Construction Manual 195 MM2

United Nations Development Programme
Sustainable Human Development
DISTRIBUTION
CONSTRUCTION MANUAL
DISTRIBUTION SECTOR
UNDP – ENRP
REVISION 2 : FEBRUARY 2002

UNDP-ENRP Distribution Sector
CONSTRUCTION STANDARDS
FOR
OVERHEAD POWER DISTRIBUTION LINES
AND
DISTRIBUTION TRANSFORMERS
Contents Page
1.0 Background 1-1
2.0 Scope 2-1
3.0 Guidelines for Overhead Power Distribution Lines 3-1
4.0 Design Criteria 4-1
5.0 Items used in Overhead MV and LV Construction 5-1
6.0 Overhead Line Construction 6-1
7.0 Safety of Personnel 7-1
8.0 Deviations to the Manual 8-1
9.0 Drawings 9-1
10.0 Tables and Charts 10-1
Annexes
Annex 1 Distribution Material Drawings
Annex 2 Low Voltage Construction Drawings
Annex 3 Medium Voltage Construction Drawings
Annex 4 Pole Top Construction Drawings for Bare Conductor LV Lines
Annex 5 Pole Top Construction Drawings for Aerial Bundled Conductor LV Lines
Annex 6 Pole Top Construction Drawings for MV Lines
Distribution Construction Standards Page i

Annex 7 Pole Top Construction Drawings for MV & LV Combine Runs
Annex 8 Typical Conductor Configuration Drawings for LV Lines
Annex 9 Typical Conductor Configuration Drawings for MV Lines
Annex 10 Typical Conductor Configuration Drawings for MV & LV Combine Runs
Annex 11 Distribution Transformer Drawings
Annex 12 Terminal Pole (H Pole) Construction for Substations
Annex 13 List of Distribution Construction Materials
Annex 14 Distribution Safety Guide Lines
Annex 15 Implementation Procedures
Manual Compiled by : Distribution Sector

UNDP/ENRP
Revision Number :2
Revised on : February 2002
Distribution Construction Standards Page ii

CONSTRUCTION STANDARDS
FOR
OVERHEAD POWER DISTRIBUTION LINES
AND
DISTRIBUTION TRANSFORMERS
1.0 Background
The electricity supply system in the three Northern Governorates of Iraq suffered severe damage, as a
result of the Gulf War and the ensuing internal conflicts of the country. Several distribution and
transmission lines were put out of commission, many substations were destroyed due to these unsettled
situation of the country. After the departure of the Government forces from the Northern Governorates,
even more damage was sustained by the network principally from scavenging of materials. The non-
availability of equipment, materials and spare parts, due to the UN imposed sanctions, led to the continued
deterioration of the electricity network.
The Governorates of Erbil and Sulaimany had been cut off from the national grid and both Governorates
had to rely on Dokan and Derbandikhan hydropower for supply. The generation capacity of these dams,
however, was insufficient to meet the demand. However, due to the deteriorated condition of the existing
distribution network even the available energy could not be delivered to the customers in a reliable and
efficient manner.
Under the UN Security Council Resolution 986 (SCR 986/1995), an emergency programme had been
launched by UNDESA in 1997/98 to assist the Local Electricity Authorities in obtaining urgent
requirements for distribution materials to carry out most urgent work to relieve the system from further
deterioration/collapse. However, this measure was not adequate to improve the system to a satisfactory
condition.
In order to address this problem in a more systematic way, UNDP started the Electricity Network
Rehabilitation Project (ENRP) in 1999. Under this project UNDP is in the process of implementing various
sub projects to improve the condition of the electricity network of three Governorates.
The Distribution Sector of ENRP is engaged in executing Distribution Network Rehabilitation Projects to
develop and rehabilitate the existing distribution network of the three Governorates. For the successful
implementation of these projects, it is essential to develop a construction standard for all distribution
construction/rehabilitation works, in order to maintain the quality of work and to introduce good/safe work
practises for Local Electricity Authorities.
This Distribution Construction Manual will help the construction and rehabilitation staff to fulfil the above
task in distribution line and distribution transformer construction / rehabilitation.
Distribution Construction Standards Page 1-1

2.0 Scope
This Construction Standards manual provides the necessary guidelines for the design of Medium Voltage
and Low Voltage power lines, technical specifications of materials, selection of materials, construction
methods of overhead MV and LV lines, standard material requirements for different pole top arrangements
for overhead MV and LV power lines with drawing and tables.

3.0 Guidelines for Overhead Power Distribution Lines
3.1 General
3.1.1 Overhead Medium Voltage (MV) and Low Voltage (LV) power distribution lines shall be routed
along the roads and be straight as far as possible.
3.1.2 Clearance/approval from other relevant service authorities such as Municipality,

Telecommunication Authority, Road Authority etc. shall be obtained for the proposed line routs.
3.1.3 Private land and/or vegetations should be avoided as far as possible in construction of MV and
LV lines.
3.1.4 Overhead MV and LV lines shall be routed to avoid crossing of other power and
telecommunication lines as far as is practicable.
3.1.5 MV line pole positions shall be located so as to accommodate future construction of LV lines on
existing poles.
3.1.6 LV line poles shall be located so as to provide maximum number of service connections to the
prospective consumers with the minimum use of service poles and wires.
3.1.7 Low Voltage lines in urban densely populated and developing areas shall be three phase while in
rural areas the Distribution Planning Engineer is given the option of choosing the line
configuration (ie. Single phase or three phase).
3.1.8 Following points shall also be considered when locating the pole positions along the lines.
i. Access for construction and future maintenance work.

ii. Environment and aesthetic considerations.
iii. Availability and suitability of land to erect poles.
3.1.9 Following shall be avoided as far as possible when locating pole positions.
i. Heavy angles and deviations of lines.

ii. Drainage lines, water pipes, side drains, culverts, marshy lands etc.
iii. Crossing of probable building sites, playgrounds, road widening routes, places with
valuable vegetations etc.
iv. Construction of MV and LV lines in parallel with existing telephone lines on the same
side of the road.
3.1.10 Poles and stays shall be positioned so as to cause least obstruction to the public movements.
3.1.11 Ensure that poles and stays are not at risk of being damaged by vehicles from driveways.
3.1.12 MV lines shall be generally constructed with 11m Tubular Steel Poles and LV lines shall be
generally constructed either with 9m Tubular Steel poles or 9m Reinforced Concrete poles.
However, different pole heights may be used to maintain ground clearances in road crossings
and elevated areas.
3.1.13 Maximum span for MV and LV lines shall be in accordance with Clause 6.3 of this document.
3.1.14 In urban and densely populated areas, the LV line spans shall be designed based on the
assumption that double circuit lines would be constructed in future.

3.1.15 Standard conductor clearances to the ground, permanent structures and trees shall be maintained
as specified in Clause 4.7 of this manual. Close proximity of overhead power lines to trees shall
be avoided to;
i. Ensure public safety.

ii. Minimise the risk of fires caused by contact between trees and overhead lines.
iii. Reduce the power outages and improve the reliability of supply.
iv. Protect plant and equipment from damage.
v. Minimise the loss of energy through tree conductivity to earth.
3.1.16 MV overhead lines shall be strung using Aluminium stranded bare Conductors with Steel
Reinforced (ACSR) in ‘Delta’ formation for single circuit lines and vertical formation for double
circuit lines of same voltage.
3.1.17 Low voltage overhead distribution lines shall be strung using All Aluminium stranded bare
conductors (AAC) in vertical formation or neutral supported Aerial Bundled Conductors (ABC).
3.1.18 In cases where overhead circuits of different voltages cross each other the conductors of the
higher voltage circuit shall be placed above the conductors of the lower voltage circuit.
3.2 Guide Lines for Selection of Aerial Bundled Cables (ABC) for Low Voltage Lines
3.2.1 The capacity of the distribution line can be increased by running a second set of ABC cables on
the same poles. Therefore, ABC lines shall be used in densely populated developed areas to
avoid voltage drop and to provide a reliable power supply.
3.2.2 ABC lines are also suitable where buildings are located very close to the roads.
3.2.3 ABC lines may be drawn on narrow and congested lanes where bare conductor lines cannot be
installed and also in parks/gardens where poles are to be avoided for aesthetic reasons.
3.2.4 Bare conductor lines may be connected to ABC lines as an extension, only if ABC line will not be
overloaded.
3.2.5 Where vertical and/or horizontal clearances of bare conductor lines cannot be maintained, the use
of ABC is recommended.

4.0 Design Criteria
4.1 Voltage Definitions
In this manual, references to voltage levels are in accordance with following values.
Extra Low Voltage Normally not exceeding 30 Volts
Low Voltage Exceeding 30V, but not exceeding 650V to each or 1kV
between phases
Medium Voltage Exceeding 1kV, but not exceeding 11kV
High Voltage Exceeding 11kV, but not exceeding 33kV
Extra High Voltage Exceeding 33kV
4.2 Low Voltage System
Nominal System Voltage 400 / 230 Volts
Maximum System Voltage 424 / 244 Volts
System Frequency 50 Hz
Type of System Grounding Neutral Earthed at Distribution Transformer
4.3 Medium Voltage System
Nominal System Voltage 11 kV
Range of System Operating Voltage 10 kV – 12 kV
System Frequency 50 Hz
Type of System Grounding Neutral resistive earthing through earthing

transformer at Substation
4.4 Environmental Conditions
The following physical design parameters have been considered as general environmental
conditions in Iraq.
Altitude up to 1000m above sea level
Maximum outdoor temperature 50°C
Minimum outdoor temperature -10°C
Maximum relative humidity 92%

Maximum wind speed 125 km / hr
Isoceraunic level 15
Pollution level Frequent and strong dust storms
Maximum Rainfall 500mm
Maximum ground temperature 350C at 100mm depth
4.5 Wind Loading
Design wind speed is considered as 125 km / hr.
The relationship between dynamic wind pressure and wind velocity for a cylindrical surface is
given by the following formula.
P = 0.625 V2
Where, P = Wind pressure (N/m2)

V = Wind velocity (m/sec)
This dynamic free stream pressure can be converted to a force on an obstacle by multiplying it by
a force coefficient.
The following force coefficient and design wind loadings have been considered.
Force Design
Coefficient Wind Pressure
Cf N / m2
Conductors, round or octagonal shaped poles 0.8 603
Electrical equipment, I-shaped & Vierendeel poles 1.2 904
Flat sided members of lattice towers 1.9 1432
4.6 Conductor Parameters
Conductor sag and tension will be determined in accordance with the following parameters.
- Maximum tension of the conductor is determined at –100C with wind and ice loading of 603
2
N/m .
- Maximum sag of the conductor is determined at 800C with no wind load.
- Constant conductor tension occurs at a defined normal everyday temperature of 250C. This
is the average temperature assumed at which conductor stringing shall be carried out.
- Average tension of the conductors shall be limited at 17% of the ultimate tensile strength
(UTS) of the conductor.
- Maximum allowable stress with wind and ice at –100C temperature shall be limited to 50% of
UTS.

4.7 Clearance from Ground and Structures
4.7.1 Above Ground
Overhead line conductors shall be so located that the distance to ground in any direction from
any position to which any point of such conductors may sag under the influence of load current
shall not be less than the distance specified below.
i. Low Voltage Bare Conductor
- across the road / street 5.5 m

- along the road / street 5.0 m
- in any other places 4.5 m
ii. Low Voltage Aerial Bundled Conductors

iii. Medium Voltage (11kV) Bare Conductor

4.7.2 From buildings and other structures
The minimum clearance from any structure, building to any position to which a conductor in an
overhead line may swing under the influence of wind shall be as specified below.
U < 1000V 1kV<U<33kV
Bare Bare Bare or

Insulated
Neutral Active Insulated
A - Vertically above any structure normally

2.7 m 2.7 m 3.7 m 4.5 m
accessible to persons
B - Vertically above any structure not

normally accessible to persons but on 0.1 m 2.7 m 2.7 m 3.7 m
which a person can stand
C - In any direction (other than vertically

above) any structure normally
accessible to persons or from any parts 0.1 m 0.9 m 1.5 m 2.1 m
not normally accessible to persons but
on which a person can stand
D - In any direction any structure not

0.1 m 0.3 m 0.6 m 1.5 m
normally accessible to persons

Note: The distances A, B C & D are as illustrated in the figure below.
4.7.3 From other Conductors
i. Conductors of different circuits on different supports
The vertical separation between any conductor of the lower circuit and any point to which a
conductor of the higher circuit may sag under the influence of load current (excluding fault
current) shall be less than the values specified in the Table –1 below.
ii. Conductors of different circuits on the same support
The lower voltage and the vertical clearances between conductors of the different circuits at any
point on the support under normal working conditions shall not be less than the values specified
in the Table – 2 below.

Table 1 - Vertical Separation for Unattached Crossings
UPPER CIRCUIT
U </= 33kV
U </= 33kV U < 1000V
U </= 132kV U > 1000V Other Cables Other Cables
U > 1000V Bare, Covered
U > 33kV Bare or (Conductive) (Conductive)
Insulated or Insulated
Covered
132kV >/= U > 33kV No Wind 2.4 m

Bare Wind 1.5 m
33kV >/= U > 1000V No Wind 2.4 m 1.2 m

Bare or Covered Wind 1.5 m 0.5 m
33kV >/= U > 1000V No Wind 2.4 m 1.2 m 0.6 m 0.5 m

Insulated Wind 1.5 m 0.5 m 0.4 m 0.3 m
LOWER
CIRCUIT U < 1000V Bare, No Wind 2.4 m 1.2 m 0.6 m 0.6 m 0.4 m
Covered or Insulated Wind 1.5 m 0.5 m 0.4 m 0.4 m 0.2 m
Other Cables No Wind 2.4 m 1.2 m 0.6 m 0.6 m 0.4 m 0.4 m

(Conductive) Wind 1.5 m 0.5 m 0.4 m 0.4 m 0.2 m 0.2 m
Other Cables No Wind 0.5 m 0.5 m 0.5 m 0.5 m 0.4 m 0.4 m

(Conductive) Wind 0.3 m 0.3 m 0.3 m 0.3 m 0.2 m 0.2 m

Table 2 – Vertical Separation for Attached Crossings
UPPER CIRCUIT
U < 33kV
U < 33kV U < 1000V
U < 132kV U > 1000V U < 1000V Other Cables Other Cables
U > 1000V Bare or
U > 33kV Bare or Insulated (Conductive) (Conductive)
Insulated Covered
Covered
132kV > U > 33kV

2.4 m 0.2 m
Bare
33kV > U > 1000V

2.4 m 0.9 m 0.9 m 0.2 m
Bare or Covered
33kV > U > 1000V

2.4 m 0.9 m 0.2 m 0.6 m 0.2 m
Insulated
LOWER U < 1000V

2.4 m 1.2 m 0.6 m 0.3 m 0.3 m 0.2 m
CIRCUIT Bare or Covered
U < 1000V
2.4 m 1.2 m 0.6 m 0.3 m 0.2 m 0.3 m 0.2 m
Insulated
Other Cables
2.4 m 1.2 m 0.6 m 0.3 m 0.3 m 0.2 m 0.2 m
(Conductive)
Other Cables
0.2 m 0.2 m 0.2 m 0.2 m 0.2 m 0.2 m 0.2 m
(Conductive)

iii. Horizontal spacing between different circuits
The horizontal spacing between different circuits shall not be less than specified below.
Higher Voltage Low Voltage Horizontal
400/230V Bare/Insulated 0.3 m

11kV Bare/Insulated 1.2 m
33kV Bare/Insulated 1.5 m
iv. From telephone lines
Bare Low Voltage 1.2 m

Aerial Bundled Conductor Low Voltage 0.6 m
4.7.4 Clearance from Trees
MV and LV line conductors shall have the following minimum vertical and horizontal clearances
from trees.
Vertical Clearance Horizontal Clearance
Low Voltage Bare Conductor 2.7 m 1.5 m

Low Voltage Aerial Bundled Conductor 0.15 m 0.15 m
Medium Voltage (11 kV) Bare Conductor 3.7 m 2.9 m
4.7.5 Safety Clearances
To ensure personal safety the following minimum safety working clearances shall be maintained
between,
i. Low voltage bare conductor and

- Any part of the human body 0.15 m
ii. Low voltage ABC and

- Any part of the human body 0.10 m
iii. Low Voltage line, bare or insulated conductor

- Any mechanical equipment 3.5 m
- Any construction of building/structure 4.0 m

4.8 Conductor Sag and Tension
4.8.1 Wind Span
Wind Span is the maximum possible half span lengths (total) on either side of the pole, which
can withstand the design wind speed.
Wind Span = Sum of half span lengths of adjacent spans.
The maximum possible wind spans for different types of poles & conductor combination are
given below. Designed wind speed is 125km/h.
Max. Possible
Type of Pole Conductor Combination
Wind Span (m)
9m Steel Tubular Pole AAC 35 90
AAC 50 75
AAC 70 65
AAC 95 55
ABC 3x70+1x50+1x16 65
ABC 3x95+1x50+1x16 60
11m Steel Tubular Pole ACSR 50/8 95
ACSR 95/15 70
ACSR 120/20 60
11m Steel Tubular Pole ACSR 50/8 + AAC50 45
ACSR 95/15 + AAC70 35
ACSR 120/20 + AAC 95 30
ACSR 120/20 + ABC 70 35
ACSR 120/20 + ABC 95 35
4.8.2 Basic Span (Equivalent Span)
Basic Span of a line section between two tension points can be calculated by using following
formula.
Sum of Cubes of Span Lengths

Basic Span =
Section Length
OR
L13+L23+L33+………..+Ln3
Basic Span =
L1+L2+L3+…………+Ln
Where, L1, L2, L3, …. etc. are individual span lengths of a section of the line.

0
Considering span lengths of an existing line, wind spans, maximum conductor tensions (at –10 C
with Ice) and loads on poles and stay wires, general basic spans have been established for Low
Voltage and 11kV+LV combine runs as given below.
Line Type Basic Span (m)
Low Voltage Lines 35
11kV Lines 50
11kV + Low Voltage Lines 25
Note: Calculation of individual basic span for each section is carried out only for Transmission
lines. For distribution lines General Basic Spans are used.
4.8.3 Equations used for Sag and Tension Calculation
Sag of any span can be determined by the following formula.
(Actual Span Length) 2

Sag on any Span = Sag on Basic Span X
(Basic Span Length) 2
Sag of the conductor on a flat terrain is greatest at mid-span. Further, this sag will increase with
temperature and be a maximum at the maximum operating temperature.
The sag and tension relationship can be expressed in terms of the following formula.
2
Maximum Sag (S) = WL
8T
Where, S = Sag (m)

W = Weight per unit length of conductor (N / m)
L = Lengths of design span (m)
T = Tension at maximum temperature (N)
The variation of conductor tension (T) due to wind pressure and temperature variation can be
calculated using the following formula.
2 2 2 2 2 2
T2 {T2 - (T1 - xAE [Q2 - Q1] - AEF1 L /[24T1 ])} = AEF2 L / 24
Where,
T1 - Tension in initial condition (daN )
T2 - Tension in final condition (daN)
x - Coefficient of liner thermal expansion (per 0C)
2
A - Conductor Area (mm )
E - Young’s Modulus (daN /mm)
0
Q1 - Conductor temperature in initial condition ( C)
0
Q2 - Conductor temperature in final condition ( C)
F1 - Resultant wind and weight force in initial condition (daN /m)
F2 - Resultant wind and weight force in final condition (daN /m)

Calculation of load on a pole can be expressed in terms of the following formula.
MT = MC + MW + ME
MC = Bending moment due to tension of conductors and the wind on the conductors (kNm)
MW = Bending moment due to wind force on the surface of the pole (kNm)
ME = Bending moment due to weight of the equipment depending on their method of support
(kNm)
MC = 2nTLa Sin(x / 2) + Lanwds (kNm)
Where,
n = No of conductors in any plane
T = Conductor tension (kN)
La = Distance of conductors above ground (m)
x = Angle of deviation of conductors (degrees)
d = Conductor diameter (m)
2
w = Design wind pressure (kN/m )
s = Wind span (m)
The relationship between conductor spacing (b) and sag is defined by the following formula.
Conductor Spacing (b) = 0.75 √ S + ( V2 / 20000) meters
Where,
b = Conductor spacing (m)
S = Sag (m)
V = Voltage (kV)

5.0 Items used in Overhead MV and LV Construction
All equipment is specified to the latest version of relevant international standards and UNDP specifications.
5.1 Poles
9m Tubular Steel Poles and 9m Reinforced Concrete Poles shall be used in construction of low
voltage overhead lines. In the case of MV (11kV) overhead lines and MV+LV combined run, 11m
Steel Tubular Poles shall be used as shown in the Drawing Nos. DSS-MT-001 to DSS-MT-004.
Pole positions are classified as Terminal, Tension (Shackle) and Intermediate and are defined
below.
Terminal Pole Where the line is terminated with MV tension or LV shackle

insulators on one side of the pole (also called dead end poles).
Tension (Shackle) Pole Where the line is terminated with MV tension or LV shackle
insulators on both side of the pole.
Intermediate Pole Where the line is continuous and supported on MV pin

insulators or LV shackle insulators.
Self-supported poles shall be constructed in urban and densely populated areas, where Stays
cannot be erected.
General details of different types of poles are as follows.
Working Buried
Item
Description Load Purpose Length
Code
(kg) (m)
A 02 05 9m Tubular Steel Pole 200 LV Lines, intermediate poles 1.5
9m Tubular Steel Pole LV Lines, terminal & section

A 02 15 700 1.5
(Lattice Equivalent) poles
MV only or MV & LV
A 02 25 11m Tubular Steel Pole 250 combined run, intermediate 1.8
pole
MV only or MV & LV
11m Tubular Steel Pole
A 02 35 700 combined run, terminal & 1.8
(Lattice Equivalent)
section poles
9m Reinforced Concrete
A 03 05 115 LV Lines, intermediate poles 1.5
Pole

5.2 Conductors
Physical data of the standard bare All Aluminium Conductors (AAC) and Aluminium Conductor
Steel Reinforced (ACSR) used in distribution construction are as follows.
• All Aluminium Conductors (AAC)
Item Code D 02 05 D 02 10 D 02 15 D 02 20
Conductor Name AAC95 AAC70 AAC50 AAC35
Nominal Size (mm2) 95 70 50 35
Mean Cross Section of Conductor (mm2) 93.27 65.81 49.48 34.36
Stranding (Nos / mm) 19/2.5 19/2.1 7/3.0 7/2.5
Overall Diameter (mm) 12.5 10.5 9.0 7.5

2
Modules of Elasticity (kN/mm ) 57 57 60 60
Coefficient of Thermal Expansion
23 23 23 23
(per 0C x 10-6)
Ultimate Tensile Strength (kN) 15.68 11.32 7.94 5.78
Weight (daN /m) 0.256 0.181 0.135 0.094

0
Conductor Resistance at 20 C (ohm/km) 0.3095 0.4386 0.5786 0.8332
Maximum Current Rating, at 350C (Amps) 324 261 219 175
Maximum Current Rating, at 500C (Amps) 245 199 168 135
• Aluminium Conductor Steel Reinforced (ACSR)
Item Code D 03 05 D 03 10 D 03 20
Conductor Name ACSR120/20 ACSR 95/15 ACSR 50/8

2
Nominal Size (mm ) 120 95 50
Cross Section of AL Conductor (mm2) 121.57 94.39 48.25

2
Cross Section of St Core (mm ) 19.85 15.33 8.04
Stranding (Nos / mm) 26x2.44 / 7x1.9 26x2.15/7x1.67 6x3.2/1x3.2
Overall Diameter (mm) 15.5 13.6 9.6

2
Modules of Elasticity (kN/mm ) 77 77 81
Coefficient of Thermal Expansion
18.9 18.9 19.2
(per 0Cx10-6)
Ultimate Tensile Strength (kN) 44.94 35.17 17.18
Weight (daN /m) 0.494 0.383 0.196
Conductor Resistance at 200C (ohm/km) 0.2374 0.3058 0.5946
Maximum Current Rating, at 350C (Amps) 389 332 220

0
Maximum Current Rating, at 50 C (Amps) 291 250 168

5.3 Distribution Transformers
All distribution transformers shall be three-phase either 33/0.4kV or 11/0.4kV double wound, with
vector group Dyn11. Ratings will be selected from preferred values of 63kVA, 100kVA, 160kVA,
250kVA, 400kVA and 630kVA. The distribution transformers can be either of the hermetically
sealed type or conservator type.
Generally the distribution transformers of capacity less than 400kVA are double pole mounted or
in special cases installed indoor in large consumer installations.
Characteristics of distribution transformers are as follows.
Primary Voltage 11 kV 33kV

Secondary Voltage (no load) 400/230 Volts 400/230Volts
Type Oil immersed, outdoor, bushing type
Standard IEC 60076
Cooling Type ONAN
Vector Group Dyn11
Off-load tapping (primary side) +5.0%, +2.5%, 0, -2.5%, -5.0%
Insulation Levels (IEC 76) 12/28/75kV 36/75/170kV
Short circuit impedance @ 750C 4% for 63kVA, 100kVA & 250kVA
6% for 400kVA & 630kVA
Maximum winding temperature rise 550C
Maximum oil temperature rise 500C
Protection and isolation for distribution transformers are provided by 11kV and 33kV pole
mounted drop-out fuses (Link Fuse cut-outs). These fuse cut outs have a latch mechanism to
open the fuse element, when the fuse has operated. In addition, they are capable of being
opened from ground, by using fibreglass operating sticks under no load to permit transformer
isolation.
5.4 Stay Wire
Seven strands galvanised steel stay wire is used. Typical characteristics of stay wire are as
follows.
Stranding (No / mm) 7 / 3.25mm

SWG 7 / 10
Purpose 11kV & LV lines
Maximum working load 16.26 kg
Ultimate tensile strength 40.65 kN
Nominal area 70.00 mm2
Diameter 9.75 mm
Weight 460 kg/km
5.5 Stay Assembly
Stay assembly consists of the following items as shown in the Drawing No. DSS-MT-009.
i. Stay rod with ratchet nut

ii. Stay tightener (stay buckle)
iii. Thimble
iv. Stay plate

All parts of the stay assembly after cutting, drilling and threading are hot dip galvanised to
prevent corrosion.
The typical characteristics of the stay assembly shall be as follows.
Rod Length 2.0 m

Rod Diameter 20 mm
Height of the tightener 380 mm
Round Iron used for the tightener 16 mm
Stay Plate 500 x 500 x 5 mm
Thimble 48 x 70 mm
Grove Diameter for the thimble 22 mm
5.6 Conductor Attachments
5.6.1 D Bracket & Shackle Straps
i. Both D Brackets and Shackle Straps are suitable to use with 90mm x 76mm LV
Insulators and made of 40 x 6mm flat steel. All holes on the bent surfaces of the D
Bracket and on the Shackle Straps are of the same size to allow a 16 mm diameter bolt
to pass through as shown in the Drawing No. DSS-MT-005.
ii. All parts of the D Bracket and Shackle Straps are Hot Dip Galvanised after cutting and
drilling operations.
5.6.2 Bolts and Nuts
Following sizes of hot dipped galvanised bolts are used for MV and LV line construction.
B 04 02 M12 x 30 mm GS Bolt and Nut with Flat & Spring Washers

5.7 Insulators
In Low Voltage bare line construction LV Shackle Insulators are used. In the case of MV line
construction Pin and Tension Insulators are used.
LV and MV insulators are made out of good commercial grade wet porcelain.

5.7.1 LV Insulators for D Bracket and Shackle straps
Low Voltage insulators shall be manufactured from hard brown glazed porcelain, in accordance with
IEC 60672 (HD426).
The insulators should conform to the following dimensions.
Conductor groove 15 mm
Overall Height 80 mm
Maximum diameter (bottom of skirt) 80 mm
Minimum diameter (inside face of Conductor groove) 50 mm
Hole for spindle 18 mm diameter
Failing load 9.5kN
Highest Working Voltage 600V
The Insulator is suitable for use with a single bolt of 16mm diameter and bare conductor of
overall diameter 12.5mm.
5.7.2 Pin Insulators
Pin insulators are made out of brown glazed porcelain. These pin insulators incorporate a hot
dipped galvanised steel spindle, nut, spring and flat washers. Threaded portion of the spindle
shall be long enough to fix it on a 100 x 50 x 6 mm channel iron cross arm.
The failing load for pin insulators is 10 kN for 11kV and 12.5 kN for 33kV.
5.7.3 Tension Insulators
Tension insulators are disc type and are made out of either porcelain or glass. The hardware part
of the disc insulator is a cap and pin type assembly with a 16mm ball and socket coupling,
incorporating a locking device.
5.8 Connectors used in Bare Conductor AAC and ACSR Lines
The Aluminum Connectors and termination are made out of high strength and high conductivity
aluminium. They shall be tubular or H type construction.
The inside of each Aluminium tube and the internal faces of other connectors are coated with
oxide inhibiting grease to improve the electrical contact.
The compression connectors and terminations have markings to indicate the size of conductor
and die sizes for easy identification. Markings are also available on the surface of the connector
to show the location and sequence of the crimping.
5.8.1 Non-Tension Jumper Connector (H Type)
H shape compression connectors are suitable for making main line non-tension jumper
connection and T-off connections. It is suitable to accommodate conductors of equal and un-
equal sizes.
There are three sizes of H Connectors used in MV and LV line construction as given below.
D 05 30 H Connector, Crimp Type 150-120 / 150-120 sqmm


5.8.2 Full Tension Compression Connectors (Midspan Joint)
Midspan jointing sleeves are tubular type and suitable for jointing two conductors of the same
size. They are provided with a central stop meant for correct positioning of conductors. Midspan
Jointing Sleeves used for ACSR conductor are a 2 part fitting with one for Aluminium and the
other for steel wire. The main seven types of full tension compression connectors are as
indicated below.
D 05 20 Midspan Joint for ACSR 120/20 sqmm Conductor

D 05 24 Midspan Joint for AAC 95 sqmm Conductor
5.8.3 Parallel Grove Bolted Clamp (PG Clamp)
The clamp body shall be made of high corrosion resistant Aluminum alloy. This system ensures a
high quality contact and avoids damaging the conductors’ strands. It shall be suitable to
accommodate conductors of un-equal sizes.
The commonly used PG clamps in distribution construction are as follows.
D 05 40 Parallel Grove Clamp, Bolted Type, Al 25-150/25-150 sqmm

D 05 41 Parallel Grove Clamp, Bolted Type, Al 16-95/16-95 sqmm
D 05 42 Parallel Grove Clamp, Bolted Type, Cu 50/50 sqmm
5.8.4 Bi-metallic Bolted Connector
The clamp body shall be made of high corrosion resistant aluminium alloy and the tap contact
shall be made by copper. Also the clamp shall be suitable for connecting aluminium conductor
with copper conductor/cable. Bi-metal connectors shall be so designed as to provide and maintain
complete separation of the two conductors, and to ensure no chemical reaction takes place during
the service life of the connection.
The commonly used Bi-metallic PG clamps in distribution construction are as follows.
D 05 50 Bi-metallic Bolted Type Connector, Al /Cu, 35-150/16-95 sqmm

D 05 51 Bi-metallic Bolted Type Connector, Al/Cu, 35-95/2.5-10 sqmm
5.9 Low Voltage Aerial Bundled Conductor and Accessories
5.9.1 Aerial Bundled Conductors
Five-wire Aerial Bundled Conductor system comprises, three separately insulated aluminium
conductors with XLPE (Cross Link Poly Ethylene), aluminium alloy neutral conductor/messenger
wire and street lighting conductor. All these five conductors are twisted together to form a
bundled conductor. The neutral conductor supports the weight of the bundle. The insulation
XLPE is hard and resistant to abrasion and corrosion. With carbon black filler, it can withstand
harmful ultraviolet radiation present in sunlight. The conductors are ribbed to identify phases and
neutral.

Technical details of the two types of ABC are given below.
Item Code F 01 05 F 01 10
Conductor Name ABC95 AAC70
Nominal Size (mm2) 3x95 + 50 + 16 3x70 + 50 + 16
Stressed Area (Messenger/neutral) (mm2) 50 50

2
Phase Conductor (mm ) 95 70
Overall Diameter (mm) 41 37
Phase Conductor Diameter (mm) 11.5 9.8
Neutral Conductor Diameter (mm) 8.4 8.4
Modules of Elasticity (kN/mm2) 60 60

0 -6
Coefficient of Thermal Expansion (per C x 10 ) 23 23
Ultimate Tensile Strength of messenger (kN) 14.75 14.75
Weight (daN / m) 1.134 0.908

0
Phase Conductor DC Resistance at 75 C (ohm/km) 0.390 0.541
Neutral Conductor DC Resistance at 750C (ohm/km) 0.827 0.827
Ind. Reactance of Comp. Cable at 50Hz (ohm/km/ph) 0.095 0.095

0
Maximum Temperature ( C) 90 90
Max. Current Rating of Ph. Conductor at 350C (Amps) 195 162
5.9.2 Suspension Assembly
Each suspension assembly includes,
i. One suspension bracket made out of Aluminium Alloy.

ii. One movable articulated link made out of thermoplastic material.
iii. One suspension clamp made out of thermoplastic without any steel component as
shown in the Drawing No. DSS-MT-013.
Suspension bracket is made out of Aluminium Alloy suitable for attachment to a steel tubular
pole or concrete pole by either M16 galvanised steel bolt or by two stainless steel straps
20x0.7mm. The ultimate load of the brackets are as shown below.
Vertical load 700 kg

Horizontal load 1800 kg
Longitudinal load 250 to 450 kg
5.9.3 Dead End (Tension) Assembly
Each dead end assembly includes,
i. One tension bracket made out of Aluminium Alloy.

ii. One wedged type dead end clamp made out of thermoplastic material.
iii. Two insulation straps made out of polyamide for clamping bundled conductors.

The bracket is made out of Aluminium Alloy for attachment to a steel or concrete pole by either
M16 bolts or stainless steel straps as shown in the Drawing No. DSS-MT-013.
Ultimate loads of the bracket are as follows.
Vertical load 700 kg

Horizontal load 2500 kg
Longitudinal load 1100 kg
The clamping part of the dead end assembly is made out of mechanical and weather resisting
plastic insulating material.
5.9.4 Large Angle Assembly
Description of sub components of the large angle assembly is the same as for the dead end
assembly described above, but 2 Nos. of wedged type clamps are included as shown in the
Drawing No. DSS-MT-013.
5.9.5 Pre-Insulated Sleeves
The sleeves are pre-insulated, i.e. the compression is directly made over the insulation but
crimping must not deteriorate the insulation of the sleeve. The pre-insulated sleeves shall be
waterproof type.
The pre-insulated sleeves are pre-filled with oxide inhibiting compound or silicon grease. The
sleeves for the reduced strain phase conductor fittings are made out of aluminium. The strain
bearing neutral sleeve is an aluminium alloy tube. A central stop is marked on sleeve to ensure
that the conductors are correctly positioned as shown in the Drawing No. DSS-MT-011.
The types of pre-insulated sleeves used in LV ABC construction are as shown below.
F 03 45 Pre-insulated Sleeve for Phase Conductor – 95 mm2

2
F 03 46 Pre-insulated Sleeve for Phase Conductor – 70 mm
F 03 47 Pre-insulated Sleeve for Neutral Conductor – 50 mm2
2
F 03 48 Pre-insulated Sleeve for Street Lighting Conductor – 16 mm
5.9.6 Bi-metallic Lugs
The Bi-metallic Lugs shall be suitable for making connections between bundled conductors to
copper terminals. The lugs are pre-filled with an oxide inhibiting compound or silicon grease.
The types of Bi-metallic lugs identified for LV ABC constructions are as follows.
D 05 70 Bi-metallic Lug Al Conductor / Cu Terminal - 95mm2 / 13 mm dia Hole

2
D 05 71 Bi-metallic Lug Al Conductor / Cu Terminal - 70mm / 13 mm dia Hole
D 05 72 Bi-metallic Lug Al Conductor / Cu Terminal - 50mm2 / 13 mm dia Hole
2
D 05 73 Bi-metallic Lug Al Conductor / Cu Terminal - 16mm / 10.5 mm dia Hole
5.9.7 Insulated Tee-off Piercing Connectors
These connectors are of insulated piercing type for both main and tap conductors. The housing
is made entirely of mechanical and weather resistant plastic insulation material and no metallic
part outside the housing except for the tightening bolt. The bolts shall be shear head type and
insulated piercing connectors are waterproof. A special rubber seal has been provided to make
the connector watertight. Teeth of the connector are greased to prevent moisture penetration.
The bolt washers shall be of corrosion resistant type, either galvanised steel or alloy steel.

There are three sizes of insulated piercing connectors are used in LV ABC construction.
2
D 05 65 Insulated T-off Piercing Connector – Type A, 2 Bolts, 35-95 / 35-95 mm
D 05 66 Insulated T-off Piercing Connector – Type B, 1 Bolts, 25-95 / 6-35 mm2
2
D 05 67 Insulated T-off Piercing Connector – Type C, 1 Bolts, 6-25 / 6-25 mm
5.9.8 Insulation End Cap
The Insulation End Caps shall be used at the terminations of bundled conductors to avoid entry
of moisture.
The caps shall be made of black colour EPDM (Ethylene Poly Propelin Di-Monomer). There is no
penetration of water into the cap as a heat shrinkable sleeve is provided to cover the end of the
bundled conductor.
5.9.9 Insulating Binding Strap
The Binding Strap shall be used for binding the Aerial Bundled Conductor at different locations.
The strap shall be made out of polyamide. The strap has a locking and releasing facility. The
dimensions of the strap are as per the Drawing No. DSS-LV-009.
5.9.10 Stainless Steel Straps and Buckles
Stainless Steel Strap shall be used to fix the accessories to poles. Stainless Steel shall be of
grade 18/8 and 20 mm and 0.7 mm thickness approximately as shown in the Drawing No. DSS-
MT-012.
The Buckles used for strapping shall be made of stainless steel and compatible with the above
Stainless Steel Straps.

6.0 Overhead Line Construction
6.1 Selection of Route
There are no laid-down conditions on the routing of MV and LV distribution power lines. However
due consideration shall be given for the following factors when selecting routes for the MV and
LV distribution lines.
a. One side of the road is used as far as possible.

b. Clearance / approval from other service authorities should be obtained.
c. Amount of way leave to be cleared shall be minimized.
d. Inconvenience caused to the other services shall be minimised.
e. Swampy ground and areas liable to flood shall be avoided.
f. Routes which would involve excavation in rock shall be a voided.
g. The use of taller poles at uplifts shall be avoided and construction of tension points at
uplifts also be avoided.
h. As far as possible the most economical route should be selected.
6.2 Location of Poles
Poles in residential, commercial on industrial areas are generally spaced at more frequent
intervals than in rural areas. Poles should be located so as to provide access of consumer
connection lines of prospective consumers down driveways, right of ways and side streets. Some
compromise may also be required to ensure that the poles located on corners and at driveways
will not unduly obstruct the traffic.
The location of all poles shall be pegged before commencing construction.
Following are the recommended maximum distances for pole spacing.
Span at
Span Span
Places no
Circuit Description Across Along
access to
the Road the Road
vehicles
LV (bare) only on 9m Tubular Steel Pole 20 m 35 m 45 m
LV (ABC) only on 9m Tubular Steel Pole 35 m 40 m 45 m
11kV only on 11m Tubular Steel Pole 55 m 60 m 60 m
11kV & LV (bare) Comb. Run on 11m T/Steel Pole 20 m 30 m 30 m
11kV & LV (ABC) Comb. Run on 11m T/Steel Pole 35 m 35 m 35 m
However, actual spans shall be determined according to terrain and the pole height.

The distance between shackle poles should not exceed either of the following.
Maximum Maximum Number

Circuit Description
Span of Spans
Low Voltage (bare) only 280 m 08
Low Voltage (ABC) only 320 m 08
Medium Voltage (11kV) only 360 m 06
11kV & LV Combined Run on 11m Tubular Steel Pole 280 m 08
6.3 Selection of Poles
Poles used in Low Voltage lines shall be either Tubular Steel Poles or Reinforced Concrete
Poles and in the case of Medium Voltage 11kV lines only Tubular Steel Poles shall be used.
Since these poles are designed for specific maximum loads, the ground clearances shall be
maintained as per Clause 4.7 of this manual. Correct selection of poles for each type of
construction is essential. Generally 9m/200kg steel tubular pole and 9m/115kg RC pole shall be
used for LV line intermediate poles and 9m/700kg steel tubular (Lattice equivalent) pole shall be
used for section and terminal poles of LV lines.
Similarly, 11m/250kg steel tubular pole shall be used for 11kV line intermediate poles and
11m/700kg steel tubular (Lattice equivalent) pole shall be used for section and terminal poles of
11kV lines.
Considering ground clearances and load on poles, the maximum possible span on flat ground
and maximum possible angle of deviation without using stays for the types of pole used for
different conductor configurations are tabled below for quick reference.
Max.
Maximum
Maximum Maximum Possibl
Span,
Span, Span, e Angle,
Pole Type, Basic Span & Conductor Places no
Across Along with No
Configuration access to
Road Road Stays,
vehicles
(m) (m) Lattice
(m)
Pole
9m Tubular Pole, 35m Basic Span
AAC 35, Vertical 20 35 45 350

0
AAC 50, Vertical 20 35 45 30
AAC 70, Vertical 20 35 45 200
0
AAC 95, Vertical 20 35 45 15
ABC 3x70+50+16 35 40 45 750
0
ABC 3x95+50+16 35 40 45 60
0
ACSR 50/8, Delta 55 60 60 40
ACSR 95/15, Delta 55 60 60 200
0
ACSR 120/20, Delta 55 60 60 15
ACSR 50/8, Delta + AAC 50, Vertical 30 20 35 300

0
0
ACSR 120/20, Delta + ABC 3x70+50+16 35 35 35 20
ACSR 120/20, Delta + ABC 3x95+50+16 35 35 35 190

6.4 Excavation of Pole Pits
The position of the pole pit shall usually be marked by a peg. The pole pit must be excavated so
that the pole is erected in its correct position. If the peg indicates the centre of the pole pit, it is
advisable to place a temporary peg at a definite distance away so that it is not disturbed during
digging operations. The pit can be excavated either by manually or by a truck mounted auger.
The depth of the pit is usually made equal to one sixth of length of the pole as indicated in
Clause 5.1 of this manual.
Precautions should be taken to prevent possible soil subsidence while excavating in loose
ground or in close proximity to roadways or buildings. To prevent soil subsidence, it may be
necessary to support the walls of the pit with wooden planks or empty barrels without top and
bottom.
When it is required to excavate a pit adjacent to an existing pole, temporary stays should be
fixed to the pole prior to excavation, to prevent the existing pole collapsing.
6.5 Pole Foundation
The pole foundation shall be filled with concrete with mixing ratio of 1:2:4 (grade 20) as shown in
the Drawing Nos. DSS-LV-200, DSS-LV-201, DSS-MV-225 and DSS-MV-226.
The pole pit shall be filled with concrete mixture as indicated in above drawings and temporary
stays shall be used to support the pole until the concrete is hardened. The concrete filling shall
be up to a height not less than 100mm above ground level.
6.6 Erection of Poles
The preferred method of erection is by cranes of adequate capacity for the weight of pole being
handled. Lifting slings used to lift the steel poles shall be soft type, which prevent abrasion of
zinc coating of the pole. Suitable methods shall be employed to divert/guide normal
vehicular/pedestrian traffic for obstructions caused while construction work is in progress.
Manual methods of pole erection are acceptable in locations inaccessible to cranes.
Poles should be erected vertically. The direction of holes should be kept perpendicular to the LV
line direction, in intermediate and section poles. But in the case of terminal poles the direction of
holes should be aligned with the LV line. At angle points, the direction of holes should bisect the
angle of the LV line.
D brackets, shackle straps etc. shall be fixed to the pole using nuts and bolts at the ground level
before erection of the pole.
6.7 Installation of Stays
When a line changes direction, an additional force is introduced at the angle pole. This force is
the resultant of line tensions acting at the pole. The resultant force tries to move the top of the
pole in the direction that bisects the angle between the conductors. These forces may be
considerable. The Stays shall be fixed to neutralise the resultant force on the poles.
The number of stays to be used at any particular pole location is designed on the overturning
force acting on the pole and topography of the location. The force acting on the pole depends on
the following factors.
• Number of conductors and size of the conductor along with conductor tension
• Length of adjacent spans

• Angle of deviation of the line

• Equipment mounted on the pole
• Topography at the pole position
7/3.25 mm, Grade 700, Stranded Galvanised Steel Wire shall be used as a Stay wire for
distribution line construction. Thimbles and Brackets shall be used as indicated in Drawing Nos.
DSS-LV-202 and DSS-MV-227.
Following shall be noted in fixing stays.
a. The angle between pole and the stay wire shall not be less than 300.
b. Stays should be erected so as to avoid disturbances to pedestrians or vehicular traffic.
c. It shall be ensured that the correct side of the ratchet nut faces the ratchet face of the
cross head of the buckle before tightening the stay buckle.
d. Stays shall be installed conforming to Drawing Nos. DSS-LV-202 and DSS-MV-227.
e. Splicing of Stay Wire shall be done according to Drawing Nos. DSS-LV-202 and DSS-
MV-227.
f. Stay pit shall be in accordance with the Drawing Nos. DSS-LV-202 and DSS-MV-227.
g. Stays shall be installed and kept in position before conductors are strung to avoid over-
straining of supports.
h. Pits for stays should be excavated in locations marked by pegs. Stay rods shall be in
line with the resultant of load and be so installed that the buckle of the stay assembly is
above ground level by not more than 300mm after the load is applied.
6.8 Fixing of Cross Arms and Mounting of Insulators
Cross Arms shall be mounted to the pole top in different pole locations (intermediate, tension,
angle, terminal etc.) as given in Drawing Nos. DSS-MV-350 to DSS-MV-359. Insulators shall be
mounted on the cross arm as shown in above drawings. Extreme care shall be taken while
handling and installing of insulators to prevent any damage.
Pin insulators shall be mounted on the cross arm at intermediate positions and at small angle
points. The top grove of the insulator shall be in line with the line of the conductor.
6.9 Stringing of Conductors
During running out, the conductor drum should be securely supported on drum jacks with an
axle, so that the conductor is pulled from the top of the drum. The drum jacks should be on a
firm foundation and the axle of the drum jack should be levelled horizontally.
Sufficient employees shall be engaged at site to ensure that the conductors are not damaged by
contact with the ground or pole hardware during running out. Stringing pulleys shall be used
while stringing conductors. Care should be taken to avoid kinking, twisting or abrading the
conductor in any manner. The conductor should not be trampled on, run over by vehicles or
dragged over the ground. Vehicles should not be used to run out conductors.
Extreme care must be taken about the other existing electrical systems in close proximity when
running out conductors. In 11kV medium voltage lines, conductors shall be strung in ‘Delta’
formation for single circuit lines and vertical formation for double circuit lines. In the case of low
voltage distribution lines, the conductors shall be strung in vertical formation only. Stays shall be
installed and kept in position before conductors are strung to avoid over straining of poles.

6.10 Tensioning and Binding
In MV and LV distribution lines, the conductor shall be tensioned using Ratchet Pullers and
suitable Wire Grips (Come-along Clamps) designed to prevent damage to the conductor while
tensioning.
One midspan joint per conductor shall be allowed in between two shackle points. All midspan
joints shall be compression type. Conductor shall be sagged in accordance with the Sag and
Tension Charts given in Chapter 10.
6.10.1 Low Voltage Bare Conductors
All Aluminium 19/2.50mm [95 mm2], 19/2.10mm [70 mm2], 7/3.00mm [50 mm2] and 7/2.50mm
[35 mm2] Conductors shall be used for LV Lines.
Conductors shall be strung in vertical formation as per Drawings Nos. DSS-LV-500, 501, 502,
DSS-CR-600, 601 and 602. After final tension of the conductor, LV shackle insulator shall be
fixed to the D brackets at the intermediate poles. Conductors shall be bound to the insulator at
each support using Aluminium Binding Wire No. 11 (3.00mm) as shown in Drawing No. DSS-LV-
203. Only one midspan joint per conductor shall be allowed for a shackle point span. All midspan
joints shall be compression type.
During stringing of conductors maximum precautions shall be taken to prevent excessive strain
and damage to the conductor. Standard sags and tensions applicable to the particular size of
conductor shall be maintained.
6.10.2 Low Voltage Aerial Bundled Conductors
XLPE insulated 3x95+1x50+1x16 mm2 and 3x70+1x50+1x16 mm2 aluminium conductors shall
be used in LV ABC lines.
The conductor should be pulled from the top of the drum. Bundled Conductor shall not be
dragged on the ground. A suitable ‘drum brake’ mechanism shall be used to prevent the
conductor over-run. Stringing pulleys compatible with Bundled Conductor shall be installed on
every pole. The bundled conductor shall be fitted with a complete pulling grip system such that
the main pulling force comes only on the neutral messenger. During running out the conductor
should be pulled only by hand or by using a Nylon Pulling Grip designed for bundled conductors.
Insulating conductor grips designed to prevent damage to the insulation of the conductor shall
be used for tensioning. Every care must be taken to avoid damage to the conductor insulation.
Dead end fittings shall be fitted to the conductor after tensioning at each shackle point.
Intermediate fittings shall then be fitted at major angles and then the smaller angles. After all
fittings are in place the sagging should be checked at two places and corrected if necessary.
Insulation straps (cable ties) shall be used to tie the conductor at each supporting point as
shown in Drawing Nos DSS-LV-300, 301 & 302.
6.10.3 Medium Voltage (11kV) ACSR Conductors
Three different sizes of Steel Reinforced, Aluminium Conductors shall be used in MV distribution
line construction, as given below.
ACSR 120/20 - 26x2.44 mm / 7x1.90 mm

ACSR 95/15 - 26x2.15 mm / 7x1.67 mm
ACSR 50/8 - 6x3.20 mm / 1x3.20 mm

6.10.3.1 Pin Point
Conductors shall be bound to pin insulators at intermediate points using Aluminium Binding Wire
No. 9 (3.6mm), according to the Drawing No. DSS-MV-228. Pin (intermediate) points shall be
made according to the Drawing Nos. DSS-MV-350, 354 & 357. Conductors shall be tied on the
top groove of the insulators for straight line and on the side of the insulator for angle points. Pin
insulator binding shall be performed only after the final tension and the tension points have been
completed satisfactorily.
6.10.3.2 Tension (Shackle) Point
At tension points conductors shall be mounted to tension insulators using tension clamps.
Tension points shall be made according to the Drawing Nos. DSS-MV-351, 355, 356 & 358 as
applicable. At tension points jumpers shall be placed over the cross arm (not underneath) using
pin insulators and connected together by crimp type H connectors or PG bolted clamps.
Temporary stays shall be used while tensioning to overcome the effects of unbalanced forces on
the cross arms. The centre conductor shall be pulled and tensioned first and then the outer
conductors are pulled and tensioned to the centre conductor sag.
6.10.3.3 Terminal Point
At terminal points conductors shall be mounted to tension insulators as specified in clause

6.10.3.2 above. Construction of terminal points shall be in accordance with Drawing Nos. DSS-
MV-352 and 359 as applicable.
6.11 Danger Boards
Danger Boards shall be mounted on each pole 3000 mm from the ground level. The danger
board shall be made as per Drawing No. DSS-MT-014 to indicate the danger of electrocution
when approached.
6.12 Installation of LV Conductor Attachments
6.12.1 Bare Conductor Attachment

(Installation of "D" Brackets, Shackle Straps and Insulators)
D Brackets and Shackle Straps shall be installed using bolts and nuts according to the pole top
arrangement as shown in Drawing Nos. DSS-LV-250 to 265 and DSS-CR-450 to 455. Care shall
be taken in handling and installing LV Insulators. In the case of conductors at straight line and at
angles going away from the pole, it shall be tied to the inner groove of the insulator and in the
case of angles turning towards the pole, the conductor shall be tied on to the outer groove of the
insulator. Hot Dipped Galvanised Steel M16 Bolt with 140mm length shall be used connect the
insulator to the D Bracket.
Binding shall be performed as shown in the Drawing No. DSS-LV-203 by using soft drawn
Aluminium Binding Wire with 3.00 mm diameter. Binding at intermediate insulators shall only
proceed after the terminal shackle points have been completed at both ends.
6.12.2 Aerial Bundled Conductor Attachment
The correct attachment shall be selected and installed on the poles in different positions, such
as small angle point, shackle point, large angle point etc., as shown in Drawing Nos. DSS-LV-
300, 301 & 302.

6.13 Installation of Connectors
6.13.1 Bare Conductors
Compression type aluminium fittings should be used for all terminal, midspan and selected
jumper connections, which are not subjected for opening once installed. For the jumper
connections, which are used to open frequently, Parallel Grove (PG) Clamps are used.
Utmost care should be exercised in installing connectors to ensure that contact surfaces of
clamps and wires are clean and bright.
Bolts of non-tension jumper connectors (PG Clamps) should be tightened hard, but the threads
must not shear. Jumpers shall be made at the tails of the conductors wherever possible.
Where mid-span tension joints are required, the conductor ends should be examined and any
damaged strands should be trimmed back as necessary.
All mid span connectors for ACSR conductors are of two-part construction, steel wire shall be
crimped first.
H type compression connectors shall be used for connecting the branch conductor to the main
conductor at the T-off points. H type compression connectors may also be used for connecting
conductors of unequal size.
All jumpers shall have adequate length so as not to apply any force to the main conductor.
Adequate clearances shall be maintained around all jumpers at congested poles such as Tee-off
and right angles.
Compression connectors could be crimped using both hydraulic and mechanical compression
tools with the correct sizes of dies.
6.13.2 Aerial Bundled Conductor
All joints except T-offs shall be of compression type insulated connections. Special care must be
taken to ensure that the correct size and type of connectors are used for each conductor.
Tension connectors are employed for mid-span joints on the neutral messenger only. Non-
tension connectors can then be applied to all other conductors ensuring that no tension force is
applied to these other conductors.
Insulated piercing connectors shall be used for all tee-off jointing. They shall be applied over the
insulation of the conductor and screwed down into the conductor using special shear head
screws. These must be tightened until shearing of the bolt head takes place, thus making a
permanent watertight connection. Once applied the 'T' off connectors should not be removed. If it
is required to remove the 'T' off Branch Conductor, it shall be cut-off and the exposed ends shall
be sealed with end caps.
Piercing connectors shall be fixed such that their bolts are positioned vertically with bolt head
upward. Branching terminals shall be covered using the terminal cap provided with the
connector. All terminal points of the ABC shall be covered using terminal caps as shown in
Drawing No. DSS-LV-302.

7.0 Safety of Personnel
The personnel safety of all working staff is the highest priority. The Supervisor-in-Charge of work together
with all employees shall ensure their safety and safety from danger arising from the course of work. All
possible accidents and inconveniences arising out of the activities of the electricity authority, to pedestrian
and vehicular traffic shall be minimized by displaying Warning Sign Boards, Caution, Notice and Danger
Notices, placing barricades etc., as appropriate and whenever necessary. The Supervisor-in-charge of
work before starting any work shall satisfy himself that all conditions of personnel safety are ensured as
per guidance and instruction.
In case if any contractor is employed, the Contractor will be held responsible for the safety of men, when
the system is under his control for the purpose of executing the construction work for the electricity
authority. Safe working condition once imposed shall continue to be maintained till the completion of work
undertaken.
It shall also be noted that a minimal disturbance be caused to unaffected areas by works carried out in
effected areas. For all exercises in this regard, the hand in charge of work places will be held responsible.
For all norms and purposes to ensure safety of men at work places, supervisory control shall be
implemented in accordance with proper guidance and instructions from the Supervisory Staff who are
assigned for execution works.

8.0 Deviations to the Manual
This manual serves only as a guideline for the construction of Medium and Low Voltage distribution lines,
Distribution Transformers and Terminal Poles of Substations.
The Engineer-in-Charge at the work site reserves the right to modify, amend or adjust the construction
arrangement / design according to the circumstances that may arise at site. He may make slight
deviations depending on the ground condition.

9.0 Drawings
Description Drawing No Annex
9.1 Drawings for Material Required for Medium and Low Voltage Line Construction
9.1.1 9m Tubular Steel Pole DSS-MT-001 A 1/01

9.1.2 9m Tubular Steel Pole (Lattice Equivalent) DSS-MT-002 A 1/02
9.1.3 11m Tubular Steel Pole with accessories DSS-MT-003 A 1/03
9.1.4 11m Tubular Steel Pole (Lattice Equivalent) with accessories DSS-MT-004 A 1/04
9.1.5 D Bracket, Shackle Straps, GS Bolts & Nuts DSS-MT-005 A 1/05
9.1.6 Bare All Aluminium Conductors (AAC) DSS-MT-006 A 1/06
9.1.7 Bare Aluminium Conductor Steel Reinforced (ACSR) DSS-MT-007 A 1/07
9.1.8 Connectors used in Bare Conductor LV Lines DSS-MT-008 A 1/08
9.1.9 Stay Assembly DSS-MT-009 A 1/09
9.1.10 Earth Rod and Accessories DSS-MT-010 A 1/10
9.1.11 Connectors used in Aerial Bundled Conductor LV Lines DSS-MT-011 A 1/11
9.1.12 Accessories used in ABC Lines DSS-MT-012 A 1/12
9.1.13 Brackets and Clamps for ABC Line DSS-MT-013 A 1/13
9.1.14 Danger Board – 11kV DSS-MT-014 A 1/14
9.1.15 GS C-Clamps for 11m Tubular Poles DSS-MT-015 A 1/15
9.1.16 GS Channels and Angles DSS-MT-016 A 1/16
9.1.17 Cable Drum Stand DSS-MT-017 A 1/17
9.2 Construction Drawings for Low Voltage Lines
9.2.1 Pole Foundation for LV line (Manual Digging) DSS-LV-200 A 2/01

9.2.2 Pole Foundation for LV line (Auger Digging) DSS-LV-201 A 2/02
9.2.3 LV Stay Arrangement DSS-LV-202 A 2/03
9.2.4 LV Insulator Bindings DSS-LV-203 A 2/04
9.3 Construction Drawings for Medium Voltage Lines
9.3.1 Pole Foundation for MV line (Manual Digging) DSS-MV-225 A 3/01

9.3.2 Pole Foundation for MV line (Auger Digging) DSS-MV-226 A 3/02
9.3.3 MV Stay Arrangement DSS-MV-227 A 3/03
9.3.4 MV Insulator Bindings DSS-MV-228 A 3/04
9.4 Pole Top Construction Arrangements for Low Voltage Lines
9.4.1 LV 3 - Phase Intermediate Pole DSS-LV-250 A 4/01

9.4.2 LV 1 - Phase Intermediate Pole DSS-LV-251 A 4/02
9.4.3 LV 3 - Phase Shackle Pole DSS-LV-252 A 4/03
9.4.4 LV 1 - Phase Shackle Pole DSS-LV-253 A 4/04
9.4.5 LV 3 - Phase Terminal Pole DSS-LV-254 A 4/05
9.4.6 LV 1 - Phase Terminal Pole DSS-LV-255 A 4/06
9.4.7 LV T-off, 3Ph-3Ph, Intermediate Pole (Line Side) DSS-LV-256 A 4/07
9.4.8 LV T-off, 3Ph-3Ph, Intermediate Pole (Opposite Side) DSS-LV-257 A 4/08
9.4.9 LV T-off, 3Ph-1Ph, Intermediate Pole (Line Side) DSS-LV-258 A 4/09
9.4.10 LV T-off, 3Ph-1Ph, Intermediate Pole (Opposite Side) DSS-LV-259 A 4/10
9.4.11 LV T-off, 3Ph-3Ph, Shackle Pole (Line Side) DSS-LV-260 A 4/11
9.4.12 LV T-off, 3Ph-3Ph, Shackle Pole (Opposite Side) DSS-LV-261 A 4/12
9.4.13 LV T-off, 3Ph-1Ph, Shackle Pole (Line Side) DSS-LV-262 A 4/13
9.4.14 LV T-off, 3Ph-1Ph, Shackle Pole (Opposite Side) DSS-LV-263 A 4/14
9.4.15 LV X-Junction, 3Ph-3Ph-3Ph, Intermediate Pole DSS-LV-264 A 4/15
9.4.16 LV X-Junction, 3Ph-3Ph-3Ph, Shackle Pole DSS-LV-265 A 4/16
9.4.17 LV Stay Construction DSS-LV-266 A 4/17

9.5 Pole Top Construction Arrangements for Low Voltage ABC Lines
9.5.1 ABC Intermediate Pole construction DSS-LV-300 A 5/01

9.5.2 ABC Large Angle Pole construction DSS-LV-301 A 5/02
9.5.3 ABC Dead End Pole construction DSS-LV-302 A 5/03
9.6 Pole Top Construction Arrangements for Medium Voltage Lines
9.6.1 Single Circuit, Intermediate Pole – 11kV DSS-MV-350 A 6/01

9.6.2 Single Circuit, Section Pole – 11kV DSS-MV-351 A 6/02
9.6.3 Single Circuit, Terminal Pole – 11kV DSS-MV-352 A 6/03
0
9.6.4 Single Circuit, 90 Angle Pole – 11kV DSS-MV-353 A 6/04
9.6.5 Single Circuit, T-off from Intermediate Pole – 11kV DSS-MV-354 A 6/05
9.6.6 Single Circuit, T-off from Section Pole – 11kV DSS-MV-355 A 6/06
9.6.7 Single Circuit, X-Junction on Section Pole – 11kV DSS-MV-356 A 6/07
9.6.8 Double Circuit, Vertical, Intermediate Pole – 11kV DSS-MV-357 A 6/08
9.6.9 Double Circuit, Vertical, Section Pole – 11kV DSS-MV-358 A 6/09
9.6.10 Double Circuit, Vertical, Terminal Pole – 11kV DSS-MV-359 A 6/10
9.6.11 MV Stay Construction DSS-MV-360 A 6/11
9.7 Pole Top Construction Arrangements for Medium & Low Voltage Combine Runs
9.7.1 Intermediate Pole – 11kV & 3-Ph LV Combine Run DSS-CR-450 A 7/01
9.7.2 Section Pole – 11kV & 3-Ph LV Combine Run DSS-CR-451 A 7/02
9.7.3 Terminal Pole – 11kV & 3-Ph LV Combine Run DSS-CR-452 A 7/03
9.7.4 T-off from Intermediate Pole – 11kV & 3-Ph LV Combine Run DSS-CR-453 A 7/04
9.7.5 T-off from Section Pole – 11kV & 3-Ph LV Combine Run DSS-CR-454 A 7/05
9.7.6 X-Junction on Section Pole – 11kV & 3-Ph LV Combine Run DSS-CR-455 A 7/06
9.8 Typical Conductor Configurations for Bare and ABC LV Lines
9.8.1 Conductor Configuration for LV (Bare) Line – Across Road DSS-LV-500 A 8/01
9.8.2 Conductor Configuration for LV (Bare) Line – Along Road DSS-LV-501 A 8/02
9.8.3 Conductor Configuration for LV (Bare) Line – Other Places DSS-LV-502 A 8/03
9.8.4 Conductor Configuration for LV (ABC) Line – Across Road DSS-LV-503 A 8/04
9.8.5 Conductor Configuration for LV (ABC) Line – Along Road DSS-LV-504 A 8/05
9.8.6 Conductor Configuration for LV (ABC) Line – Other Places DSS-LV-505 A 8/06
9.9 Typical Conductor Configurations for MV Lines
9.9.1 Conductor Configuration for MV Line – Across Road DSS-MV-550 A 9/01

9.8.2 Conductor Configuration for MV Line – Along Road DSS-MV-551 A 9/02
9.8.3 Conductor Configuration for MV Line – Other Places DSS-MV-552 A 9/03
9.10 Typical Conductor Configurations for MV and LV Combined Runs
9.10.1 Conductor Config. for MV / LV Combined Run – Across Road DSS-CR-600 A 10/01
9.10.2 Conductor Config. for MV / LV Combined Run – Along Road DSS-CR-601 A 10/02
9.10.3 Conductor Config. for MV / LV Combined Run – Other Places DSS-CR-602 A 10/03
9.11 Distribution Transformer Construction
9.11.1 Distribution Transformer Construction – 11/0.4kV DSS-DT-650 A 11/01
9.12 Terminal Pole (H Pole) Construction for Substations
9.12.1 Terminal Pole (H Pole) Construction – 11kV DSS-TP-700 A 12/01

9.12.2 Terminal Pole (H Pole) Construction – 33kV DSS-TP-701 A 12/02

10.0 Tables and Charts
10.1 Standard Material Requirements – New Construction
10.1.1 LV Bare Conductor Line, 1 - Phase, 1 km Length Table - 1

10.1.3 LV Aerial Bundled Conductor Line, 1 km Length Table - 3
10.1.4 11kV Single Circuit Line, 1 km Length Table - 4
10.1.5 Distribution Transformer Table - 5
10.1.6 Terminal Pole (H Pole) – 11kV Table - 6
10.1.7 Terminal Pole (H Pole) – 33kV Table - 7
10.2 Standard Material Requirements – Rehabilitation

10.2.3 11kV Single Circuit Line, 1 km Length Table - 10
10.2.4 Distribution Transformer Table - 11
10.3 Standard Manpower Requirement
10.3.1 Standard Manpower Requirement for Construction & Rehabilitation Works Table - 12
10.4 Sag and Tension Charts for MV, LV and MV+LV (Combined Run) Lines
10.4.1 LV Line with 35 mm2 All Aluminium Conductor & 35m Basic Span Chart - 01
2
10.4.3 LV Line with 70 mm All Aluminium Conductor & 35m Basic Span Chart - 03
2
10.4.5 LV Line with 70 mm2 Aerial Bundled Conductor & 35m Basic Span Chart - 05
2
2
10.4.12 11kV Line with 50/8 mm ACSR Conductor & 25m Basic Span Chart - 12
10.4.13 11kV Line with 95/15 mm2 ACSR Conductor & 25m Basic Span Chart - 13
2
2

STANDARD MATERIAL REQUIREMENTS
FOR
CONSTRUCTION & REHABILITATION
Distribution Construction Standards

Table - 1 : Standard Material Requirement for a New 1-Phase Low Voltage Line - 1 km
Qty Required
Item Code Item Description Unit
per km
A 02 05 9m Tubular Steel Poles each 25
A 02 15 9m Tubular Steel Pole (Lattice Equivalent) each 8
B 01 05 D-Bracket complete with LV Insulator, 2 x 140 mm Bolts & Nuts, Plain & Spring Washers each 50
B 01 10 D-Bracket complete with LV Insulator, 140 and 210mm Bolts & Nuts, Plain & Spring Washers each 16
B 01 25 Shackle Strap complete with 150mm Bolt & Nut each 32
B 03 10 Galvanised Steel Staywire - 7/3.25mm (Grade 700) m 120
B 03 15 Stay Assembly complete with Stay Rod & Plate each 12
C 01 05 LV Insulator each 16
D 02 05 All Aluminium Conductor (AAC) - 95 sqmm km 2.1 *
D 05 15 Aluminium Binding Wire (No 11) - 3.0mm kg 5
D 05 24 Midspan Joint for Al 95 sqmm each 2 **
D 05 31 H Connector, Crimp Type - 120-70 / 120-70 sqmm each 10
D 05 32 H Connector, Crimp Type - 70-35 / 70-35 sqmm each 10
D 05 41 Parallel Groove Clamp, Bolted Type, Al - 16-95/16-95 sqmm each 6
Note : * Only one type of Conductor should be selected
** Midspan joint should be selected in accordance with the conductor

Table - 2 : Standard Material Requirement for a New 3-Phase Low Voltage Line - 1 km
Qty Required
per km
A 02 05 9m Tubular Steel Poles complete with all accessories each 25
A 02 15 9m Tubular Steel Pole (Lattice Equivalent) complete with all accessories each 8
D 05 31 H Connector, Crimp Type - 120-70 / 120-70 sqmm each 20 **
Note : * Only one type of Conductor should be selected.
** Midspan joints and H Connectors should be selected in accordance with the conductor.
No street lamp conductor is used

Table - 3 : Standard Material Requirement for a New LV ABC Line - 1 km
Qty Required
per km
B 04 20 M16x140mm GS Bolt & Nut with Flat and Spring Washers each 24
F 01 05 LV OH Aerial Bundled Cable 3X95+50+16 sqmm Al Conductor km 1.01 *
F 01 10 LV OH Aerial Bundled Cable 3X70+50+16 sqmm Al Conductor km 1.01 *
F 03 25 Suspension Bracket each 25
F 03 30 Suspension Clamp each 25
F 03 35 Tension (dead end) Bracket each 6
F 03 40 Tension (dead end) Clamp each 8
F 03 45 Pre-insulated Sleeve for Phase Conductor - 95sqmm each 4
F 03 46 Pre-insulated Sleeve for Phase Conductor - 70sqmm each 4
F 03 47 Pre-insulated Sleeve for Neutral Conductor - 50sqmm each 4
F 03 48 Pre-insulated Sleeve for Street Lighting Conductor - 16sqmm each 4
F 03 50 Insulation End Cap for 95sqmm Conductor each 2
F 03 55 Insulating Binding Strap each 80
F 03 60 Stainless Steel Strap m 5 **
F 03 65 Stainless Steel Buckle each 5 **
Note : * Only one conductor type should be selected.
** Quantity should be decided as per the requirement.
2 x 90 degree angles and 2 x large angles are assumed.

Tabel - 4 : Standard Material Requirement for a New 11 kV Line - 1 km
Qty Required
per km
B 06 05 Danger Board - 11kV each 27
C 03 05 Pin Insulator with Galvanized Spindle - 11kV each 69
C 03 10 Tension Insulators with all Accessories and Hardware - 11KV each 30
D 03 05 Aluminium Conductor Steel Reinforced (ACSR) - 120/20 sqmm km 3.15 *
D 05 20 Midspan Joint for ACSR 120/20 sqmm each 3 **
D 05 21 Midspan Joint for ACSR95/15 sqmm each 2 **
D 05 40 Parallel Groove Clamp, Bolted Type, Al - 25-150/25-150 sqmm each 6 **
** Midspan joints, PG Clamps and H Connectors should be selected in accordance with the conductor.

Table - 5 : Standard Material Requirement for a New Distribution Transformer
Item Code Item Description Unit Qty Required per DT
B 05 12 50x50x5mm, 1000mm long GS angle each 2
B 05 30 100x50x6mm, 2.3m long GS channel each 4
B 05 45 25mm dia, 6m long GS Pipe each 1
D 05 42 Parallel Groove Clamp, Bolted Type, Cu - 50/50 sqmm each 1
D 05 50 Bi-metallic Bolted Type Connector Al / Cu, 35-150 / 16-95 sqmm each 13
E 03 40 Cable Ties (10x800mm) each 20
G 01 05 Linkage fuse 12kV with fuse holder each 3
H 03 10 Cu Wire - 50sqmm (for DT Jumper connections) m 21
H 03 15 Cu Earth Wire Tinned 50 sqmm Stranded No 7 m 18
H 03 20 Cu Earth Rod, 16mm Diameter, 1.5 m Length each 2
J 01 05 Lightning Arrestor 12kV, 10 kA each 3
F 02 20 LV Cu cable 1x50 sqmm, PVC insulated m 10
F 03 20 Cu, Cable Terminal Lugs for 50 sqmm Cable each 1
Transformer Capacity (kVA) 63 100 160 250 400 630

F 02 05 LV Cu cable 1x150 sqmm, PVC insulated m 24 112 224 224
F 02 10 LV Cu cable 1x95 sqmm, PVC insulated m 24 64
F 03 05 Cu, Cable Terminal Lugs for 150 sqmm Cable each 8 24 48 48
F 03 10 Cu, Cable Terminal Lugs for 95 sqmm Cable each 8 8
F 03 20 Cu, Cable Terminal Lugs for 50 sqmm Cable each 4 10 2 2 4 4
G 05 20 Fuse elements 11 kV, 6A each 3
H 01 05 Distribution Transformer 11/0.4 kV, 63 kVA each 1
H 01 10 Distribution Transformer 11/0.4 kV, 100 KVA each 1
H 01 30 Distribution Transformer 11/0.4 kV, 630KVA each 1
K 02 41 LV Board with 2 x 3pole 100A MCCB + N-Link each 1 1
K 02 42 LV Board with 2 x 3pole 150A MCCB + N-Link each 1
K 02 43 LV Board with 2 x 3pole 250A MCCB + N-Link each 1 2 2
K 02 65 Pole Mounting Bracket for LV Board with Nuts & Bolts each 1 1 1 1 2 2

Table - 6 : Standard Material Requirement for 11kV Terminal Pole Construction at Substation
Item Quantity
Description Unit
Code Required

B 02 25 GS C Clamp - Type 1 each 8
B 05 05 50x50x5mm, 2.3m long GS angle each 5
E 03 55 Clamp for 11kV UG Cable with Nuts & Bolts each 9
E 03 90 Aluminium Pipe 125mm dia, 2m long for UG Cables each 1
F 03 60 Stainless Steel Strap m 8
F 03 65 Stainless Steel Buckle each 12
G 02 05 Pole Mounted Type Air Break Switch, Outdoor, 3P, 300A-11kV each 1
H 03 20 Cu Earth Road, 16mm Diameter, 1.5 m Length each 2

Table - 7 : Standard Material Requirement for 33kV Terminal Pole Construction at Substation
Item Quantity
Description Unit
Code Required
B 05 07 50x50x5mm, 2.5m long GS angle each 5
E 03 75 Clamp for 33kV UG Cable with Nuts & Bolts each 18
E 03 90 Aluminium Pipe 125mm dia, 2m long for UG Cables each 3
F 03 60 Stainless Steel Strap m 8
F 03 65 Stainless Steel Buckle each 12
G 02 10 Pole Mounted Type Air Break Switch, Outdoor, 3P, 300A-33kV each 1
H 03 20 Cu Earth Road, 16mm Diameter, 1.5 m Length each 2

Table - 8 : Standard Material Requirement for Rehabilitation of 1-Phase Low Voltage Line - 1 km
Qty Required
per km
** Mid-span joints & Connectors should be selected in accordance with the conductor.

Table - 9 : Standard Material Requirement for Rehabilitation of 3-Phase Low Voltage Line - 1 km
Qty Required
per km
** Mid-span joints & Connectors should be selected in accordance with the conductor.

Table - 10 : Standard Material Requirement for Rehabilitation of 11 kV Line - 1 km
Qty Required per

km
B 06 05 Danger Board - 11kV each 27
D 05 21 Midspan Joint for ACSR95/15 sqmm each 3 **
** Midspan joints, PG Clamps and H Connectors should be selected in accordance with the conductor.

Table - 11 : Standard Material Requirement for Rehabilitation of Distribution Transformer
Item Code Item Description Unit Qty Required per DT
B 05 12 50x50x5mm, 1000mm long GS angle each 2
D 05 42 Parallel Groove Clamp, Bolted Type, Cu - 50/50 sqmm each 1
E 03 40 Cable Ties (10x800mm) each 20
G 01 05 Linkage fuse 12kV with fuse holder each 3
H 03 10 Cu Wire - 50sqmm (for DT Jumper connections) m 21
H 03 20 Cu Earth Rod, 16mm Diameter, 1.5 m Length each 2
F 02 20 LV Cu cable 1x50 sqmm, PVC insulated m 10
Transformer Capacity (kVA) 63 100 160 250 400 630
F 02 05 LV Cu cable 1x150 sqmm, PVC insulated m 24 112 224 224

F 03 05 Cu, Cable Terminal Lugs for 150 sqmm Cable each 8 24 48 48
F 03 10 Cu, Cable Terminal Lugs for 95 sqmm Cable each 8 8
F 03 20 Cu, Cable Terminal Lugs for 50 sqmm Cable each 4 10 2 2 4 4
K 02 41 LV Board with 2 x 3pole 100A MCCB + N-Link each 1 1
K 02 42 LV Board with 2 x 3pole 150A MCCB + N-Link each 1
K 02 43 LV Board with 2 x 3pole 250A MCCB + N-Link each 1 2 2
K 02 65 Pole Mounting Bracket for LV Board with Nuts & Bolts each 1 1 1 1 2 2

Table - 12 : Standard Manpower Requirements - New Construction & Rehabilitation

S# Item Description Unit M.Hrs
1.0 Excavation of pole pits
1.1 9m Steel Pole each 6.0
1.2 11m Steel Pole each 8.0
2.0 Excavation of stay pits each 6.0
3.0 Erection of poles
3.1 for 9m Tubular each 6.0
3.2 for 11m Tubular including Cross-arm each 9.0
3.3 for 9m Tubular (Lattice Equivalent) each 6.8
3.4 for 11m Tubular (Lattice Equi) including Cross-arm each 12.0
4.0 Removal/Straigtning/Rotation of poles
5.0 Concreting of Poles Including Material
6.0 Erection of stays Including Material each 6.0
7.0 Fixing of Insulators
7.1 Complete D Shackle/Shackle Straps/LV insulator each 0.2
7.2 Pin Insulator each 0.6
7.3 Tension Insulator set each 1.8
8.0 Removing and replacing of insulators or D Shackle
8.1 Complete D Shackle/Shackle Straps/LV insulator each 0.5
8.2 Pin Insulator each 1.2
8.3 Tension Insulator set each 3.6
9.0 Fixing of Additional Cross Arms
9.1 Tubular each 1.8
9.2 Lattice each 2.3
10.0 Removing and Replacing Cross Arms
10.1 Tubular each 3.6
10.2 Lattice each 4.5
11.0 Stringing Including Binding and fixing of PG Clamps
11.1 ACSR 120/20 Conductor km 96.0
11.5 AAC 95 Conductor km 60.0
11.8 ABC 3*95+50+16 Including Accessories Conductor km 80.0
11.9 ABC 3*70+50+16 Including Accessories Conductor km 80.0
12.0 Removing and Coiling of conductors
12.1 11kV Conductor Conductor km 36.0
12.2 LV Conductor Conductor km 24.0
13.0 Retentioning of conductors
13.1 11kV Conductor Conductor km 72.0
13.2 LV Conductor Conductor km 48.0
14.0 Erection of transformer with Lightning arrestors & MV fuses & Earthing
14.1 11/.4kV, 100kVA to 250kVA each 90.0
15.0 Erection of LV Cabinet complete with Load wires
15.1 For one MCCB each 9.0
16.0 Erection of LV Cabinet complete with Load wires each 2.3
17.0 Erection of LV Cabinet complete with Load wires each 0.8

STANDARD COST FOR NEW SERVICE CONNECTION
Standard Material Requirement for a New Service Connection
Item Unit Cost Qty per
Item Description Unit
Code US$ Ser.Con
A 01 05 Service Pole - 6m, 75mm dia GS Pipe each 40 0.2
B 01 05 D-Bracket complete with LV Insulator, 2 x 140 mm Bolts & Nuts, Plain & Spring Wa each 2.9 2
D 05 51 Bi-metallic Bolted Type Connector Al / Cu, 35-95 / 2.5-10 sqmm each 1.2 2
F 02 35 PVC Double Insulated Twin Cable, Al - 10sqmm m 0.72 25
K 01 25 Miniature Circuit Breaker (MCB), 1-Phase - 30A each 20 1
L 02 05 Energy Meter (kWh) Three Phase 400V - 10 - 40A each 40 1
L 04 50 Meter Board+Box with Nuts & Bolts etc. each 5 1
STANDARD COST FOR REHABILITATION OF A SERVICE CONNECTION
Standard Material Requirement for Rehabilitation of a Service Connection

Item Unit Cost Qty per
Item Description Unit
Code US$ km
A 01 05 Service Pole - 6m, 75mm dia GS Pipe each 40 0.05
B 01 05 D-Bracket complete with LV Insulator, 2 x 140 mm Bolts & Nuts, Plain & Spring Wa each 2.9 2
D 05 51 Bi-metallic Bolted Type Connector Al / Cu, 35-95 / 2.5-10 sqmm each 1.2 2
F 02 35 PVC Double Insulated Twin Cable, Al - 10sqmm m 0.72 10
K 01 25 Miniature Circuit Breaker (MCB), 1-Phase - 30A each 20 1
L 02 05 Energy Meter (kWh) Three Phase 400V - 10 - 40A each 40 1
L 04 50 Meter Board+Box with Nuts & Bolts etc. each 5 1

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Titoli correlati

United Nations Development Programme

Sustainable Human Development

REVISION 2 : FEBRUARY 2002

2.0 Scope 2-1

3.0 Guidelines for Overhead Power Distribution Lines 3-1

4.0 Design Criteria 4-1

5.0 Items used in Overhead MV and LV Construction 5-1

6.0 Overhead Line Construction 6-1

7.0 Safety of Personnel 7-1

8.0 Deviations to the Manual 8-1

9.0 Drawings 9-1

10.0 Tables and Charts 10-1

Annex 1 Distribution Material Drawings

Annex 2 Low Voltage Construction Drawings

Annex 3 Medium Voltage Construction Drawings

Annex 4 Pole Top Construction Drawings for Bare Conductor LV Lines

Annex 6 Pole Top Construction Drawings for MV Lines

Distribution Construction Standards Page i

Annex 7 Pole Top Construction Drawings for MV & LV Combine Runs

Annex 8 Typical Conductor Configuration Drawings for LV Lines

Annex 9 Typical Conductor Configuration Drawings for MV Lines

Annex 10 Typical Conductor Configuration Drawings for MV & LV Combine Runs

Annex 11 Distribution Transformer Drawings

Annex 12 Terminal Pole (H Pole) Construction for Substations

Annex 13 List of Distribution Construction Materials

Annex 14 Distribution Safety Guide Lines

Annex 15 Implementation Procedures

Manual Compiled by : Distribution Sector

Revised on : February 2002

Distribution Construction Standards Page ii

Distribution Construction Standards Page 1-1

Distribution Construction Standards Page 2-1

3.0 Guidelines for Overhead Power Distribution Lines

3.1.2 Clearance/approval from other relevant service authorities such as Municipality,

i. Access for construction and future maintenance work.

i. Heavy angles and deviations of lines.

Distribution Construction Standards Page 3-1

i. Ensure public safety.

Distribution Construction Standards Page 3-2

4.0 Design Criteria

4.1 Voltage Definitions

Extra Low Voltage Normally not exceeding 30 Volts

Medium Voltage Exceeding 1kV, but not exceeding 11kV

High Voltage Exceeding 11kV, but not exceeding 33kV

Extra High Voltage Exceeding 33kV

4.2 Low Voltage System

Nominal System Voltage 400 / 230 Volts

Maximum System Voltage 424 / 244 Volts

Type of System Grounding Neutral Earthed at Distribution Transformer

4.3 Medium Voltage System

Nominal System Voltage 11 kV

Range of System Operating Voltage 10 kV – 12 kV

Type of System Grounding Neutral resistive earthing through earthing

4.4 Environmental Conditions

Altitude up to 1000m above sea level

Maximum outdoor temperature 50°C

Minimum outdoor temperature -10°C

Maximum relative humidity 92%

Distribution Construction Standards Page 4-1

Maximum wind speed 125 km / hr