NSC-400-CE-3110-MOS-01-A-Method Statement For 69kV Transmission Line Construction

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METHOD STATEMENT FOR 69KV

TRANSMISSION LINE CONSTRUCTION

ENGINEERING, PROCUREMENT, AND CONSTRUCTION (EPC) FOR

GARCIA-2 SOLAR POWER PROJECT

Doc
Document Number Rev Doc Data Issued
Type
Tite

Method Statement for


MOS A 17th September 2022
NSC-400-CE-3110-MOS-01 69Kv Transmission Line
Construction

Owner
Nuevo Solar Energy Corp.

Owner ’s Representative
RINA Tech Singapore Pte. Ltd.

Main Contractor
Consortium of JCE and SUMEC Philippines

Prepared by: Checked by: Verified By: Employer:

Name: Li Chenxiao Name: Riddle Yang Name: Name:


Date: Date: Date: Date:

SUMEC COMPLETE EQUIPMENT AND ENGINEERING CO., LTD.


CONTENTS
Contents
1. INTRODUCTION..............................................................................................................................4
2. PURPOSE..........................................................................................................................................4
3. DEFINITION.....................................................................................................................................4
4. PROCUREMENT..............................................................................................................................4
5. RESPONSIBILITIES.........................................................................................................................4
6. SAFETY.............................................................................................................................................6
7. TRANSPORTATION & HANDLING..............................................................................................8
8. UNLOADING....................................................................................................................................9
9. LIFTING FOR THE FINAL PLACEMENT...................................................................................11
10. METHODOLOGY OF CHECK SURVEY WORKS......................................................................13
11. METHODOLOGY OF POLE ERECTION.....................................................................................15
12. METHODOLOGY OF STRINGING..............................................................................................18
13. RISK ASSESSMENT......................................................................................................................27
1. INTRODUCTION
Generally, Transmission Circuits will be protected by overhead earth wire and be suitable for the preferred
concrete pole construction. For this project, the construction type will be specified on an individual basis.

2. PURPOSE
This describes the requirements relating to the handling, positioning and erection of concrete
poles & steel poles for 69kV Transmission Line.

3. DEFINITION

OWNER: Nuevo Solar Energy Corporation


Contractor: Consortium of JCE and SUMEC Philippines
Responsible in the supervision of the sub-contractor who will perform the construction work
and all related activities as outlined in this procedure.

Sub-contractor: Responsible in the execution of the construction works as well as the tests
required in accordance to this procedure.

4. PROCUREMENT
 All materials and equipment’s for the double circuit transmission line is procured by Gen
Con.
 Materials for the twenty-eight (28) concrete poles bypass line is procured by Sub Con.

5. RESPONSIBILITIES

a) Project Director:

Full assessment of the risks especially safety risk through the project; Ensure that safety
organization is in place for the project with adequate resources.

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b) Project Manager
Full assessment of the risks especially safety risk through the project. Directs and leads staff; to
implement the company safety policy, rules, practices and statutory requirements, such that safety
precautions are strictly observed.

c) Construction Manager:

Responsible in ensuring the implementation of construction procedure and method statement, the
quality control of work, supervise the work and reporting the progress of work to site manager.

d) Safety/Environment Officer:

Responsible in ensuring that all activities are carried out safely. He will responsible to patrol
at the site, establishing the site safety plan, conducting continuous safety inspection and stop
any work deemed unsafe and risk to personal.

Taking action to rectified the unsafe condition and report to project manager and preparing the
nots of safety meeting.

e) Site Nurse:

Provide nursing care to injured or ill workers; participate in health maintenance examination.
If a physician is not available, to perform work activities which are within the scope allowed
by the nursing profession, and if more extensive examinations are needed, to refer the same to
a physician.

f) QA/QC Engineer:

Responsible to monitor the execution and performance of the works in relation to this method
statement, ensure approved drawings and materials specifications; detect and report non-
conformance; ensure that all non-conformance products or activities are reported; propose the
corrective and preventive action where possible and appropriate and record the completion of
the non-conformance by using approved report format.

g) Site Engineer & Foreman:

Responsible to make sure that all activities on site are carried out in accordance with the
schedule and construction drawing. Take care of all worker to make sure that they work as per
their responsibilities. Make necessary decision when some non-conformance is occurring and
report to construction manager.

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h) Line Man:

Have a duty to take reasonable care to safeguard their own health and safety; have a duty not
to intentionally interfere with or misuse anything provided in the interests of health, safety or
welfare. Have a duty to comply with all the regulations which affect their work and to report
to the appropriate person any defective equipment or any hazardous situations.

A Safety & QA/QC officer with enough knowledge and experience in transmission line
installation must be assigned. Safety officer must be present for the entire transmission line
installation.
The supervisor shall have enough experience and knowledge in transmission line installation. He
also shall ensure that no persons shall access the work area throughout the work procedure
without first gaining his approval.

6. SAFETY

Refer to the site safety policy for general safety controls. One of the main aspects of this
procedure is safety and health control.

This is to control occurrence of injuries as well as damage to equipment and properties during
the entire construction period, the following safety measures will be implemented.

4.1. Machinery and Equipment:

Prior to using any machinery / equipment at site, it shall be inspected and certified by
qualified person. All lifting equipment shall be of an approved type, fit for purpose and be
within the current pole erection.

Periodic preventive maintenance shall be made on all equipment and machinery.

All operators and drivers are to be equipped with valid driver’s/ operator license or permit
from concerned government agency.

Only authorized signalman shall be assigned together with the operator or driver.

All lifting equipment as well as its accessories such as sling wire, nylon sling, shackles, chain
blocks crane hook and latch shall be inspected daily.

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4.2. Personal Protective Equipment:

Personal Protective Equipment (PPE) shall be issued to all workers such as safety shoes,
hardhat, working gloves, earplug, safety goggles and safety belt and or safety harness for
workers who will be assigned in elevated places 1.2 meter and above.

Wearing of the basic PPE shall be enforced fully.

4.3. Safety arrangement during the Construction Work:

All new recruits shall undergo proper orientation and safety induction before they are deployed
at site for work. (Emergency Action Plan– refer to appendix A)

4.4. Permit to Work System:

For a number of work activities, a Permit to Work system may be used. The Permit to Work
system is based on a written procedure including suitable form(s) used to control potentially
dangerous operations by authorizing personnel to carry out specific activities within a certain
time frame, and at the same time identifying the main precautions needed to complete the task
safely. (Work Permit Form – refer to appendix B)

Activities that will require a Permit to Work include, but are not limited to:

Hot works (welding, grinding, cutting, or danger of an ignition source)

 Excavations/trenching (more than 300mm in depth, with additional


controls where working in the vicinity of services)

 Electrical works

 Heavy Lift/Vehicles (heavy vehicle transport, off road, non-4x4 access)

 Area access (where Contractors take control of a designated area)

 Other work or locations designated by EPC Contractor

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7. TRANSPORTATION & HANDLING

a) When poles are loaded in more than one layer, timber spacers/bearers are not less than
100mmx75mm should be placed between each layer, vertically above the bottom row
supports.
b) Poles in the second and subsequent layers must have steel chocks placed at the butt ends of
the two outside poles, with the tips of the poles resting in scalloped timber bearers.
c) When there are two or more layers. The poles in the second and subsequent layers should
alternate in direction, with the tips above the butts of the preceding layer, to provide the best
load sharing between axle.
d) The completed load of steel poles should be fastened down using a minimum of four sets of
chains and load binders only. The fastening points should always be over the timber bearers.
e) All fastening points must have a rubber pad placed between the chains and contact point of
the steel pole, to prevent the chains damaging the external surface of the poles.
f) No loads are to be secured with nylon load restraints only. Loads will not be permitted to
leave any Steel poles yard unless secured by a minimum of four sling and load binders.

Fastening timber bearers Align poles must not be


secured via joints lugs

g) Poles of mixed sizes should arrange to provide the best possible sharing of weight across the
tray of the vehicle. When poles of different diameters are placed in one layer, a short
support bearer in conjunction with packing timbers can be used to support the overlying
bearer.
h) Pole of different diameter require support bearers and timber packing.
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8. UNLOADING

While unloading, it is paramount that the following guidelines are followed to maintain the
integrity of the product and, most importantly, to ensure the highest level of safety. (Crane and
Lifting Equipment Plan Form

a) When unloading, it may be necessary to roll a pole sideways to gain access for fitting a
lifting sling.
b) Before removing the chocks, ensure that a second set of chocks is in place, to limit the
movement of the pole.
c) Until lifting slings are fitted to a pole and secured, the pole and every other pole remaining
on the truck should be chocked on both sides to prevent accidental side movement.
d) Before unloading the poles, the vehicle must be positioned with a minimum of cross-fall to
prevent the load from moving. The outrigger will be extended fully.
e) If the transport operator considers the cross-fall too excessive to allow safe unloading, a
more suitable area or positioning of the truck must be sought, at the discretion of the
operator.
f) If a cross-fall cannot be avoided, the pole on the higher side must be the first pole of each
layer to be unloaded. Even when on level ground, always unload the outer pole first – never
take an inner pole
g) The vehicle must not be moved while any part of the load is unsecured.

h) If the vehicle is required to move only a short distance and the speed does not exceed 8km/h
on smooth and level ground, the poles can be secured with a single sling and chocks on the
two outside poles on each layer. When unloading by crane on site, a dual point lift using
double-legged slings must be used. The balance point is marked on the pole or pile (at
approximately 0.4 x length) from the butt of a tapered pole or at the midpoint of parallel-
sided pile. A sling is normally used, but a fabric sling can be used as an alternative.

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Unloading poles with cable sling

9. LIFTING FOR THE FINAL PLACEMENT

Slinging and load handling is perhaps the most vital part of any lifting operation. Do not get
involved in any slinging or elevator operations unless you have been adequately trained and
authorized to do so.
Failure to follow this advice could lead to death or injury. A proper risk assessment must be
completed, all slings and equipment must be inspected before use, any faults reported and if
damaged removed from services. Lifting equipment Must have permit for safe to use from
certifying entity and must be inspected before use.
Duties include:

a) Attaching and detaching the load to and from the base machine

b) Using the correct lifting accessories in accordance with the lifting plan or procedure

c) Visually checking the lifting accessories for damage before use

d) Initiating and directing the movement of the load by giving the appropriate signals to place
the load safety
Due to the nature of the work performed be earthmoving plant, often in unstable ground
conditions, it is necessary to consider machine self-recovery (de-bogging) as part of an operator’s
duties.
Immediately a machine becomes bogged, the operator should:

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a) Stop all drive to the tracks or wheels.

b) Make the machine safe, e.g. if bogged down at an angle, lower attachments towards side.

c) Climb off the machine from the high side

d) Assess the situation

An operator will worsen the situation by repeatedly driving the machine back and forth until
self- recovery is all but impossible. However, most hydraulically powered machines are capable
of self- recovery, using the attachments as hydraulic jacks. For example, a tracked hydraulic
excavator attachment can he lowered until the track is clear of the ground; the track can then be
packed up with timbers or slewed out of all but the worst situation. If it is necessary to use
another machine to push or tow, it is important that the towing point or the pushing point is
chosen carefully; parts are likely to be damaged by pushing or pulling must never be used.
Machine recovery can be hazardous and the following basic rules must be observed:

a) One person only should be given instructions (unless an emergency arises)

b) All persons must be kept well clear of tow ropes our winch ropes under load

c) The recovery vehicle should have a cab to protect the driver from the whiplash of a broken
rope
d) The load carrying capacity of any wire rope used for towing must he carefully assessed

e) ropes used for towing must not subsequently be used for lifting operations

f) A check must be made that all recovery equipment is correctly applied before attempting the
recovery
g) Tools, not hands, should be clear any obstruction

For steel poles, such as the power distribution ranges, the quickest and easiest method of lifting
the pole for installation is by using sling. This can be achieved by wrapping a sling around the
pole at least 600mm from the tip of the pole. Most power distribution and lighting poles include
a though-tube in this area than can be used to secure a bolt above the sling to prevent slip.

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10. METHODOLOGY OF CHECK SURVEY WORKS
 INTRODUCTION

At this stage of the work the angle points are available physically at the site and the profile built on the
basis of the approved alignment has the poles at various change duly plotted. The objective of the check
survey is to establish the poles physically at the site as per the profile and re-ascertain from the site that
the pole positions are in conformity with the profile. In case any variations are encountered the same are
to be recorded, brought to the notice of the Customer and the pole position should be suitably shifted.
The correction then intern would be incorporated in the profile and the same would be revised.

The physical implementation of the check survey involves traversing along the aligned route between
the angle points using GPS and compass so that at the spans mentioned in the profile, the pole would be
pegged and verification would be made on the correctness of the pole position with respect of the same
by interpolation of the coordinates as secured using the GPS. This would be carried out at every pole
position until section is completed.
 OBJECTIVE

The purpose of the statement is to explain in detail, the procedures required to be adopted for execution
of the survey works. This procedure sets forth the guidelines and requirements for the Transmission
Line Final Check Survey and verifies the correctness of the original plans, profiles and the true contours
of the ground. It also establishes all the location of all adjacent obstacles along the Line route.
 SCOPE

Include Reconnaissance of the Transmission Line site, checking of plans, profiles, topographic maps,
detailed map of each pole site including the establishing of formation levels in accordance with
approved plans and specifications.
 RESPONSIBILITY

It is the responsibility of the Contractor to determine and verifies the validity of the original survey
plans and profiles. It is also their responsibility to report any discrepancy between the original survey
and the check survey to Customer and shall revise the plan and profile with the approval of the
Customer.
 PROCEDURE

The following are the Procedures to be followed by the Contractor in accordance with the established
surveying methods.
 FIELD WORK

a. Prior to the start of the actual check survey, a reconnaissance of the line route
should be done to determine the type of terrain and to familiarize the survey
group with the site.
b. The contractor will conduct the following in accordance with the approved
specifications.
 Centerline Checking
 Topographic Survey
 Profile Checking
 Staking/Lay-out

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c. Back sight should always be done /check from the nearest back sight pole and the
nearest foresight pole.
d. A series of reference points for lay-out must be established to easily locate
transmission line axis and the centerline of the pole.
e. All data gathered during the survey must be recorded properly and all
calculations/computations must be checked before actual plotting/drawing of the
plan and profile.
f. All calculated figures of tolerance and measured deviations shall be rounded off
to integral cm.
g. Deviation of measurements between the original survey and check survey should
be within allowable tolerances and should be reported to the customer before any
revision of the transmission plan and profile is to be made.
h. Proper surveying instrument must be used to maintain accuracy of measurements
thus minimizing errors of line route and pole lay-outs.
 INSPECTION

a. Inspection of the proposed pole site and line route, contractor will finalize the
survey results for approval of the customer.
b. Inspection should also include study of the adjacent obstacles along the line route
to formulate solution and recommendations.
 PROFILE

a. In plotting the line profile, the following details should be taken into account.
 Distance and elevation should be drawn for every span starting from the
original pole point.
 Adjacent obstacles, hillsides should be drawn.
 Pole point to pole point should be connected with a straight line.
 PLAN

The following details should be included in the plans:


 Span length for every span starting from the original pole point.
 Indicate coconut plantation, rice fields, creeks, roads and electrical
distribution line.
 Building structures indication distance from the center line.
 APPROVAL

The result of the check survey together with the plans and profiles will be submitted to
the customer for approval.
 REMARKS

 Upon approval of check survey results, plans and profiles by the customer, excavation
works will start in accordance with the specified schedules.
 Partial approval of plans and specifications will also start excavation works on approved
items/sections.

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 CONCLUSION

With the above said activities, the surveying works including the check profile survey would have been
completed and final pole schedule would be ready for submission. At this time, we would submit the
same after incorporation all the changes encountered during the check survey and the final bill of
quantities would also be furnished as per the requirements of the specification and in the format given
by the customer.

11. METHODOLOGY OF POLE ERECTION


 PURPOSE

This describes the requirements relating to the handling, positioning and erection of concrete and steel
poles for 69kV Transmission Line.
 INTRODUCTION

Generally, Transmission and sub transmission circuits will be protected by overhead earth wire and be
suitable for the preferred concrete pole construction. However, in some circumstances steel poles may
be preferable. For this project, the construction type will be specified on an individual basis.
 EXCAVATION

 All tools and equipment must be inspected prior to use.


 All excavations shall be done by hand excavation and using an auger, except in rock
spots where mechanical excavation shall be done by jack hammer or portable jack drills.
In case of extremely hard rock, the hole location may be adjusted to a suitable workable
spot with prior approval of the engineer.
 Manual or Hand digging to be perform below 1.5m to avoid damage of underground
utilities, any underground utilities locate shall be inform to the respective owner prior
for auger machine will be executed.

 The auger size should allow sufficient room to either adequately place and ram solid the
backfill, or pour and vibrate the concrete backfill. As a rule of thumb, the hole diameter
should be a minimum of the pole butt diameter plus 200mm, rounded up to the nearest
standard auger diameter.
 All excavations shall be carried out under supervision by the supervisor.
 All excavated areas shall be barricaded to prevent any person and vehicles from falling
into the excavation.

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Excavated by Auger

 POLE ERECTION

 Concrete Pole Inspections and Treatment


All concrete poles will be inspected and found to be free from defects such as
transport damage or surface cracks.
 Steel Pole Inspections and Treatment
All Steel poles will be inspected and found to be free from any defects such as
general transportation damage, dents, surface cracks or coating defects.
 Buried Pole Erection
a. A sling should be attached around the pole approximately two-thirds up to
ensure that when the load is released, the sling will loosen and lower under
its own weight.
b. Begin lifting pole. After lifting the top of the pole approximately 1m above
the ground, stop and check the arrangement. Ensure that the safety rope is
still taut and that begins to rotate around in line with the lift.
c. Continue lifting the pole ensuring that the safety rope remains taut at all
times and that the sling continues to rotate around.
d. Carefully place the pole into the augured hole, can be manually lifted into
place and inserted into the hole.
e. Remove the lifting load from the pole and retrieve the lifting device.
f. Pole the lifting load from the pole and retrieve the lifting device.
g. Dewatering pump shall be made available for erection of poles on wet soil
and during rainy season.
h. Necessary tools for the pole erection must be made available during
transmission line installation. Tools shall be calibrated (e.g. Torque Wrench
etc.) and with permit for safe to use by certifying entity (if necessary).

Pole Erection by mobile crane

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 Staying of Poles
A Pole which subjected to unbalance loads should be guyed so that the resultant
force tends to pull the pole to the vertical.
 Backfilling
To ensure the stability of erected poles, approved type of backfilling is to be used.
It should be ram compacted every 150mm thick to the ground line and shall fill the
hole. The compaction level for the layered backfill is to be 98% of standard
compaction.

12. METHODOLOGY OF STRINGING


 TASK

Stringing conductors on concrete poles for single circuit transmission line system.
 OBJECTIVE

To define step by step procedure to be undertaken for stringing of conductors in a manner


which will ensure propriety of sag, tension, erection loading and others.
 DEFINITION

It is the orderly process established for undertaking stringing of conductors.


 UTILIZATION

This method has been prepared for the purpose of stringing operations on the single circuit
transmission lines.
 STEPS TO BE UNDERTAKEN

 Planning of Works

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a. General

A detailed plan in advance of the actual stringing operation shall be


prepared. This is to allow adequate time for the deployment of materials
and ancillary equipment. Only approved construction drawing provided by
customer shall be used for the whole scope of work. The equipment shall be
installed as per local laws/regulations (e.g. safety regulations) and in
accordance with the instructions.

b. Selection of Stringing Section

For the selection of Stringing Section, it is important to patrol the line route
to ensure that the section for stringing is clear. It is also important to
consider the following aspects and requirements.
 Pole (structure) list
 Stringing Plan
 Bill of Materials (given in the drawings)
 Special Requirements/Instructions (if any)
 Profile Drawings (e.g. crossings)

c. Drawings/Specifications/Documents

Only approved drawings provided by the client will be used during


construction. The Stringing Engineer is requested that all
drawings/instructions are made available on site, e.g.
 Contract Documents
 Technical Specifications
 Applicable Standards
Stringing Engineer is also responsible for as-built documentation (e.g.
revision of stringing plan) and all requested records (e.g. sagging records).

 Preparation of Works

a. Transportation

All materials, tools and stringing equipment shall be transported to the site
as set out in the stringing plan.
b. Handling and Storage

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The Insulators (insulating parts, metallic parts and attached hardware) shall
always be handled and transported in such a way that they are not
scratched, chipped or otherwise damage by mechanical and/or chemical
action. Insulators that come in crates shall be handled and transported in
such crates. Insulators and hardware shall be stored in a clean environment
protected from abrasive dust and corrosive chemicals. Storage shall be in
accordance with manufacturer’s instructions. Crates shall not be stacked
higher than two levels.

c. Laying of Pilot Wires

Pilot Wire, spooled in reels, in varying lengths of approximately 900 meters


will be made available to suit the normal installation requirements. Pilot
Wire reels will be distributed along the line and pulled manually or using
tractor. Individual lengths can be joined together using pilot wire
connectors to achieve requisite length of section. Pulling of pilot wire will
continue until it reaches the tensioner end, where the pilot wire will be
connected with a swivel and attached to the conductor.

d. Setting of Stringing Equipment

Stringing Machines will be positioned behind the tension towers at


approximately twice the height of the tower. The criteria for selection of
puller/tensioner locations will have equal consideration to minimize the
movement of equipment’s as much as practicable. One pull length shall
compromise of single section or multiple sections involving two or more
angle towers according to terrain and site conditions. Machines will be
grounded by the means of conventional earthing rods and copper leads.
e. Tensioner and Reels (Drum Yard)

Tensioner will be positioned at one end and puller will be positioned at the
other end with the conductor reels at tensioner side. Reels of pilot wires will
be either distributed along the line or positioned at either end, preferably
ending at puller end. Care will be taken to ensure the tensioner is positioned
on almost level ground level and also at minimum off-set from center line
as far as possible. Machine will be anchored using spikes driven in the
ground to counter the pull force. Reels will be placed on reel stands,

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facilitated with hydraulic or helical screw jacks. Reel stands will be
positioned approximately 10 meters behind tensioner on level ground. In
case of soft or uneven ground, necessary anchors may need to be provided.
Wooden battens fixed around conductor spools will be removed and
conductor end taken out, checked, and inserted in pulling grip attached with
swivel connector then passed around the grooves of tensioner bull wheel
using nylon rope.
f. Puller (Engine Yard)

Puller will be positioned at the other end of pulling section, as far as


possible on level ground. Two rear anchors will be provided using spikes
driven in the ground or by concrete blocks as substitute. Care has to be
taken to minimize the angle of pull line with a minimum limitation of 30
degrees from center line axis of stringing section, similar to tensioner
positioning.

 Installation of Insulators

Insulators, running out blocks and the fittings transported to each pole location and
lifted carefully by winch and rope. Be sure that the insulators type installed are
according to the pole schedule for each pole type. Numbers of string of insulators
should be installed according to pole schedule and fixed. On working on poles, line
man will be provided appropriate PPE (i.e. double lanyard harness), a rope will be
needed for lifting purpose. Provision for safe distance working to live wire will be
coordinated with the local distribution utility. Contractor will request DU to
provide an insulated cover for the live wire. List of tools:
 Small winch 3 tons
 Rope 150m
 Tool keys
 Truck
Note: Number of insulators should be according to pole schedule and type of pole
structure.

 Stringing Works
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a. Communication

Communication will be established between winch and tensioner and at


designated points along pulling section by walkie-talkies.

b. Conductor Paying Out

The Supervisor will confirm if all pilot wires are positioned in the rollers and that the
connector is properly secured. On confirmation of above, pulling will be started,
slowly but steadily by synchronizing the operation of Puller and Tensioner, through
radio communication. Conductor and earth wire will be kept off the ground and other
obstructions by controlled tension. A linesman will walk along with the headboard
during stringing with radio equipment monitoring the progress of the pull, especially
at rollers where probability of derailing is more likely. Pulling will continue until the
conductor end is approximately 5 meters through winch tower in order to facilitate
sagging and tying in with pole cross arm. Hold-down blocks or similar devices will
be used to uplift locations. Full tension joints shall be pressed during paying out and
covered with joint protectors which will be removed at the end of the pull before
sagging.
c. Compression of Joints and Dead Ends

Joint and dead ends for conductors shall be pressed using a hydraulic compressor of
10-ton capacity.

d. Resistance of Joints and Dead Ends

All joints and dead ends shall have their electrical resistance measured by Digital
Micro Ohmeter.

e. Sagging

Sagging will be carried out in accordance with the following requirements:


 Approved sag tables available, with values available for stringing (initial
sags).
 A thermometer to read accurate conductor temperature (conductor
thermomter will be used for measuring the temperature while sagging).
 All sagging tools available.
 Regulating spans or sag sighting spans identified.
 Temporary grounding is provided with requisite points.
 Temporary back guys are in position.

f. Sag Measurement Method

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Measurement of sag can be done by one of the following methods (at site as agreed by
Engineer):
1. Using sagging transit and sag board for
a. Equal distance method
b. Unequal distance method
2. Using dynamometer
g. Conductor Clipping

It is the procedure in which the conductor will be fixed in clamps at final erection
position. Prior to taking up this activity, conductors will be grounded using pole cross
arms as earth continuity. In order to release the rollers, conductors will be lifted from
the roller grooves using pull lifts. Then rollers will be released and lowered and
conductors are then clamped into suspension lamps. Armour rods, spacer and
vibration dampers will be fixed in position during clipping operation. Crane bucket if
available shall be used to provide accessibility of linemen to the working point.
Alternatively, ladders may be used.

h. Damper and Warning Sphere Installation

Clipping will be followed by installation of vibration dampers on the conductor and


vibration dampers and warning spheres if required on earth wire.

 METHODOLOGY FOR OPGW INSTALLATION

 Purpose

To describe the system used for installation and delivery of OPGW fiber optic cables.

 General

In general, the system and the equipment used for installation of the OPGW Cable with
optical fiber are similar to those used for installation of the standard ground wire cable.
Nevertheless, since there is an optical fiber core, special care should be taken to avoid
any damage to the fibers by observing the minimum bending radius at all times.
Therefore, specific components and machinery are used for the OPGW cable: pullers,
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tensioners, anti-twisting counterweights, swivels, pulling grips, pulley-blocks, self-
gripping clamps, pulling ropes, pulling cables, etc.

The existing OPGW shall be held with long wooden stick or other tools until new lines
are built and switch.

 Procedures

a. Survey of the line

Prior planning for installation of the OPGW cable is performed by monitoring the
line, taking into account the following parameters:
1. Length of Each Drum
The OPGW drum lengths are determined based on the following
considerations: position of the tension pole, pole access, distance between
supports and crossing with other lines, roads, railways, routes, services and
other obstacles.
2. Splices

The position of the splices depends on the maximum available length of


OPGW, on the position of the towers and the tower access.
3. Transport, Loading, Unloading and Storage

The following procedures are recommended to prevent damage to the cable


during handling, transport and storage:
 The drums should always be transported in vertical position with the
cable ends fixed to prevent cable from slackening. All the staves
and/or safeguards should be maintained until the drums are situated
for immediate installation.
 After the transport, the drums should be inspected to verify that they
have not been damaged and that none of the staves and/or safeguards
are broken.
 The drums should never, under any circumstances, be thrown from the
lorry during unloading, nor moved by uncontrolled rolling.
 Loading and unloading are performed so that the drum remains in
vertical position and the sides of the drum are not damaged.
 The drums can be moved by rolling a short distance ensuring that
there are no objects that may damage the staves. The direction in
which the drum turns should be the same as that in which the cable is
wound during manufacture.
 The drum should not be stored on its side under any circumstances
whatsoever.
 The ends of the cable should be sealed to prevent water penetration.
 The drums should be stored on flooring that is strong enough to
prevent sinking.
 The drums should be stored to facilitate handling and loading. They
should be located far from any activity that may damge them.
b. Preparation for the Installation
21
1. Positioning the Equipment
 Drum - The drum is placed at the selected site (with the space required
for its location) so that the cable outlet is on the upper part and aligned
with the planned laying direction. The drum must be located at a
distance of 2 or 3 meters from the tensioner. The lifting components
usually used are hydraulic jacks and a bar with suitable dimensions
inserted in the central opening of the drum. The drum must be located
at a height of 10 to 15 cm from the ground.
 Puller and Tensioner - Either the puller or the tensioner must be
placed at a minimum distance from the tower equal or greater than 2
times the height of the tower. The tensioner as well as the puller
should be placed aligned with the conductors. The maximum
acceptable deviation angle is 30°.If it is not possible to achieve this
angle, the puller and/or the tensioner are placed close to the following
pole, using an additional cable of the required length.90° or less re-
tracking of the optic cable is not allowed. The tensioner as well as the
puller should be positioned at a minimum distance equivalent to twice
the height of the support to which the cable is fastened. In an
installation with re-tracking, the smallest angle must be more than 90°
and the final pulley should be placed at a distance equal to 2 times the
height of the tower. In the tensioner, the first groove the cable will
pass through must be perpendicular to the axis of the drum. The
tensioner must be equipped with a dynamometer. Its reels must be
protected with material that does not damage the outer layer of the
OPGW cable. The puller must be equipped with a dynamometer. With
automatic disconnection in case of over tension on the cable. The
pulling cable should be joined to the OPGW cable by a swivel and a
pulling grip. The minimum diameter of the reels (where the OPGW is
to be coiled) used during the installation should be at least 80 times
the diameter of the OPGW cable. For example, the tensioner reels for
a 15 millimeter cable should have a diameter of approximately 1. 2
meters. Both the breaking device and the puller have to suitably
connected to the ground by a system of moveable rollers. This also
applies to the OPGW cable and the pulling cable, if it is a metal one.
 Pulleys – The tower pulleys should have a minimum diameter of at
least 0.8 meters in the following cases:
 In all poles with a change in laying direction equal to or
greater than 15 degrees.
 In the first and in the last pole of a single installation.
 If the distance between the towers is greater than 600 meters.

In all other cases pulleys with a diameter of 0.6m can be used.


The pulleys have to be under good use conditions. The pulley
groove should be protected with neoprene or other similar
material.
In case of sharp angles, the pulley must be placed so that the cable
always passes through the center of the groove.
22
If the angles are greater than 45 degrees, dual pulley system must
be in order to increase the bending radius during installation. The
diameter of each pulley should be at least 0.6m.

c. Installation of OPGW Cables

1. As a rule, one drum at a time of OPGW cable installed.


2. The minimum bending radius during all installation operations. Ensure that
the metal part of the pulleys do not make contact with the cable to prevent it
from being damaged.
3. The maximum permissible stringing speed is 40 meters per minute. It always
depends on the stringing conditions and must be reduced to avoid damages to
the optical fibers, the aluminum tube and the OPGW cable.
4. The recommended pulling tension shall be lower than 1.5 times the weight
(kg) of 1km OPGW cable length.
5. The minimum bending radius are as follows:
 On tensioner reels, 40 times the cable diameter
 During installation, 400mm.
 After installation 20 times the cable diameter.
6. Communications during stringing - the personnel located at the puller, the
tensioner, the pulley crossings and the cable ends are in communication at all
times by communication system.

7. Sagging of the cable - Generally, the methods used to obtain the correct sag
values of the OPGW cables are the same used for conventional ground wire
cables. The specific recommendations are as follows:
 Pulling is performed by a preformed fitting or tension clamp (in
intermediate spans) or with the pull jacket at the end.
 Sagging of the cable and fittings installation are always performed
after stringing. At this time, the attachment fittings are also installed to
prevent damage to the OPGW.
 The installer is responsible for any damage to the OPGW cable that
may occur due to failure cause by incorrect application of the previous
points.
8. Installation of fittings and accessories - the fittings, tension clamps,
suspensions, earthing clamps, dampers, etc. should be installed in accordance
with the manufacturer’s instructions and using the appropriate tools.
9. Transmission test during the installation phases – Prior to as well as during
the installation phases, the transmission characteristics of the fiber optic
23
cables are verified in order to ensure proper installation and be sure that the
final tests are within the specified range of tolerances.
10. Measurement before OPGW cable installation – prior to OPGW cable
installation, each optical fiber is verified using OTDR.

 TRANSMISSION TEST DURING THE INSTALLATION PHASES

Prior to as well as during the installation phases, the transmission characteristics of the OPGW
cables are verified in order to ensure proper installation and be sure that the final tests are within
the specified range of tolerances.

 FINAL ACCEPTANCE TEST


After the installation, a final measurement of the transmission characteristics is done and the
values are duly recorded.

13. RISK ASSESSMENT

According to detail jobs in steel pole installation of Transmission Line, the risk assessment as
shows in Tab. 12.1.

24
Tab. 12.1 Risk Assessment Worksheet

Task Identified Risk Potential Impact Severity Probability Risk Level Mitigation / Strategy Remarks

Heavy
Competent worker or flag equipment
Mobilization of Ergonomic, hazard Bump of Collision, will ensure
3 B 3B man/certificate of 3rd party/operator
crane hand/foot injury Hit/ Bump Person their task
with NC2
per activity

Less cost
Damage of Collision from the
Unloading and 3 party certification/ NC2 for
rd impact for
property, hit by the road / crane hit 3 B 3B motor pool
lifting use crane operator/driver license
equipment fatality the property department
/injury
Provide barriers or People are
Structural
Falls into Excavation Person injury fatality 2 B 2B warning/danger/caution sign. isolated from
Excavation risk of fall
(Reflectorized if left overnight).
People are
isolated on
Excavated soil/rocks Striped the wall of excavation for risk of cave
Structural in, if
or other object falls Person injury fatality 2 B 2B loose soil/rocks that slides, roll and
Excavation provided by
on workers fall to the workers.
means of
access/egress

Erect men at work sign &


appropriate signage to slow
Structural Traffic Control Speeding traffic 2 A traffic and reduces speed
2A
Excavation (complete traffic management
plan)
Wear high visibility safety vest
Traffic – site 2 A 2A Position witches hats or barriers
Structural Traffic Control worker being hit
around work area
Excavation by a car
Observe for vehicle traffic
before moving from the work
site.
Trench collapsing Possible injury Trenching supervisor to
Structural to a person 2 A 2A inspect the trench before
Excavation exposed to worker enter to trench.
activity.

Electrocution – Possible damage Look up and live


overhead or to Dial before you dig & cable
Structural 2B
location contractor.
underground property/vehicle. 2 B
Excavation Have a spotter to observe to
services
works.
Underground Possible damage Dial before your dig(yes/no)
hazards – to Use accredited cable
Structural electrical/ property/vehicle. 2 B 2B contractor to test the area.
telecom
Excavation Excavation by hand around
identified assets.

Accumulation
Used water pump in pumping out of water can
Structural Ingress of water the water and make sure that the be controlled
Damage of property 2 A 2A by pump to
Excavation causing flood discharge water does not cause any
lessen cost
problem elsewhere.
incurred

Reinforcing Steel Make sure that the workers used People can
Hand cuts Person injury fatality 2 B 2B
Bars proper PPE during rebar cutting and mitigate risk
installation and check all the by providing
machine guarding. appropriate
PPE’s
Workers are
on a good and
Reinforcing Steel Keep all construction debris acceptable
Slips/Trips/Falls Person injury fatality 2 A 2A
Bars removed on a daily basis. safety
culture

Workers are
on a good and
Clean the excess concrete after the acceptable
Concrete Pouring Slips/Trips/Falls Person injury fatality 2 A 2A
pouring activity. safety
culture

Consequences Probability
Severity

Unlikely Likely Frequently


People Assets Environment
A B C

Unacceptable risk, further


Low No health
No damage No effect control is required to be
1 effect/injury
planned or added

medium Minor health Localized Localized Acceptable risk with


2 effect/injury damage effect proper control
high Several Extensive Massive Acceptable risk, no
3 fatalities damage impact further action required

Probability:
Unlikely Likely Frequently
A B C
 Conceivable but unlikely to occur during life cycle  Isolated incident Likely to occur during life cycle  Happens often and might be expected during life cycle
 Less than one occurrence a year  Annual occurrence or more (> 1/year)

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