Purpose

To discuss and promote awareness on Requirements for Material

specification, Stringing & Testing of 115 KV ACAR(Aluminum
Conductor Aluminum Alloy Reinforced) Conductor for this
contract.

SCHEDULE “A”: GENERAL TERMS AND CONDITIONS

SCHEDULE “B”: JOB SPECIFICATION
SCHEDULE “C”: CONTRACT PRICE AND PAYMENT PROVISIONS
SCHEDULE “E” : SETTLEMENT OF DISPUTES, ARBITRATION AND CHOICE
OF LAW

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 Table of Contents
• General Requirements

• Materials Specifications

• Materials Handling and Storage

• ACAR Conductor Installation & Safety Precautions

• ACAR Conductor Testing

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 General Requirements

• ACAR Conductor shall be in accordance with the Saudi Aramco-approved project-

specific design drawings, diagrams, schedules, lists, database, and associated design
documents. ACAR Conductor shall be new and unused.
• Material Test Reports (MTR) shall be available for verification for compliance of the
materials with applicable standards and specifications prior to release to be used as
part of the work.
• Materials, parts and components including partially fabricated assemblies shall have
an identification either by using tags, stamps, color coding, stencils or labels in
accordance with approved procedure.

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 Materials Specifications

• The rated strength of ACAR conductors shall be aggregate sum of the strengths of
Aluminum 1350 and Aluminum alloy 6201 components and strength shall be calcaulated
and conformed to ASTM B524/ASTM B 524M.
• ACAR Electrical volume conductivity of the individual Aluminum alloy wires before
stranding shall not be less than 61.2% of IACS(International annealed copper standard)
respectively.
• Aluminum alloy wires removed from the conductor shall be capable of meeting the
bending radius properties sated in ASTM B 398/B 398 M.
• ACAR Conductor composed of 37 wires, the welded joints in the same wire or any other
wire in the conductor shall not be closer than 7.5 M. In ACAR conductor composed of
wires less than 37 ,the welded joints in the Aluminum wires shall not be closer than 15M to
another or to either end of the wire. No more than 2 such Joints shall be present in any
reel length of the conductor.
• No joints shall be made in the aluminum alloy during the final drawing or in the finished
wires. The surface of the conductor shall be smooth and free from surface imperfections
not consistent with good manufacturing practice.

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 Materials Specifications

The area of cross section of the conductor shall not be less than 98% of the area of the
cross section of the conductor size specified in the table-1.

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 Materials Specifications

• Aluminum alloy wires with diameters 3mm to 4.75mm,the diameter shall not vary from
the specified by more than +/-1% .

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 Materials Handling and Storage

• ACAR conductor shall be furnished on non –returnable wooden reels ,protected by

wood lagging to facilitate filed handling and long term outdoor storage .Blocking
shall be used to prevent movement or rolling of reels.
• The designated storekeeper shall have complete set of plans and specifications of
the project. He shall also have a complete bill of materials, bill of lading. shop and
fabrication drawings for checking the material as and when they are delivered to the
site for storage as per TCS-P-122-02-R0,Sec 4.4.2 .
• Members with dissimilar finishes shall not be stored over one another to minimize
discoloration of the lower members.

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Materials Handling and Storage

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Materials Handling and Storage

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 ACAR Conductor Installation & Safety Precautions

• The Tension stringing method will be used to install ACAR conductor and in this
method conductors are kept under controlled tension during stringing process. This
method used keep the conductors clear of the ground, energized circuits and
obstacles which might cause damage to the conductors.
• The minimum safety & grounding procedures shall be followed during the stringing
operations in the sections with parallel existing energized high voltage lines.
Temporary electrical grounding shall be placed at both ends of the sections, and at
intervals along with the line which is under construction. The minimum grounding
requirements include bonding & grounding of all machines involved in stringing of
conductors, pulling line or pilot line.
• Prior to initiation the Conductor stringing activity in any section of the line ensured
that:
• Installation of all structures with in the section of the line is satisfactorily
completed

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 ACAR Conductor Installation

• The stringing loads will not exceed the design load for any of the structure and
if any stringing load is exceeding the design load, temporary bracing shall be
provided for such structure and bracing shall be subject to client approval.
• Stringing and sagging operation is such that no sudden loads will be applied
on the structures.
• Linemen shall not work directly under the lines during pulling of conductors &
shall wear proper protective equipment.
• Whenever any crossing like Power line, Communication line, highway or rail
road is to be crossed the owners shall be notified well in advance and
temporary changes shall be pre arranged.
• Adequate control & traffic signs shall be provided whenever the conductor
being pulled at crossings.
• ACAR Conductor Stringing, Tensioning, Deadending & Clipping activity shall be as
per TCS-P-122-07 Sec 8 & 9.

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 ACAR Conductor Installation

• Typical Procedures for Stringing operations.

1)Site selection: The location of pull, tension, Anchor and splicing sites shall be
considered accessibility ,location of dead ends
2) Equipment location :The location of Puller ,tensioner and Intermediate anchors
shall be selected so that the snub structures are not overloaded.
3)Anchors: Anchors shall be required for to hold the Equipments.
4) Equipment Grounding :Adequate grounding shall be established
5)Crossing Structures :When crossings are there then supplementary crossing structure
shall be employed.
6)Traveler Installation

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 ACAR Conductor Installation

• ACAR Conductor sagging: A complete set of Design criteria including structure

design data ,line profiles and conductor sag templates etc for the sag section should
be available in the filed prior to start of stringing in activities in any section of
Transmission line the as-built span lengths shall used for the planning of pulling setups
and sagging of conductors.
• After being pulled in to the travelers the conductor in a sag section shall be sagged
within 24 hours and conductors shall be sagged in accordance with the approved
SAG Charts.
• All splices shall be made at least 15 meters away from structures and no splices shall
be made in dead-end spans or spans greater than 600 meters or the spans crossing
over highways, railroads and transmission line voltages of 33 kV and above.

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 ACAR Conductor Installation

• As a rule not more than one joint or splice shall be made in any one conductor in any
one span and may allowed two if approved by Client.
• A tolerance of +10 mm of the sag per 30 meter of horizontal span length, but not to
exceed 150 mm in any one span, will be permitted, provided the upper sub-
conductors in the span assume the same sag.
• The dies used to compress the compression joints shall be of correct size, and all
“presses” shall be made in the proper sequence specified by the manufacturer.
• Compression joints shall be installed using presses with remote motor operated
hydraulic pumps.
• Repair Of Conductor: Any damage on the conductor shall be repaired by following
methods whichever is appropriate. a)Repair by Manual polishing b) Installation of
repair Sleeves over the damaged part. C) Replacement with New conductor.

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 ACAR Conductor Installation

• Where compression type dead ends are used jumper connection shall be one
continuous piece, and compression type jumpers bolted to the dead ends shall be
used.
• After conductor being sagged shall be allowed to hang on the Travelers for not less
than 2 hours before clipping in is commenced, to permit the conductor tension to
equalize.
• The total time during which the conductor is allowed remain in the travelers before
being clipped in shall not exceed 72 Hours.
• Vibration dampers shall be placed on the conductors and ground wires immediately
following clipping to prevent any possible damage due to Aeolian vibration.
• Field measurements of Aeolian vibrations on conductors shall be required to verify the
performance of the installed damping system (vibration dampers).

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 ACAR Conductor Installation

• The section of conductor and thermometer shall be suspended from the structure, in
full sun near the sag man position, at least half hour prior to sagging the span of
conductors.
• The sag man and the inspector shall monitor the temperature during the sagging
operation in order to determine the correct value of sag to be used in the span.
• Following the Clipping sequence of operations for bundled conductor lines space
dampers shall be installed

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ACAR Conductor Installation

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 ACAR Conductor Installation

PARELLALING AND CROSSING TRANSMISSION LINES:

• Adequate clearances shall be provided between parallel and crossing Transmission
lines.
• Transmission line crossing shall be avoided if possible, but when these are not
avoidable ,they shall be arranged in such a way that higher voltage line crosses over
the Lower voltage line.

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 ACAR Conductor Installation

• All line structures where foundations are located with in 30 MTR from edge of road
shall be protected by barriers.
• TES-P-122-09-R1:Minimum Vertical Clearance from Line to all type of Crossing

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 ACAR Conductor Installation

Vertical Clearance's Between Line conductors for same Circuit on the same structure

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 ACAR Conductor Installation

Minimum Clearance Of Phase conductor to Its own supporting structure

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 ACAR Conductor Installation

Minimum Clearance between the Conductor of One line to another Line Conductor

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 ACAR Conductor Installation

Horizontal Clearance of conductor to other supporting structure

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 ACAR Conductor Testing

TCS-P-105-00-R1
115KV OVERHEAD LINE TESTING REQUIREMRNTS

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