In a landmark project that was India’s first pilot, Bajaj Electricals Ltd energized a transmission line in Punjab using monopoles made with Steel Caisson Technology. It was also the first deployment of monopoles in Punjab’s transmission landscape. Here is a case study discussing the achievement, and how the challenges en route were successfully surmounted.
In June 2022, Bajaj Electricals Ltd energized a landmark project which is India’s pilot project introducing Steel Caisson Technology, in Ludhiana, Punjab.
The transmission line running 6.11 km is a remarkable achievement and an important project for state power T&D utility Punjab State Power Corporation Ltd (PSPCL) as it instituted monopoles for the first time into its grid system.
PSPCL planned a 66kV transmission line to connect the 220/66kV Ladowal substation and 132/66kV GT Road substation in Ludhiana. This 66kV double-circuit transmission line stretched for around 6.11 km in the highly populated area of Ludhiana — from Hussainpura to ChauraBazar.
It consists of 45 double-circuit monopoles and two multi-circuit monopoles. The line designed on lattice structures could only be built partially and was left incomplete owing to various hindrances like severe right-of-way issues, lower footprint availability, proximity to NH44, infringement of other existing utilities, and other clearance issues.
While the option of underground cabling was explored, it was ruled out as apart from being a costlier alternative, the option was also fraught with challenges in terms of getting clearances and NOCs for laying the cable through a congested route. Consequently, the only option was to find a way to install towers along the road with a minimum footprint to construct the line with minimum disturbance to the public and other utilities.
PSPCL hence floated a tender for transmission of power from the 220kV Ladhowal/Amaltash substation to the 66kV GT Road substation, Ludhiana. Four bidders participated in the tendering process of which Bajaj Electricals was found to be most technically and commercially competent and thus was awarded the tender.
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Challenges faced
The execution and completion of the project was fraught with challenges, and Bajaj Electricals faced a maze of hurdles. The transmission line passed through a crowded residential, commercial and industrial belt of Ludhiana where the construction corridor was a constraint. It passed through a narrow road portion of approximately 5m width under the jurisdiction of the Public Works Department (PWD). However, National Highways Authority of India (NHAI) approved only 2m.The said corridor adjacent to the road was already dominated by HT/LT lines. There were several crossings like the New Delhi-Jammu main railway track, one National Highway, and four power line crossings of diversified voltage levels. There were also some predicaments for the finalization of the route and its statutory clearances due to NOCs from various government bodies like the Indian Railway, PWD, NHAI, and Municipal Corporation of Ludhiana. Apart from this, the execution of the project started amid a crucial phase when the world was facing of COVID-19 surge.
The innovative turnkey solution
Bajaj Electricals offered a unique environment-friendly solution for the project by introducing Steel Caisson Foundation having a footprint of just a 1.15m diameter. The base embedded section with the flange joint, and the pole shaft designed with slip joints not only met the stringent foundation footprint requirement but could also be installed with a minimum construction period, thereby obviating longer-duration power outage.
Amid the execution of the project, there was a requirement to complete the foundation, erection and stringing activities at location AP15/0 Jassian Village, Ludhiana within a short span of time to avoid long power outage.
The Bajaj Electricals team had taken this challenge and came up with an innovative solution to replace the conventional civil foundation, which normally takes 14-20 days for casting and curing period to enable erection on that foundation. Bajaj Electricals’ engineering team came up with Steel Caisson in lieu of civil foundation which can be driven using the vibro hammer used for driving the sheet piling sheets. This has enabled the monopole structure constituting its foundation, erection and stringing of the adjacent spans about location AP15/0, Type PBSS+3, in a record time of precisely 8:30 hours on April 25, 2022 — to the complete satisfaction of Punjab State Power Corporation Ltd.
The project also encompasses concrete Caisson foundation, structures of double-circuit single-sided configuration, double-circuit double-sided configuration and multi-circuit poles of 66/66kV and 132/66kV having two circuits perpendicular to the other two circuits.
Bajaj Electricals has always dealt with safety and HSE compliances with utmost priority and hence made sure the line had zero safety incidents.
Empowering lives, inspiring trust
Bajaj Electricals Ltd has stood the test of time and has unparalleled expertise in the power transmission segment for over 15 years. It is proudly known as the undisputed leader in monopoles in India and is the first to design manufacture and erect steel monopoles in India.
Bajaj Electricals monopoles are manufactured indigenously at Bajaj Electricals Ltd’s plant Ranjangaon, Pune, Maharashtra. Many varieties of monopoles have been successfully type tested at CPRI, Bangalore and SERC Chennai. Equipped with a team of experts, a futuristic R&D department, a world-class manufacturing unit, and a legacy of trust, Bajaj Electricals provides turnkey solutions to the challenges faced. The company provides solutions that contribute positively to the energy ecosystem making it apt for sustainable development and a futuristic power transmission system in India. The company ensures each project stays true to its promise of inspiring trust.
