Technical Specification for OPGW Fibre Optic Cable

&
Associated Hardware

DAMODAR VALLEY CORPORATION

DVC Towers, VIP Road, Electricity Department,
SPE Section: Communication Wing, 9th Floor, Kolkata 700054.
Website: www.dvc.gov.in
 Specification for OPGW cabling and associated hardware & fittings

The broad scope of this specification include the design, engineering, manufacturing, supply, transportation,
insurance, delivery at site, unloading, handling, storage, testing, demonstration for acceptance and
documentation for:

a) OPGW fibre optic cable including all associated hardware, accessories & fittings

This section of the technical specification describe the functional and technical specifications of OPGW cabling
and associated hardware and fittings.

1.0 Fibre Optic Cabling

In this section of the technical specification, the functional & technical specifications of OPGW cable,
associated hardware & fittings for the requirements for G.652D Dual-window Single mode (DWSM)
telecommunications grade fibre optic cable is mentioned. Bidders shall furnish with their bids, detailed
descriptions of the fibres & cable(s) proposed.
All optical fibre cabling including fibre itself and all associated installation hardware shall have a minimum
guaranteed design life span of 25 years. Documentary evidence in support of guaranteed life span of cable &
fibre shall be submitted by the Contractor.

1.1 Required Optical Fibre Characteristics

The optical fibre to be provided should have following characteristic.

1.1.1 Physical Characteristic

Dual-Window Single mode (DWSM), G.652D optical fibres shall be provided in the fibre optic cables.DWSM
optical fibres shall meet the requirements defined in Table- 1.

1.1.2 Attenuation

The attenuation coefficient for wavelengths between 1525 nm and 1575 nm shall not exceed the attenuation
coefficient at 1550 nm by more than 0.05 dB/km. The attenuation coefficient between 1285 nm and 1330 nm
shall not exceed the attenuation coefficient at 1310 nm by more than 0.05 dB/km. The attenuation of the
fibre shall be distributed uniformly throughout its length such that there are no point discontinuities in excess
of 0.10 dB. The fibre attenuation characteristics specified in table- tenuation
of any & every fibre reel.

The overall optical fibre path attenuation shall not be more than calculated below:

Maximum attenuation @ 1550nm: 0.21 dB/km x total km + 0.05 dB/splice x no. of splices + 0.5 dB /
connector x no. of connectors

Maximum attenuation @ 1310nm: 0.35dB/km x total km + 0.05 dB/splice x no. of splices + 0.5 dB /
connector x no. of connectors
 Table- 1
DWSM Optical Fibre Charateristics
Fibre Description: Dual Window Single Mode

Mode Field Diameter: 8.6 to 9.6 µm (±0.6 µm)

Cladding Diameter: 125 µm ± 1 µm

Mode field concentricity error:

Cladding non-circularity:

Cable Cut-off Wavelength cc :

1550 nm loss performance: As per ITU-T G.652 D

Proof Test Level:

Attenuation Coefficient:

Chromatic Dispersion; Maximum: 18 ps/(nm x km) 1550 nm

3.5 ps/(nm x km) 1288-1339 nm
5.3 ps/(nm x km) 1271-1360 nm

Zero Dispersion Wavelength: 1300 to 1324 nm

Zero Dispersion Slope: -0.092 ps/(nm2 x km) maximum
Polarization mode dispersion coefficient:

Temperature Dependence: -60°C to +85°C )

Bend Performance: @ 1310 nm (75±2 mm dia Mandrel), 100 turns;

@ 1550 nm (75±2 mm dia Mandrel), 100 turns;

@ 1550 nm (32±0.5 mm dia Mandrel), 1 turn;

1.2 Fibre Optic Cable Construction

The OPGW (Optical Ground Wire) cable is proposed to be installed on the EHV transmission lines. The design
of cable shall account for the varying operating and environmental conditions that the cable shall
experience while in service. The OPGW cable to be supplied shall be designed to meet the overall
requirements of all the transmission lines. Normally the tower span of the lines shall not exceed 400 m,
however, some of the spans may be up to around 800 m or more.

1.2.1 Optical Fibre Identification

Individual optical fibres within a fibre unit and fibre units shall be identifiable in accordance with EIA/TIA
598 or IEC 60304 or Bellcore GR-20 colour-coding scheme. The colour coating shall be permanent thus
withstanding normal handling e.g. during termination, testing or cable relocation throughout the design life
of the cable.
Colouring utilized for colour coding optical fibres shall be integrated into the fibre coating and shall be
homogenous. The colour shall not bleed from one fibre to another and shall not fade during fibre
preparation for termination or splicing.

Each cable shall have traceability of each fibre back to the original fibre manufacturer's fibre number and
parameters of the fibre. If more than the specified number of fibres is included in any cable, the spare fibres
shall be tested by the cable manufacturer and any defective fibres shall be suitably bundled, tagged and
identified at the factory by the vendor.

1.2.2 Buffer Tube

Either Loose tube or tight tube buffer construction shall be implemented. The individually coated optical
fibre(s) shall be surrounded by a buffer for protection from physical damage during fabrication, installation
and operation of the cable. The fibre coating and buffer shall be strippable for splicing and termination.
Each fibre unit shall be individually identifiable utilizing colour coding. If loose tube buffer construction is
provided, buffer tubes shall be filled with a water-blocking gel.

1.2.3 Optical Fibre Strain & Sag-Tension chart

The OPGW cable shall be designed and installed such that the optical fibres experience no strain under all
loading conditions defined in IS 802. Zero fibre strain condition shall apply even after a 25 year cable creep.

For the purpose of this specification, the following definitions shall apply:

Maximum Working Tension (MWT) is defined as the maximum cable tension at which there
is no fibre strain.
The no fibre strain condition is defined as fibre strain of less than or equal to 0.05%, as
determined by direct measurements through IEC/ ETSI (FOTP) specified optical
reflectometry
The Cable strain margin is defined as the maximum cable strain at which there is no fibre
strain.
The cable Maximum Allowable Tension (MAT) is defined as the maximum tension
experienced by the Cable under the worst case loading condition.
The cable max strain is defined as the maximum strain experienced by the Cable under the
worst case loading condition.
The cable Every Day Tension (EDT) is defined as the maximum cable tension on any span
under normal conditions.
The Ultimate /Rated Tensile Strength (UTS/ RTS/ breaking strength) is defined as the
maximum tensile load applied and held constant for one minute at which the specimen
shall not break.

While preparing the Sag-tension charts for the OPGW cable the following conditions shall be met:

The Max Allowable Tension (MAT) / max strain shall be less than or equal to the MWT/
Strain margin of the cable.
The sag shall not exceed the earth wire sag in all conditions.
The Max Allowable Tension shall also be less than or equal to 0.4 times the UTS.
The 25 year creep at 25% of UTS (creep test as per IEEE 1138) shall be such that the 25 year
creep plus the cable strain at Max Allowable Tension (MAT) is less than or equal to the cable
strain margin.
The everyday tension (EDT) shall not exceed 20% of the UTS for the OPGW cable.
1.2.4 Cable Materials

The materials used for optical fibre cable construction, shall meet the following requirements :

1.2.4.1 Filling Materials

The interstices of the fibre optic unit and cable shall be filled with a suitable compound to prohibit any
moisture ingress or any water longitudinal migration within the fibre optic unit or along the fibre optic
cable. The water tightness of the cable shall meet or exceed the test performance criteria as per IEC 60794-
1-F-5.

The filling compound used shall be a non-toxic homogenous waterproofing compound that is free of dirt
and foreign matter, nonhygroscopic, electrically nonconductive and non-nutritive to fungus. The compound
shall also be fully compatible with all cable components it may come in contact with and shall inhibit the
generation of hydrogen within the cable.

The waterproofing filling materials shall not affect fibre coating, colour coding, or encapsulant commonly
used in splice enclosures, shall be dermatologically safe, non-staining and easily removable with a non-toxic
cleaning solvent.

1.2.4.2 Outside Jacket Materials

The outer cable jacket for wrap around cable shall consist of carbon black polyethylene resin to prevent
damage from exposure to ultraviolet light, weathering and high levels of pollution. The jacket shall conform
to low density, medium density and high density polyethylene standards as defined in ASTM D1248.

Gel filled stainless steel tube meeting the criteria to protect the fibres from exposure to ultraviolet light,
weathering, high levels of pollution etc. may also be offered

1.2.4.3 Protection Tubes

The optical core, including fibres shall be contained and protected by a tube. The tube may be made of
Aluminium alloy that is continuous, fully sealed, water tight and without mechanical joints. Both welded
and unwelded tube is acceptable if the same meets the requirement of Water Penetration Test, as per IEC-
794-1-F5. The tube shall have sufficient resistance in order to protect the Optical Fibres from radial
compression, transmitted by the metallic wires of the external layers. Under the normal operating
conditions, including Aeolian vibration, sheeve pulling at Minimum / Maximum Temperature and Maximum
Operating Tension, the tube shall not open, fissure and shall not be deformed. The internal surface of the
tube shall be smooth, without smudges, notches, residues or roughness that may affect the Optical Fibres,
or the P.E. sheathing. The internal and external surface of the tube shall be circular and the thickness shall
remain constant, as specified earlier. No tube joints shall be allowed in the finished OPGW. Stainless steel
tube is also acceptable if the same meets the requirements.

1.2.4.4 Metallic wires

a) The OPGW shall conform to the applicable Clauses of the IEC 1089 related to standard conductors.
Adjacent wire layers shall be stranded with reverse lay directions. The direction of lay of the external layer
shall be left hand.

b) Alluminium alloy / aluminium clad steel wires shall be smooth, uniform and free from all imperfections
that are visible in the naked eye, such as spills and splits, die marks, scratches, abrasions and kinks. When
the fibre optic cable design incorporates metallic elements in its construction, all metallic elements shall be
electrically continuous.
1.2.4.5 Sheathing Removal

The cable sheath design shall permit easy removal without damage to the optical fibres or fibre units.

1.3. Optical Ground Wire (OPGW)

The OPGW cable construction shall comply with IEEE- 1138, 2009. The cable provided shall meet both the
construction and performance requirements such that the ground wire function, the optical fibre integrity
and optical transmission characteristics are suitable for the intended purpose. The cable shall consist of
optical fibre units as defined in earlier. There shall be no factory splices within the cable structure of a
continuous cable length.

The OPGW structure shall be based on the following characteristics:

The composite fibre optic overhead ground wire shall be made up of multiple buffer tubes embedded in a
water tight aluminium/aluminium alloy/stainless steel with aluminium coating protective central fibre optic
unit surrounded by concentric-lay stranded metallic wires in single or multiple layers. Each buffer tube shall
have maximum 12 no. of fibres. All fibres in single buffer tube or directly in central fibre optic unit is not
acceptable. The dual purpose of the composite cable is to provide the electrical and physical characteristics
of conventional overhead ground wire while providing the optical transmission properties of optical fibre.

Electrical characteristics of the OPGW must be equal to or better when compared to standard ground wire.
The electrical conductivity must be designed to withstand the specified short circuit currents. The OPGW
cable selected shall withstand the temperature increase caused by the maximum short circuit current. The
Bidder shall describe the electrical parameters of the OPGW proposed.

The mechanical structure of OPGW shall be designed to withstand the wind and other environmental
conditions in the routes, which have been specified in this document. The location of the fibres inside the
structure shall be such that the application of the OPGW in the specified routes is possible. The selected
OPGW cable shall tolerate the normal installation procedures. The Bidder shall list the mechanical
parameters of the OPGW and describe the cable structure including how the fibres are located inside, and
shall furnish the cross-sectional drawing of OPGW.

The cable structure shall be such that the fibres are protected against water, hydrogen ultraviolet radiation
and other environmental hazards encountered in India.

The metallic wires have to give the OPGW, conductivity to carry fault currents and the strength to withstand
mechanical stresses. Aluminium alloy, aluminium clad steel wires or a combination of them shall be used.
The OPGW shall withstand, without change in its characteristics a lightning current of 150 kA (peak). The
minimum allowable radius of bending for OPGW within the specified temperature range should be 20 x D,
where D is the outer diameter of the OPGW.

The fibre tubes shall have a high crush resistance and minimum permanent or temporary deformation
under mechanical pressure. The fittings must be designed to prevent these pressures. OPGW elongation
under different stress situations likely during wind loads or during ground faults shall be considered.

1.3.1. Basic Construction

The cable construction shall conform to the applicable requirements of applicable clauses of IEC 1809
related to stranded conductors and Table -2 OPGW Mechanical and Electrical Characteristics. In addition,
the basic construction shall included bare concentric-lay-stranded metallic wires with the outer layer having
left hand lay. The wires may be of multiple layers with a combination of various metallic wires within each
layer. The direction of lay for each successive layer shall be reversed. The finished wires shall contain no
joints or splices; however, in case the contractor feels that joints or splices are absolutely necessary, it
should only be done upon obtaining approval from the Employer and conforming all applicable clauses of
IEC 1089 as they pertain to stranded conductors.
The wires shall be so stranded that when the complete OPGW is cut, the individual wires can be readily
regrouped and then held in place by one hand.

1.3.2. Central Fibre Optic Unit

The central fibre optic unit shall be designed to house and protect multiple buffered optical fibre units from
damage due to forces such as crushing, bending, twisting, tensile stress and moisture. The central fibre optic
unit and the outer stranded metallic conductors shall serve together as an integral unit to protect the optical
fibres from degradation due to vibration and galloping, wind and ice loadings, wide temperature variations,
lightning and fault current, as well as environmental effects which may produce hydrogen.

The OPGW design of dissimilar materials such as stainless steel tube with aluminium or aluminium clad-
steel wire strands are not allowed. Central fibre optic unit may be of aluminium or stainless steel tube with
aluminium protective coating. In case of aluminium protective coating, the coating must completely cover
the tubes leaving no exposed areas of tubing that can make electrical contact either directly or indirectly
through moisture, contamination, protrusions, etc. with the surrounding stranded wires. The tube may be
fabricated as a seamless tube, seam welded, or a tube without a welded seam.

1.3.3. Breaking Strength

The rates breaking strength of the complete OPGW shall be taken as no more than 90% of the sum of rated
breaking strengths of the individual wires, calculated from their nominal diameter and the specified
minimum tensile strength.

The rated breaking strength shall not include the strength of the optical unit. The fibre optic unit shall be
considered a load bearing tension member when determining the total rated breaking strength of the
composite conductor.

1.3.4. Electrical and Mechanical Requirements

Table-2 provides OPGW Electrical and Mechanical Requirements for the minimum performance
characteristics. Additionally, the OPGW mechanical & electrical characteristics shall be similar to that of the
earthwire being replaced such that there is no or minimal consequential increase in stresses on towers. For
the purposes of determining the appropriate Max Working Tension limit for the OPGW cable IS 802:1995
and IS 875: 1987 shall be applied. However the OPGW installation sag & tension charts shall be based on IS
802 version to which the line is originally designed. For the OPGW cable design selection and preparation
of sag tension charts, the limits specified in this section shall also be satisfied.

Table -2
OPGW Electrical and Mechanical Requirements
(1) Everyday Tension
(2) D.C. Resistance at 20ºC: < 1.0 ohm/Km
(3) Short Circuit Current
(4) Diameter 11.9 mm

1.3.5. Operating Conditions:

Since OPGW shall be located at the top of the transmission line support structure, it will be subjected to
Aeolian vibration, Galloping and Lightning strikes. It will also carry ground fault currents. Therefore, its
electrical and mechanical properties shall be same or similar as those required of conventional ground
conductors.
1.3.6. Marking, Packaging and Shipping:

This section describes the requirements for marking, packaging and shipping the overhead fibre optic cable.

(a) Drum Markings: Each side of every reel of cable shall be permanently marked in white lettering with

the type of cable, length, number of fibres, a unique drum number including the name of the
transmission line & segment no., factory inspection stamp and date.

(b) Cable Drums: All optical fibre cabling shall be supplied on strong drums provided with lagging of
adequate strength, constructed to protect the cabling against all damage and displacement during
transit, storage and subsequent handling during installation. Both ends of the cable shall be sealed as
to prevent the escape of filling compounds and dust & moisture ingress during shipment and handling.
Spare cable caps shall be provided with each drum as required.

The spare cable shall be supplied on sturdy, corrosion resistant, steel drums suitable for long periods
of storage and re-transport & handling.

There shall be no factory splices allowed within a continuous length of cable. Only one continuous
cable length shall be provided on each drum. The lengths of cable to be supplied on each drum shall
be determined by a "schedule" prepared by the Contractor and approved by the owner.

1.4. Installation Hardware:

The scope of supply includes all required fittings and hardware such as Tension assembly, Suspension
assembly, Vibration dampers, Reinforcing rods, Earthing clamps, Downlead clamps, splice enclosure etc.
The Bidder shall provide documentation justifying the adequacy and suitability of the hardware supplied.

The OPGW hardware fittings and accessories shall follow the general requirements regarding design,
materials, dimensions & tolerances, protection against corrosion and markings as specified in clause 4.0 of
EN 61284: 1997 (IEC 61284). The shear strength of all bolts shall be at least 1.5 times the maximum
installation torque. The OPGW hardware & accessories drawing & Data Requirement Sheets (DRS)
document shall consist of three parts: (1) A technical particulars sheet (2) An assembly drawing i.e. level 1
drawing and (3) Component level drawings i.e. level 2 & lower drawings. All component reference numbers,
dimensions and tolerances, bolt tightening torques & shear strength and ratings such as UTS, slip strength
etc shall be marked on the drawings.

The fittings and accessories described herein are indicative of installation hardware typically used for OPGW
installations and shall not necessarily be limited to the following:

(a) Suspension Assemblies: Preformed armour grip suspension clamps and aluminium alloy armour
rods/ reinforcing rods shall be used. The suspension clamps shall be designed to carry a vertical load
of not less than 25 KN. The suspension clamps slippage shall occur between 12kN and 17 kN as
measured.

The Contractor shall supply all the components of the suspension assembly including shackles, bolts,
nuts, washers, split pins, etc. The total drop of the suspension assembly shall not exceed 150 mm
(measured from the centre point of attachment to the centre point of the OPGW). The design of the
assembly shall be such that the direction of run of the OPGW shall be the same as that of the
conductor.

(b) Dead End Clamp Assemblies: All dead end clamp assemblies shall preferably be of performed
armoured grip type and shall include all necessary hardware for attaching the assembly to the tower
strain plates. Dead end clamps shall allow the OPGW to pass through continuously without cable
cutting. The slip strength shall be rated not less than 95% of the rated tensile strength of the OPGW.
(c) Clamp Assembly Earthing Wire: Earthing wire consisting of a 1500 mm length of aluminium or
aluminium alloy conductor equivalent in size to the OPGW shall be used to earth suspension and
dead end clamp assemblies to the tower structure. The earthing wire shall be permanently fitted
with lugs at each end. The lugs shall be attached to the clamp assembly at one end and the tower
structure at the other.

(d) Structure Attachment Clamp Assemblies [For attachment with (a) Suspension Towers & (b) Tension
Towers]:
Clamp assemblies used to attach the OPGW to the structures, shall have two parallel grooves for the
OPGW, one on either side of the connecting bolt. The clamps shall be such that clamping
characteristics do not alter adversely when only one OPGW is installed. The tower attachment plates
shall locate the OPGW on the inside of the tower and shall be attached directly to the tower
legs/cross-members without drilling or any other structural modifications. Clamp assemblies earth
wire should be provided for attachment to each suspension/tension tower

(e) Vibration Dampers :

Vibration dampers type 4R Stockbridge or equivalent, having four (4) different frequencies spread
within the Aeolian frequency bandwidth corresponding to wind speed of 1m/s to 7 m/s, shall be
used for suspension and tension points in each span. Vibration damper clamps shall be made of
aluminium or aluminium alloy, shall support the dampers during installation and shall maintain the
dampers in position without damage to the OPGW and without causing fatigue. Armour or patch
rods made of aluminium or aluminium alloy shall be provided as required to reduce clamping stress
on the OPGW. The vibration damper body shall be hot-dip galvanized mild steel/cast iron or shall be
permanent mould cast zinc alloy.

The clamp of the vibration damper shall be made of high strength aluminum alloy of type LM-6. It
shall be capable of supporting the damper and prevent damage or chaffing of the conductor during
erection or continued operation. The clamp shall have smooth and permanent grip to keep the
damper in position on the OPGW cable without damaging the strands or causing premature fatigue
failure of the OPGW cable under the clamp. The clamp groove shall be in uniform contact with the
OPGW cable over the entire clamping surface except for the rounded edges. The groove of the clamp
body and clamp cap shall be smooth, free from projections, grit or other materials which could cause
damage to the OPGW cable when the clamp is installed. Clamping bolts shall be provided with self
locking nuts and designed to prevent corrosion of threads or loosening in service.

The messenger cable shall be made of high strength galvanised steel/stain less steel. It shall be of
preformed and post formed quality in order to prevent subsequent droop of weight and to maintain
consistent flexural stiffness of the cable in service. The messenger cable other than stainless steel
shall be hot dip galvanised in accordance with the recommendations of IS:4826 for heavily coated
wires.

The damper mass shall be made of hot dip galvanised mild steel/cast iron or a permanent mould
cast zinc alloy. All castings shall be free from defects such as cracks, shrinkage, inclusions and blow
holes etc. The surface of the damper masses shall be smooth.

The damper clamp shall be casted over the messenger cable and offer sufficient and permanent
grip on it. The messenger cable shall not slip out of the grip at a load less than the mass pull-off
value of the damper. The damper masses made of material other-than zinc alloy shall be fixed to
the messenger cable in a suitable manner in order to avoid excessive stress concentration on the
messenger cables which shall cause premature fatigue failure of the same. The messenger cable
ends shall be suitably and effectively sealed to prevent corrosion. The damper mass made of zinc
alloy shall be casted over the messenger cable and have sufficient and permanent grip on the
messenger cable under all service conditions.

The contractor must indicate the clamp bolt tightening torque to ensure that the slip strength of
 the clamp is maintained between 2.5 kN and 5 kN. The clamp when installed on the OPGW cable
shall not cause excessive stress concentration on the OPGW cable leading to permanent
deformation of the OPGW strands and premature fatigue failure in operation.

(f) Fibre Optic Splice Enclosures (Joint Box):

All splices shall be encased in Fibre Optic Splice Enclosures. Suitable splice enclosures shall be
provided to encase the optical cable splices in protective, moisture and dust free environment.
Splice enclosures shall comply with ingress protection class IP 66 or better. The splice enclosures
shall be designed for the storage and protection of required number of optical fibre splices and
equipped with sufficient number of splice trays for splicing all fibres in the cable. No more than 12
fibres shall be terminated in a single splice tray. They shall be filled with suitable encapsulate that
is easily removable should re-entry be required into the enclosures.

Splice enclosures shall be suitable for outdoor use with each of the cable types provided under this
contract. Splice enclosures shall be appropriate for mounting on transmission line towers above
anti-climb guard levels at about 10 metres from top of the tower and shall accommodate pass-
through splicing.

Please note that make of OPGW and associated Hardware fittings should be same OEM and
attached approve copy of M/s PGCIL regarding OPGW Design & associated hardware fittings.
Details of OPGW hardware fittings is mentioned in ANNEXURE-I.