) should be
done
III. Ground Assembly

i. Check the leveling of the ground and housekeeping, in and around the
location.
ii. Ensure wooden ballies are used below the assembled tower modules to avoid
friction during lifting of modules.
iii. The assembled components must be placed as close as possible to the actual
point of erection so as to minimize the load on the Gin Pole.
iv. Ensure all the tightening and punching of the bolts of the fixed members to
be completed on ground before erection.
v. Members which are to be connected with another module to be kept loose.

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IV. Gin Pole Assembly

i. A two-sheave pulley must be connected to the top of the Gin Pole for lifting
tower parts.
ii. A single sheave pulley needs to be connected to the bottom of the Gin Pole.
The loose end of the rope from the two-sheave pulley on the top, passes
through this single sheave pulley at the bottom to the Winch machine.
iii. The positions of both the top and the bottom pulleys must be aligned to the
same plane of the Gin Pole.
iv. For frictionless movement of Gin Pole on the ground, steel sheets of 4 or 6
mm thickness should be used, underneath the Gin Pole.
v. Connections of the Gin Pole Modules should be done properly. Please ensure
that all bolts and nuts are tightened and locked properly.
vi. Ensure that the rotations of the top and bottom portions of the Gin Pole is
smooth.
Two Sheave Pulley Arrangement
Gin Pole
Gin Pole Guys
LOAD
Single Sheave Pulley arrangement

HYDRAULIC
Trifors WINCH
1
Stubs
1
Sling Arrangement
Tower Foundation - Chimney
V. Erection of Gin Pole

i. Derrick Pipes of 3 inches’ diameter and 4-meter length are connected

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together and fixed to the ground

ii. Single sheave pulley lifting arrangement is to be made on this derrick
arrangement for lifting Gin Pole from the ground
iii. Base plate of the Gin Pole has to be anchored on the ground with the help of
Crow bars (32 mm diameter) or anchor pins.
iv. Gin Pole should be positioned near to the lifting leg.
v. With the help of the Winch machine and the Derrick arrangement the Gin
Pole is erected on the ground.
vi. The bottom portion of the Gin Pole needs to be anchored to all the 4
chimneys of the tower
vii. Guy support needs to be given to the top of the Gin Pole, i.e., the top of the
Gin Pole needs to be anchored to the chimney with the help of Guy Ropes
(Guiding Rope which are wire ropes). This should be done in such a way that
the Bracing holes ( 2 holes at the stub which are used for Tower erection) are
not hindered
VI. Lifting of Assembled Modules (Tower Parts)

i. Lifting of assemble modules to be planned in accordance with bottom
position of Gin pole on the tower and tilting of Gin Pole.
ii. Ensure load carrying capacity of Gin Pole to be aligned with Load diagram
provided on Gin Pole.
iii. A Typical load chart diagram of Gin pole is shown below:

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C. Tower Erection by Gin Pole (Option 2 : Panel Wise)
I. Panel Lifting Sequence
i. Ensure wooden ballies are used below the assembled tower panels to avoid
friction during lifting of modules
ii. Ensure that the guy rope, opposite to the leg being lifted, is tightened with
the help of trifor
iii. Plan the position of the base plate to be anchored on ground for lifting the
Tower panels so as to minimize the no of movements of the Gin Pole.
iv. Ensure all the tightening and punching of the bolts of the fixed members to
be completed on ground before erection.
v. Shift Gin pole nearer to the next panel that is to be lifted.
vi. Lift the panel with the help of two 3 MT nylon web sling.
vii. Use 3 tag lines of 22 mm PP rope during lifting of panel to prevent
oscillation.
viii. Ensure minimum tilting of Gin Pole to maximize the lifting capacity.
ix. Ensure that the inclination of Gin pole is not more than 15 degrees to the
vertical
II. Second Panel Lifting Sequence
i. Check if the back to back length of A to B, B to C, C to

D, and D to A exceeds 25 m. If yes then a separate
wire rope guy of 18 mm is provided at the junction
point of each leg where the gin pole sling is wrapped.
ii. Ensure that the guy rope is anchored to the legs of
tower if possible. If not then anchoring to be done where three-four pieces
are connected to sustain the load during lifting of tower parts.

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iii. Ensure that the bucket of gin pole at the bottom to be

increased proportionately as the width of tower
shrinks.
iv. Ensure that all the leg guy ropes are secured tightly.
v. Ensure that all the fitters are stationed at ground till
the panel reaches its final position.
III. Earth Peak and Cross Arm Lifting

The final step in the operational procedure is Earth Peak and Cross Arm Lifting.
The following checks should be performed during Earth Peak and Cross Arm Lifting :
i. Check the trifor for its working condition and bulldog clamps for its
tightening.
ii. Ensure that the center tag line is loosened slowly
iii. Ensure availability of additional tag line of 24 mm PP rope apart from center
tag line, which would be required to control the movement of peak, so that
the minimum clear distance is maintained.
iv. Ensure Presence of Competent supervisor available
IV. Box Cross Arm Lifting Sequence
Once the lifting of second cage is completed, lifting of box cross arm is done.
The following checks should be performed during box cross arm lifting sequence:
i. Ensure that the assembled weight of any assembly is well within the SWL at
appropriate height for tower erection with GIN pole.
ii. Ensure that the tower is fully braced and bolt are fully tightened before
lifting the box cross-arm.
iii. Ensure that all the diagonals and redundant members including bracings are
in place.

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iv. Ensure that the box is assembled at ground and lifted by means of 4
numbers of web sling of 3 MT capacity. Length of Web Sling should be in
proportion to width of Cross Arm.
v. Ensure all the 4 web slings are connected by means of a D-Shackle of
required capacity.
vi. Ensure that the box is lifted by means of a 2-sheave pulley of 5 MT capacity
attached to the D-Shackle.
vii. Ensure that one no pp rope of 22 mm is connected to the center of the box
as tag line to guide the cross arm during the box lifting.
viii. Ensure that the center tag line is slowly loosened during the lifting, to
minimize the angle between the lifting wire rope and Gin Pole.
ix. Ensure that the center tag line is at a distance double the height of cross
arm to be fixed on the tower.
D. Tightening and Punching of Nuts and Bolts:

The key checks that should be carried out during tightening and punching of bolts and
nuts are as follows:
a. Ensure the presence of gang leader / supervisor at site during the tower erection to
monitor the activities.
b. Ensure that the spanners are secured to the tools bag to avoid fall of spanner from
height.
c. Ensure that all the workmen engaged in tightening and punching activities wear
safety goggles to avoid eye injury.
d. Ensure that the horizontal life line is used by all workmen during tightening and
punching of bolts and nuts.
e. Use power operated torque wrench for tightening of bolts & nuts.
E. Tack Welding
a. Once the tightening and punching of bolts and nuts are completed, tack welding
and painting of bolts and nuts is done to prevent nuts and bolts from being removed.
b. The key checks that should be carried out during tack welding are as follows:

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c. Ensure tack welders are trained to climb towers and height pass shall be
issued.
d. Ensure that tack welding activity is not performed during rain.
e. Ensure that the tack welding is done as per specification using standard
quality of welding rods, and the welding machine is earthed as required.
f. Ensure that all welders use PPE such as rope grab type fall arrestor, welding
shield mounted on helmet, Apron and chrome hand gloves during welding
process.
g. Ensure that all welding activities are carried out under the supervision.
h. Ensure MSDS of paint is available at both stores and in work location.
F. Working During Adverse Weather Conditions

The following key checks must be performed while working during adverse weather
conditions:
a. Check the wind speed with the help of Anemometer or a mobile application.
b. STOP the height work activity if the wind speed exceeds 30 km / hr measured at 1 m
from the ground.
c. Refer Beaufort wind force scale for checking the wind speed at a set distance above
ground or sea level.
d. Ensure that mid-day breaks are provided to the gang during summer, as per site
management’s decision.
e. Follow the local authorities’ instructions while working on towers during summer.
f. Provide ORS powder / Glucose to workmen during summer.

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G. Electrical Clearance for Storing Tower Material at Store
a. The following safety clearance shall be maintained for storage of tower parts
either in the stores or project site. (As per Indian Electricity Rules 1956 chapter
VII)
Clearance above
Voltage (KV)
Ground (m)
Up to 11 4.60
33 5.10
66 5.49
132 6.10
220 7.01
400 8.84
765 12.24
800 12.48
13. Post Operational Checks:
Once the operational procedures for tower erection are completed, the following post-
operational checks must be performed:
A. Ensure that the tower has been completed in all aspects i.e. all the tower members
are erected, tightened, punched, welded and painted.
B. Ensure that all unwanted materials including debris are removed and the area is
cleared
C. Ensure fitness report is completed and recorded.

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SAMPLE FORMAT FOR TOWER FITNESS CERTIFICATE

TOWER FITNESS REPORT
Loc No : Date of Inspection

Tower Type :
NAME OF SECTION :
OK - Acceptable
Sr No Description Qty in Nos Comments
XX - Not Acceptable
TOWER ERECTION
Alignment of tower wrt previous tower
1
(In case of suspension)
2 Tightening of all tower members
3 Tack welding
4 Punching Over Tack welding
5 Missing Members
Missing N&B including step bolts,

6
pack washers
7 Blank Holes
8 Rusting of Members/ Bend Members
9 Application of Zinc rich & enamel paint
10 EARTHING
i) Pipe Type
ii) Counter Poise Type
Remarks :
Certified that the above tower is completed in all aspects
Sign of Erection Incharge
14. Safety:
A. Ensure a minimum of 12 Fitters and 8 unskilled workers are engaged while erecting
the tower by gin pole.
B. Ensure that the appropriate and sufficient number of tools and tackles are available
as prescribed.

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C. Provide 4 nos. of 12 mm wire rope as guy at the top of the gin pole.
D. Anchorage point of gin pole top should be on the legs of towers during tower
erection.
E. All the eight trifors to be mounted on the stub of tower to adjust, loosen or tighten
the guy rope during lifting of materials.
F. Place the winch at least 50 m away from tower legs in the direction of the line.
G. Ensure the fleet angle for the winch is maintained.
15. Checklists, Records, Permits and Other Requirements:
A. Tower Erection Safety Checklist

B. EHS Risk Assessment
C. Height Work Permit
D. LC Shut down Work Permit
E. Equipment fitness for Vehicle and earth moving equipment
F. Do’s and Don’ts on tower erection activity
G. Height pass and safety induction card
H. Data bank of height work fitters
I. Lifting tools and tackles inspection report
J. PPE Inspection report
K. Color coding of Tools and tackles
L. Competent authority inspection report
M. Height Watcher (Safety Marshal) with whistle and binoculars
N. Fully equipped first aid box
O. Tower Fitness report
P. Reprimand Guidelines

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KEC INTERNATIONAL LIMITED

Document Name Work Instructions

Document Title SOP on Erection using Gin Pole in Transmission Line

SOP on Tower Erection Using Gin Pole

Gaurav Bhaskar Dhiraj Rajinder

Name Sign Name Sign Name Sign Name Sign

Prepared By Reviewed By Approved By

Document Title SOP on Erection using Gin Pole in Transmission Line

12. Operational Procedure: .............................................................................................................. 13

13. Post Operational Checks: ............................................................................................................ 23

Document Title SOP on Erection using Gin Pole in Transmission Line

Document Title SOP on Erection using Gin Pole in Transmission Line

ACRONYMS FULL FORM

Document Title SOP on Erection using Gin Pole in Transmission Line

5. Roles and Responsibilities:

6. Standard Machines and Tools Used:

Truck 10-12 MT Aluminum Gin Pole Hydraulic Winch

Pulley – Open/Close Two Sheave Pulley Trifor 5/7 MT

Steel Wire Rope (12mm) D-Shackles (6/8 MT) PP Ropes (22mm)

Document Title SOP on Erection using Gin Pole in Transmission Line

7. Tower Erection: Standard T&P List

8. Tower Erection: PPE Matrix

Document Title SOP on Erection using Gin Pole in Transmission Line

9. Flow Chart: Tower Erection Operation:

TRANSMISSION LINE TOWER ERECTION

SEGREGATE THE TOWER PARTS AT LOCATION

ASSEMBLE TOWER PARTS IN MODULAR SECTIONS ON GROUND WITH

SELECT THE POSITION OF GIN POLE ON GROUND FOR OPTIMUM USE

ANCHOR BASE PLATE OF GIN POLE ON SELECTED POSITION

ASSEMBLE GIN POLE AT GROUND

ERECT GIN POLE USING HYDRAULIC WINCH

ERECT THE MODULAR SECTIONS USING GIN POLE

COMPLETE THE SECTION WITH TIGHTENING & PUNCHING

SHIFTING OF GIN POLE TO NEXT LEVEL

COMPLETE THE TOWER

EARTH PEAK LIFTING

LIFTING OF CROSS ARMS FROM TOP TO BOTTOM

WELDING OF BOLT AND NUTS

PAINTING OF WELDED BOLT AND NUTS

Document Title SOP on Erection using Gin Pole in Transmission Line

10. Flow Chart: Selection of Manpower and Tools & Tackles

SUB CONTRACTOR WITH REQUISITE KNOWLEDGE AND EXPERIENCE

TL SAFETY INDUCTION TRAINING

VIRTUAL REALITY TRAINING

PREMEDICAL CHECK UP FOR WORKMEN

ISSUE OF HEIGHT PASS AND SAFETY INDUCTION CARD

ISSUE OF PPE AT STORE

ISSUE OF T&P AT STORE (THIRD PARTY CERTIFIED)

SHIFT THE MATERIAL FROM STORE TO SITE

Document Title SOP on Erection using Gin Pole in Transmission Line

11. Pre Operational Checks:

Document Title SOP on Erection using Gin Pole in Transmission Line

Document Title SOP on Erection using Gin Pole in Transmission Line

a. Ensure to check the functioning of SLI, over hoist limit

Document Title SOP on Erection using Gin Pole in Transmission Line

 Knotting of lanyards are prohibited.

Document Title SOP on Erection using Gin Pole in Transmission Line

C. Working on Hilly Region

a. Assess and record the depth of valley.

12. Operational Procedure:

a. Pl. refer the flow chart for the sequence of operation.

Document Title SOP on Erection using Gin Pole in Transmission Line

Document Title SOP on Erection using Gin Pole in Transmission Line

B. Tower Erection Using Gin Pole (Option 1: Modular Assembly)