Chapter 6 Tools & Equipment Table of Contents

Transcription

1 Chapter 6 Tools & Equipment Table of Contents ACCC Conductor Installation Guidelines WI Rev C Page 1 of PURPOSE SCOPE DEFINITIONS ASSOCIATED DOCUMENTS TOOLS & EQUIPMENT Tools & Equipment Checklists Safety Equipment Reel Handling Equipment Payout Reel Stand Tensioner Tensioner Fairlead Core Retainer (Bug) Conductor Grips, Clamps, and Socks Blocks (Sheaves or Travelers) Hoisting Equipment Puller Bucket Truck (if available) Stinger Truck (if available) Swivels Terminating and Splicing SPECIAL EQUIPMENT FOR BUNDLED APPLICATIONS Tensioner Payout Reels Tensioner Feed-In Sheaves Sheave Blocks Running Board or Balance Board Puller TEN INSTALLATION DON TS DON T OVER-BEND! ONE Tensioner DON'T TWO Payout Reel DON'TS THREE Handling and Equipment DON'TS TWO Pulling / Stringing DON TS ONE Termination DON T Appendix A Equipment Readiness Review Form Appendix B Minimum Sheave and Tensioner Sizes Appendix C Compression Dies PURPOSE 1.1. This is Chapter 6 of the ACCC Conductor Installation Guidelines, covering required tools and equipment. The Guidelines consist of nine chapters, each written to stand alone to address specific installation subjects. Taken together, the nine chapters comprise the entire Installation Guidelines: Chapter 1 General Installation Guidelines Chapter 2 Safety Chapter 3 Training

2 Chapter 4 Reel Handling and Storage Chapter 5 Site Considerations and Set-ups Chapter 6 Tools and Equipment Chapter 7 Stringing / Pulling Chapter 8 Terminations, Sagging, and Suspending Chapter 9 Maintenance and Repair WI Rev C Page 2 of The purpose of the Guidelines is to provide experienced transmission engineers, project managers and planners, field inspectors, utility personnel and linemen with guidelines, recommendations and requirements necessary to safely and successfully install the ACCC composite-core bare overhead conductor and accessories. This document is an overview and guideline covering what to do but not necessarily how to do it. It is not intended to serve as a more intensive training manual or act as a substitute for proper training, required personnel skill sets, or industry experience. 2. SCOPE 2.1. These guidelines apply to specific equipment and techniques required to successfully install all sizes of ACCC conductor These guidelines include additional equipment and techniques that are required for Ultra- Low Sag (ULS) ACCC conductor sizes. 3. DEFINITIONS 3.1. ACCC is a registered trademark of CTC Global, and is defined as Aluminum Conductor Composite Core, stranded with Aluminum (where 0 stands for fully annealed) or Aluminum Z-wire trapezoidal wire. 4. ASSOCIATED DOCUMENTS 4.1. IEEE Standard 524 Guide to the Installation of Overhead Transmission Line Conductors OSHA Electric Power Generation, Transmission, and Distribution Standards and or ISO or local country equivalent The remaining Chapters of the Installation Guidelines 5. TOOLS & EQUIPMENT 5.1. Tools & Equipment Checklists The Tools & Equipment described herein are generic for all sizes of ACCC Conductors Major equipment (tensioners, payout reel stands, pullers) and a variety of minor equipment (sheaves, grips, swivels, presses, dies, etc.) are specific to conductor size (diameter) CTC can produce a size-specific checklist upon request. Two lists are produced: one complete, including both required and recommended equipment, and one

3 5.2. Safety Equipment ACCC Conductor Installation Guidelines WI Rev C Page 3 of 18 Critical including only the minimum required equipment. Send your request, with the desired ACCC Conductor size, to: Fieldservice@ctcglobal.com Personal Safety Equipment: Hard hats, safety shoes, eye and ear protection, work gloves, rubber gloves, high visibility clothing, long sleeves, long pants, and safety harness with lanyard should be used as appropriate by personnel working around ACCC and installation equipment Grounding Safety Equipment: Hot sticks, voltage tester, ground cables with appropriate clamps, driven or screw type ground rods, grounding mats if needed, rubberized blankets if needed, equal potential area warning tape, conductor working zone boundary flags, all may be needed and should be used, but are outside the scope of this document Reel Handling Equipment ACCC Conductor is supplied on reels to customer specification and conforming to DIN or NEMA WC 26 for steel reels (recommended) or DIN or NEMA WC 26 Class 3 for wooden reels. However, minimum winding surface (drum or hub) diameters are specified per F Conductor reels may be moved by forklift. See Chapter 4 for forklift procedure and precautions Conductor reels may be moved by hoist or crane. An axle for hoisting through the arbor holes will be needed, and either a spreader bar and slings or extra long axle and extra long slings. See Chapter 4 for hoisting procedure and precautions Payout Reel Stand Brakes. The function of the payout reel stand is to feed new conductor to the tensioner UNDER CONTROLLED TENSION so the conductor feeds smoothly and evenly into the tensioner. The brakes effect this tension and must be maintained in excellent operating condition. Many reel stands are equipped with disc brakes. These are often undersized and poorly maintained. Hydraulic brakes are preferred to be used for ACCC installation, preferably synchronized with the tensioner. NEVER use timbers, boards, poles or other make-shift devices for brakes! Mandrel / Arbor Sizes ACCC is shipped on heavy duty reels appropriate to support and protect the conductor for its storage and transport mode(s). The reels, depending on conductor size, will typically have one of the following arbor (bore) sizes. Complete reel specifications are found in F ASTM (inches) International (mm) Small or 125 Large or 200 or 250

4 WI Rev C Page 4 of Bushings must be used, if needed, to adjust the payout reel mandrel size up to the arbor size so that the reel rotates evenly about it s axis Wooden Reel Stands are equipped with a mandrel that supports the weight of the reel and arms that clamp onto the wooden reel flanges and effect the rotational control of the reel. Wooden reel stands should NOT be used with metal reels unless the wooden reel stand is adapted to hold the metal reels so that good brake control is achieved. Ideally, metal reel stands should be used for metal reels and wooden reel stands should be used for wooden reels Metal Reel Stands are equipped with a mandrel that supports the weight of the reel and arm(s) with drive pins that fit into matching holes in reel flanges and effect the rotational control of the reel. Wooden reels can be used with metal reel stands as long as there is a hole in the side of the reel to anchor the wooden reel with the pin that controls the reel Whether stands are designed for metal or wooden reels, rotational control is typically provided by either disc brakes or hydraulic motor. Hydraulic motor braking is strongly preferred for ACCC installation. If disc brakes are used, the brakes must be in excellent condition and fully capable of quickly stopping a full reel rotating at payout speed.

5 WI Rev C Page 5 of Tensioner Tensioner bull wheels must be a minimum diameter as specified in Appendix B, measured at the bottom of the grooves of the bull wheel. For any ACCC conductor utilizing a ULS composite core, the tensioner bull wheel diameter shall be a minimum of 1800 mm (70 inches) Only multi-groove tensioners and a minimum of four grooves should be used. The number of grooves in the bullwheel shall be sufficient to prevent the outer layer of wires from slipping over the lower layers and to maintain good tension control Tensioner bull wheel groove depth should be minimum.55 times conductor diameter to help control strand opening Tensioner Fairlead Poor tension control of the conductor feeding the tensioner will cause the conductor to bounce on the rollers of the tensioner fairlead. This will damage the conductor core. Poor tension control at the fairlead is always caused by poor control of the brake on the payout reel stand, due either to poor condition or under capacity brake, or brake operation error. This has been the most common installation error in the history of ACCC. It is critical to a) maintain good control of payout reel braking and b) correctly set-up the tensioner fairlead A curved, multi-roller (banana) fairlead on the input side of the tensioner is highly recommended for ACCC. Pictured below is Tesmec/Condux, fairlead part number AYU Core Retainer (Bug) ACCC conductor is constructed with a smooth composite core surrounded by one or more layers of aluminum strands. The core retainer (bug) prevents the core from slipping back inside during conductor installation so that the core is accessible for termination procedures. The bug is temporary, used only during handling and pulling/stringing Bugs are ACCC specific and supplied by CTC. Bugs may be re-used but should not be used indefinitely. Do not reuse a bug when the nut does not screw into the body easily or if the inside collet appears worn or damaged.

6 WI Rev C Page 6 of Bug Installation / Removal Tools Hammer Core punch (included with bug) Fine-Tooth (32 TPI) Hack Saw Steel Wire Brush Crescent Wrench (2) 5.8. Conductor Grips, Clamps, and Socks Grips and Clamps Must be long jaw, lever type, rated for the loads as determined by the conductor size and the project pulling and sagging tensions. Klein brand Chicago style (1628 series) grips are recommended. Use P (7.25-inch jaws) for conductors mm (0.858 inches) outside diameter and smaller. Use (10.75-inch jaws) for larger conductors Clamps should be inspected for rough surfaces and rough edges which may scratch or gouge the soft aluminum surface strands of ACCC. Rough edges or surfaces must be corrected with fine tooth file or sandpaper Wire Mesh Grips or Socks must be correctly sized, and kept in good condition, free of rust or other contamination. Hubbell brand Kellems K-Type Pulling Grips or Arrow Heart K-type Heavy Duty Pulling Grips are recommended.

7 WI Rev C Page 7 of Banding Tool 5.9. Blocks (Sheaves or Travelers) Grooves should be inspected before use to avoid surface defects which may damage the fully annealed aluminum of ACCC. Grooves should be lined with material (neoprene or urethane) which will help avoid marking the surface of the conductor See Minimum Sheave Size Chart, Appendix B Hoisting Equipment A Capstan Hoist will provide a smooth hoisting alternative to manual methods which can damage the ACCC conductor core. Ensure that the hoist rating exceeds the loads.

8 WI Rev C Page 8 of Chain Hoist. Ensure that the hoist rating exceeds the loads Hoist Hooks, Rigging. ACCC conductor can be damaged by using point-contact hoisting equipment. Forces must be spread using wide hooks or nylon slings. Slings should be spread to provide for wide contact with the conductor Puller Ensure that the rating exceeds the loads.

9 WI Rev C Page 9 of Bucket Truck (if available) Personnel lifts, platforms, or buckets greatly enhance safety and efficiency Should be insulated and designed for electrical work Stinger Truck (if available) A stinger truck is a boom crane mounted on a flatbed truck equipped with outboard stabilizers. It is used for equipment handling and can be equipped with a personnel bucket, if equal potential ground is assured Swivels Pulling swivels must be in good condition, rotate freely, and be rated for the pulling tensions.

10 5.15. Terminating and Splicing Termination Hand Tools ACCC Conductor Installation Guidelines WI Rev C Page 10 of Ratchet Cutter or Cable Cutter for rough cuts only! Never use a ratchet cutter or cable cutter for final cut Cable Trimmer cable trimmers must be kept sharp and in good mechanical condition. Cable trimmers with (correctly selected) cut depth control bushings are preferred. A cable trimmer that cuts too deeply can nick or score the conductor core, which will result in failure Fine Tooth (32 TPI) Hacksaw. In all cases, the final cut of ACCC core MUST be made with a fine tooth hacksaw! Metal File Smooth tooth, to remove flashing from deadend or splice crimping process Crescent Wrenches (2) approximately 15 or 380mm length.

11 WI Rev C Page 11 of Presses and Dies Presses must be of sufficient capacity to properly crimp the termination hardware. Double-acting pumps and presses will dramatically improve the termination process time Dies - the use of proper press dies, sized and configured correctly for both the press and the hardware, is critical for successful termination hardware installation. See the Compression Die Chart, Appendix B Caulking Gun for application of AFL filler compound for Alcoa Hardware Consumables Hacksaw Blades Fine Tooth (32 TPI) Deadend Body and Splice Body Lubricant or Soap Sandpaper Grit Electrical Tape Black Permanent Felt Tip Markers HT Penetrox or Alnox Electrical Joint Compound or equivalent oxidation inhibitor. MUST be high temperature (200 C) oxidation inhibitor. o Repels water o Improves thermal transfer (helps joints run cooler) o Inhibits oxidation and corrosion OR AFL (brand) Filler Compound (AFC) or equivalent

12 WI Rev C Page 12 of 18 o Filler Compound protects the compressed steel barrels from corrosion. Compressing removes galvanizing from the forging. The filler compound acts as a barrier to moisture. o Filler Compound contains aluminum particles, which clean the strands (removing oxides) while compressing. Compressing forces the compounds within the strands. o Filler Compound blocks moisture, which can wick up through the strands. Compressing forces the compound throughout the conductor strands. 6. SPECIAL EQUIPMENT FOR BUNDLED APPLICATIONS 6.1. Tensioner Tensioners Each conductor in the bundle should be tensioned by a separately controlled set of bull wheels. A single tensioner with capacity for all conductors in the bundle is preferred so that one operator can control all conductors. The major tensioner manufacturers all offer models that handle up to 6 conductors simultaneously. Multiple tensioners may be used but must be synchronized such that a single operator is controlling all the wheels Payout Reels With multiple payout reels turning simultaneously, the payout reel brake controls are critical and must be automatically controlled from the tensioner(s). Automatic (hydraulic) reel control is an optional feature from all the major tensioner manufacturers Tensioner Feed-In Sheaves With multiple payout reels at every set-up site, perfect alignment is often not possible. A separate interim sheave between payout reel and tensioner fairlead is required for every conductor. This sheave, properly placed, will correct for vertical and elevation differences and can facilitate the placement of payout reels behind one another with respect to the tensioner. When supported in the plane of the conductor travel, the tensioner feed-in sheave can correct for horizontal or fleet angles where the payout reel(s) cannot be sufficiently aligned with the tensioner Sheave Blocks Multi-sheave blocks must be used (same diameter as would be used for single conductor pulling). Multi-sheave blocks should include one more sheave than the number in the bundle, the extra one in the center for the pilot line and running board tail. When even numbers of conductors are strung, a symmetrical arrangement is used with an equal number of conductors on each side of the pulling line. The independent center sheave is provided only for the pulling line and should be of suitable material to withstand the abrasion of the pulling line.

13 WI Rev C Page 13 of 18 When odd numbers of sub conductors are strung, the center one could follow the pulling line in the center sheave. However, this is usually not desirable because of the material of the groove or because of contaminants deposited in this groove by the pulling line, or because of both. Offset-type bundle conductor travelers are used that balance the load by properly spacing the even and odd number(s) of conductors on each side of the pulling force. These travelers are directional and should be color-coded. Care should be taken to ensure their proper orientation Running Board or Balance Board A special device called a running board or balance board (or gator ) distributes the pulling force from a single pilot line to the conductors evenly, establishes the spacing, and prevents the conductor bundle from twisting during pulling with a heavy tail which keeps the board level as it travels between structures. These must be used for pulling bundled configurations of ACCC (but not used for alignment at anchors). Multi-sheave bundle conductor type travelers and running boards must be designed to complement each other and work in unison. Running boards should only be used to pull in conductors. They should not be used to line up the conductors with an anchor (that is, running boards should not be pulled sideways). Running boards should have their safe working load displayed. It is recommended that all running boards and swivel links be proof tested to 50% over the safe working load Puller Pullers and winches must be capable of the required pulling forces. In bundled applications this is the sum of all the conductors plus the pulling line.

14 WI Rev C Page 14 of TEN INSTALLATION DON TS 7.1. DON T OVER-BEND! Don t allow the conductor to contact surfaces that present sharp angles or small diameters ONE Tensioner DON'T Don t let ACCC run hard on the end roller of the fairlead. Always use an interim sheave to feed the conductor into the middle of the tensioner fairlead opening. A multiple-roller banana fairlead is highly recommended TWO Payout Reel DON'TS Don t allow the conductor to bounce or jump up and down between the payout reel and the tensioner. When the conductor is jumping or bouncing, the core can be damaged Don t use a payout reel with insufficient brakes. Poorly maintained or undersized brakes will cause jumping and bouncing of the conductor between the payout reel and the tensioner. The payout reel brakes should allow the tensioner to draw new conductor from the reel smoothly and evenly THREE Handling and Equipment DON'TS Don t use grips that aren t designed for installing ACCC. Use Klein Chicago long jaw grips or equal, designed for the size conductor being installed. Never use pocketbook grips! Don't allow the conductor tail or the deadend to fall or droop unsupported while handling the conductor. If the tail is not controlled, it will damage the core at the back of the grip Don t hoist the conductor in any manner which causes a sharp bend in the conductor TWO Pulling / Stringing DON TS Don t install any ACCC with under-diameter sheaves on the first and last structure or any angles that are over 30 degrees Don't pull in conductor using old conductor if it is rusty. Don t use old conductor with splices or broken strands for pulling. Always cut splices and any damaged areas out and replace with Kellum grips before using old conductor for pulling. When in doubt, pull in a pilot line using the old conductor and pull in ACCC using the pilot line. Always use a pilot line for long spans and river crossings ONE Termination DON T Don t allow a sharp bend where the conductor exits the termination hardware. Hoisting conductor or deadend without paying attention to this area can damage the core at that point.

15 Chapter 6 Required Tools and Equipment WI Rev C Page 15 of 18 Appendix A Equipment Readiness Review Form

16 Chapter 6 Required Tools and Equipment WI Rev C Page 16 of 18 Appendix B Minimum Sheave and Tensioner Sizes

17 Chapter 6 Required Tools and Equipment WI Rev C Page 17 of 18 Appendix C Compression Dies

18 Chapter 6 Required Tools and Equipment WI Rev C Page 18 of 18 REVISION HISTORY REV. CHANGE REQUEST # DATE A B C Title Tools and Equipment was Required Equipment Section added 32 TPI Section 5.51 Bullwheel diameters as specified was 40D Deleted Section Added Section 6, Special Equipment for Bundled Applications Appendix A: Equip. Readiness Review was Tooling Checklist Appendix B: F _C was _B Appendix C was D; F _C was _B Copyright (footer) 2017 was 2016 July, 2017