Dobbins PDF

ADSS and OPGW Cable Installation
on Aerial Power Transmission Facilities

Patrick Dobbins Director Technology Applications

Agenda
Industry Standards
Structure Hardware
Cable Attachment Hardware ADSS
Cable Attachment Hardware OPGW
Installation Apparatus
OPGW Installation Methods
ADSS Installation Methods
Key Installation Issues

IEEE 534 2003 Guide to Installation of OH

Transmission Line Conductors
IEEE 1138-2009 Standard for Testing and

Performance of Optical Ground Wire
(OPGW) for Use on Electric Utility Power
Lines
IEEE 1222 2011 Standard for Testing and

Performance for All-Dielectric SelfSupporting (ADSS) Fiber Optic Cable for
Use on Electric Utility Power Lines
IEEE 1591 2011 Standard for Testing and

Performance of Hardware for Optical Ground
Wire
Recognized as the best practices
Working groups from Power Engineering

Society

Structure and Pole Line Attachment Hardware
For most distribution applications, 10M (5/8) pole mounting hardware is

used (eye nuts, bolts, etc).
For transmission applications higher loads and tensions must be

considered and appropriate hardware selected
Pole Line Hardware and Guying should be matched to a minimum of

fiber optic cable UTS or 2X maximum rated operating tension
(MRCL/MRDT).
Guying Rules same as for messenger supported cable or power

conductors.
Basic aerial line construction rules are applicable

Use company current safety rules on hardware standards

OPGW Attachment Hardware

Fiber Optic Cable Attachment Hardware Important

Considerations
OPGW and ADSS attachment hardware must be matched to a
specific cable type and manufacturer.
Cable diameter, cable design type, loading factors and cable UTS are
considered
Key element is the Maximum Rated Design Tension (MRDT) of
OPGW Cable or Maximum Rated Cable Load (MRCL) of ADSS cable.
Do not match based on diameter alone
Hardware must be certified by hardware and cable manufacturer as
an integrated system

OPGW Deadend Choices
Tension Points of segment
Different choices available for different

OPGW cable designs
Hardware is matched to specific cable

design
Used for wide angles, splice points, reel

ends, road, river, and railroad crossings.
Cable Diameter
MRDT and UTS
Cable Construction Type

OPGW Deadend Choices Formed Wire

Used for wide angles, splice
points, reel ends, road, river, and
railroad crossings.
Different choices available for
different OPGW cable designs
Hardware is matched to specific
cable design
Cable Diameter
Heliformed deadend
Reinforcing rods
Aluminu
Aluminum
m
or copper
ground
ground
wire
clamp
MRDT and UTS

Cable Construction Type
FiberLign deadend

OPT-GW Tangent/Suspension Choices

Hi-Bus Suspension
0 to 20 Line Angle
Slip rating to 20% for UTS under
25Klbs
Can be configured with double
yoke plate to 40
Hi-Bus Suspension
Hi-Bus Trunion
0 to 20 Line Angle
Slip rating to 20% for UTS
under 25Klbs
Top Mount Style
Superior Vibration Resistance
Hi-Bus Trunnion

OPT-GW Suspension Choices

Single Mechanical Suspension
0 to 30 Line Angle
Slip rating to 1500 lbs
Vertical load at 25Klbs
Suspension Mount Style
Single Suspension
Double Mechanical Suspension
31 to 60 Line Angle
Slip rating to 3000 lbs
Vertical load at 25Klbs
Yoke Plate/Anchor Shackle
Double Suspension

OPT-GW Grounding Choices

Bonding Clamp
Grounding of OPT-GW at each

tower
Difference Grounding Harness
depending on current carrying
requirements
Bonding Clamp

OPT-GW Tower/Pole Guides

Tower/Pole Guide Clamp
Used at splice points
Guides cables down structure
Lattice steel structures or wooden
poles
Tower Guide Clamp

Pole Guide Clamp
Used at splice points
Guides cables down structure
Used on wooden poles
Wood Pole Clamp

OPGW Vibration Dampers
Damper System
Used to control Aeolian Vibration
Engineered to cable diameter,
tension, and span
Software analysis program provides
specific recommendation of number of
dampers and locations
OPGW MFGR provides
recommendations
Stockbridge Damper
Spiral Dampers

ADSS Attachment Hardware

Attachment Hardware Important Considerations
ADSS attachment hardware must be matched to a specific cable.

Cable diameter, jacket material and cable UTS are considered
Do not match based on diameter alone
Hardware must be certified by hardware and cable manufacturer

ADSS Deadend Choices
Torque-balanced design
Hardware is matched to specific cable

design
Also Temporary Tension Grips

Used for wide angles, splice points, reel
ends, road, river, and railroad crossings.
Different choices available for different

ADSS cable designs
Mechanical Deadend
Cable Diameter
MRCL and UTS
Jacket Type
Formed Wire Deadend

Deadend Choices
Mechanical Deadened
Medium length spans

Fast Installation
Limited tension applications
Standard PE Jackets Only
Formed Wire Deadends
Medium and long spans

Special designs
Higher tension applications
Standards and Tracking Resistant
Jackets

Deadend Choices
Medium/Long Span Formed Wire DE

Tangent/Suspension Choices
Tangents are used for span lengths
< 600 feet (180 m) Heavy Loading to

1200 feet (365m) Light Loading,
angles < 22 degrees. (15 deg for
installation pulls)
Suspensions are used for
Tangent (Trunion)
Suspension
span lengths > 600 feet (180

m), angles < 30 degrees.
Formed Wire Suspension

EHV ADSS Corona Rings
For EHV ADSS Applications
Protects cable from discharge off of

Formed Wire Hardware
Under SRL layer of DE or SU units

Typical for applications above 230kV
Follow manufactures recommendation
Corona Ring

Vibration Dampers
Aeolian Vibration Control
Distribution Applications
Spiral Vibration Damper
Transmission Applications
Spiral Vibration Dampers
Stockbridge Dampers

Stockbridge Vibration Dampers
ADSS in EHV (>230Kv)

environments may require
Stockbridge damper
Due to Tracking potential on
SVD Damper
Solution must be engineered
by AFL
Damper must attach over
armor rods

Cable Reel - Visual Inspection

Visually inspect all reels for any damage that may have occurred
during transit.
Be particularly alert for damage if:
A reel is laying flat on its side (flange).
Reels are stacked on top of each other.
Other freight is stacked on the reel.
Nails have been driven into the flange or lagging.
A reel flange is damaged or lagging is damaged.
The end seals of the cable have been removed or damaged, allowing
potential moisture ingress into the cable.

Cable Preparation Prior to Install

The wood lagging or flexwrap should be the
last thing removed before installation.
The inside end tail should be loosened on
the reel prior to pulling.
This allows the inner layers of the reel to shift
and grow out if they need to.

Installation Equipment

Reel Stands
Reel stands are designed to be used with
tensioners to supply the necessary hold-back
tension to the cable
Reels are not designed to withstand the
forces developed by braking during high
tension stringing operations
Direct tension stringing from the
reel at cable installation stringing
tensions should not be attempted

Bullwheel Characteristics
Recommended guidelines
Semicircular grooves with depths of 50% or more
than the cable diameter, and with a flare angle of
5 to 15 from the vertical center line reference
The minimum radius at the bottom of the groove
should be at least 35 times the diameter of the
cable
Elastomer lined grooves or other smooth surface
finish

Puller Characteristics
The system should be capable of
maintaining a constant and even tension
Equipped with tension indicating and limiting
devices
Braking system to maintain a constant holdback tension at various pulling speeds
Positive braking systems are required for
pullers and tensioners to maintain cable
tensions when pulling is stopped
Fail safe braking systems are recommended

Travelers/Blocks
Lined Blocks Recommended
Large Diameter for:
First position after payoff
Final position before take-up
Heavy Angles (25 or greater)
Smaller Diameters
Tangent
12 minimum sheave diameter
At minimum, the first and last

traveler should be grounded to the
structure

Running Ground
Safety device for personnel
protection
Protects personnel from induced
voltages and transients
Requited at pay-out and at take-up
locations
Must be tied to a made ground of
multiple grounding rods

Sheave Groove Configuration

The minimum radius of the sheave groove (Rg) should be 55%
greater than the diameter of the cable
The minimum depth of the groove should be 25% greater than
the diameter of the cable
The sides of the groove should
between 15 to 20 from the
flare
vertical

Bending Radius for Equipment/Hardware

Equipment/HW
Diameter
(minimum)
Bull Wheel
70 X cable OD
st
1 and Last
Structure Stringing
Block
Angle Structures
(> 20 )
Tangent Structures
(< 20 )
40 X cable OD
Cable
Manufacturers
Recommendation
Typically < 30 X
cable OD

Pull Rope
Torque Balanced
High Dielectric
Low Elongation
High UTS
Abrasion Resistance

Grips and Swivels

Rated for max pull tension
2 Stage Double weave to single
Double Clevis Swivel
Rated for Load
Non-Breakaway
NEVER use the wire mesh grip to

tension or to hold cable under
tension

Anti-Rotation Device
The use of the ARD depends upon the construction of the cable.
This device is utilized to avoid cable twisting during the pulling
operation.

Tension Hoist
Rated for 2 X max sag tension

Ratchet type
Easy release mechanism
Take up length appropriate for sag
operation

OPT-GW Temporary Tension Device
Tension Grip is also called a

comealong or pocketbook grip
Specifically engineered to each cable
design
Maximum tension rating is 5000 lbs
If higher tension is required then two
grips can be used in tandum

ADSS Temporary Tension Grip
Rated for 2 X max sag tension or

2500 lbs
Easy release mechanism
Used with thimble clevis in bail
Alternative is to use a regular DE
temporary
Cannot be used on TrackingResistant Jackets.

ADSS Formed Wire FIT Tool

Used to properly install
formed wire deadends and
suspensions
Snaps armor rods into place
without damaging the cable
jacket
Screwdrivers/Pliers will cut
the jacket and lead to failure

Dynamometer
Utilized for final tensioning process
Must be rated for 2X the maximum
sagging tension
Typical accuracy is 0.5% of full
scale reading of dynamometer

OPT-GW Installation Process

Pre-Pull Checklist
Verify power system outage and key power company contacts for call
outages
Verify fiber integrity by testing reels and comparing to factory readings
Inspect pull location for best setup of payout end verses the pulling end or
the direction
Identify key concern areas such as heavy line angle changes, road
crossings or elevation changes
Verity length of pull verse length of cable. Be sure to plan for extra needed
for payout and pulling set up location. Account for sag requirements.
Frame tower or pole attachment hardware ahead of pull
Set up all travelers on tower structures
Verify communications of payout and pulling technicians

Installation Diagram
Pay-out end.
Take-up end.
Pay-out in line with first two structures.
Take-up in line with last two structures.
4 to 5 wraps on BW.
Reef per mfgr.
Low elongation pull rope or verify

integrity of existing static wire.
Payout min.15 from BW.
3:1 lead-to-height ratio.
Aerial double clevis swivel (rated) and

wire mesh grip.
Breaking mechanism.
Proper traveler sizes.
Watch for bird cage.
ADR if required.
Max pulling speed < 250 ft/min.

OPT-GW Stationary Reel Method

Complete make-ready prior to pull
Poles framed
Trees trimmed
Hazards identified
Payout pull rope through travelers of entire

reel segment (+6km)
Attach cable to pull rope with wire mesh grip
and clevis swivel
Establish 3 to 1 set up on both ends (payout and take-up)
Set up in-line with first 2 and last 2 structure
Load cable and pull rope, start pull process
Sag deadend segment to deadend segment

OPT-GW Helicopter Installations

Similar to Stationary Reel but no pull rope
payout
Structures framed
Road crossings prepared
Attach cable to helicopter leader rope
(150) with wire mesh grip and clevis
swivel
Load cable and pull rope, start payout
process with Helicopter
Transfer at last structure to puller and presag to maximum installation tension
Target sag deadend segment to deadend
segment
12-7

OPGW Sag and Tension Considerations

OPGW Sag and Tension
Catenary Curve Analytic Method
Base on AE value of composite
cable
Commercial Software like SAG10 and PLSCAD
Key Input Parameters
Diameter (in.)
Modulus (kpsi)
Weight (lbs/ft)
Maximum Rated Design Tension
(MRDT) (lbs)
Rated Tensile Strength (RTS) (lbs)
Span ranges
Critical spans
SAG-10 Output
46

Sag and Tension Rules

Target Sag (visual sag method)
Establish Soft Side DE on first structure
Sag on worse case span of DE segment
Establish reference at frame location on
both critical structures
Measure down to installation sag
requirement
Flag both structures at sag height with
visible surveyor flagging
Tension DE segment while observing sag
from one of the structures
As sag of span is in-line with both flags
the cable is at the prescribed sag.
Deadend the segment
Tension Sag (measured sag method)

Establish Soft Side DE on first
structure
Go to next deadend location on the
hard side deadend
Rig Temporary DE at 2X length of DE
from DE structure.
Rig Dynamometer in line with
temporary DE and hoist
Tension segment to requited sag
tension
Verify sag visually on critical span
segment
Deadend the segment

12-22
What Not to Do
During OPGW Installation
1.
Do not use a tensioner with undersized bull wheels.
2.
Do not utilize tensioner bull wheels without neoprene lining.
3.
Do not reeve OPGW on the tensioner bull wheels from the

wrong side.
4.
Do not locate the reel of OPGW too far from the tensioner.
5.
Do not allow the OPGW cable to sag down between the reel and
the tensioner.
6.
Do not install or string fiber optic cable without good

communications.
7.
Do not utilize travelers without neoprene groove lining.
48

12-22,23
What Not to Do
8.
Do not install travelers on tangent structures with groove

diameter less than 30x the cable diameter
9.
Do not install travelers on heavy angle structures with groove

diameters less than 40x the cable diameter.
10.
Do not fail to install temporary grounding at the tensioner and

puller.
11.
Do not fail to utilize the correct type and size of cable grips.
12.
Do not fail to install clamping devices and permanent grounding

to the cable within 24 hours of sagging and dead-ending.
13.
Do not fail to install vibration dampers within 24 hours of sagging

and dead-ending the fiber optic cable.
49

12-23
What Not to Do
14.
Do not fail to install temporary grounding on the cable if the pull

is left overnight without the installation of permanent grounds.
15.
Do not fail to check and/or test the ground resistance at the base
of each tower to ensure that it has a resistance at or below 10 to
15.
16.
Do not fail to check the condition of the existing shield wire if you
are planning to use the existing wire to pull in the cable.
17.
Do not fail to test the fibers immediately before the reels of cable
are installed.
50
ADSS Installation Process

Pre-Pull Checklist
Verify power system outage and key power company contacts for call
outages
Verify fiber integrity by testing reels and comparing to factory readings
Inspect pull location for best setup of payout end verses the pulling end or
the direction
Identify key concern areas such as heavy line angle changes, road
crossings or elevation changes
Verity length of pull verse length of cable. Be sure to plan for extra needed
for payout and pulling set up location. Account for sag requirements.
Frame tower or pole attachment hardware ahead of pull
Set up all travelers on tower structures
Verify communications of payout and pulling technicians
11-20

ADSS Installation
Back Pull Method
Pay-out end.
Take-up end.
Pay-out in line with first two

structures.
Take-up in line with last two

structures.
4 to 5 wraps on BW.
Low elongation pull rope.
Payout min. 15 from BW.
Aerial double clevis swivel (rated)

and wire mesh grip.
Breaking mechanism.
Proper traveler sizes.
Flag pulling grip for twist.

Max pulling speed < 250 ft/min.
53

11-21
ADSS Installation
Drive-off Method
Need clear right-of-way with no obstructions.

Back tension control on payout for cable overrun.
Slack tension stringing method but maintain ground clearance.
Cable payout off top of reel.
3:1 lead-to-height ratio on payout.
In-line structures strung through tangent attachments (<25).
Proper traveler sizes on heavy angles.
Guard road crossings.
Sag each dead-end segment.
54

ADSS Helicopter Installations
Similar to Stationary Reel but no pull rope payout
Structures framed
Road crossings prepared
Attach cable to helicopter leader rope (150) with

wire mesh grip and clevis swivel
Load cable and pull rope, start payout process

with Helicopter
Transfer at last structure to puller and pre-sag to

maximum installation tension
Target sag deadend segment to deadend

segment

Sag and Tension Rules

Target Sag (visual sag method)
Establish Soft Side DE on first structure
Sag on worse case span of DE segment
Establish reference at frame location on
both critical structures
Measure down to installation sag
requirement
Flag both structures at sag height with
visible surveyor flagging
Tension DE segment while observing sag
from one of the structures
As sag of span is in-line with both flags
the cable is at the prescribed sag.
Deadend the segment
Tension Sag (measured sag method)

Establish Soft Side DE on first
structure
Go to next deadend location on the
hard side deadend
Rig Temporary DE at 2X length of DE
from DE structure.
Rig Dynamometer in line with
temporary DE and hoist
Tension segment to requited sag
tension
Verify sag visually on critical span
segment
Deadend the segment

11-8
ADSS Sag and Tension Considerations

Catenary curve analytic method of sage and tension analysis
SAG10 or PLS CAD inputs of AE Value
Diameter (in. or mm)
Modulus (kpsi)
Maximum rated cable load (MRCL)
Rated tensile strength (RTS)
Deadend segment span ranges
Critical span or longest span of segment
57

11-25
What Not to Do
During ADSS Installation
1.
Do not use a tensioner with undersized bull wheels.
2.
Do not utilize tensioner bull wheels without neoprene lining.
3.
Do not locate the reel of ADSS too far from the tensioner.
4.
Do not allow the ADSS cable to sag down between the reel and
the tensioner when pulling.
5.
Do not install or string fiber optic cable without good

communications.
6.
Do not utilize travelers without neoprene groove lining.
58

11-25
What Not to Do
During ADSS Installation
7.
Do not pull cable through tangent supports on line angles

greater than or equal to 15.
8.
Do not install travelers on angle supports with groove diameters

less than 40x the cable diameter.
9.
Do not fail to install temporary grounding at the tensioner and

puller.
10.
Do not fail to utilize the correct type and size of tensioning grips.
11.
Do not fail to install vibration dampers within 24 hours of sagging

and dead-ending the fiber optic cable.
12.
Do not fail to test the fibers immediately before the reels of cable
are installed.
59

Sheath Repair

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ADSS and OPGW Cable Installation

on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation

ADSS and OPGW Cable Installation

IEEE 534 2003 Guide to Installation of OH

IEEE 1138-2009 Standard for Testing and

IEEE 1222 2011 Standard for Testing and

IEEE 1591 2011 Standard for Testing and

Recognized as the best practices

Working groups from Power Engineering

ADSS and OPGW Cable Installation

Structure and Pole Line Attachment Hardware

For most distribution applications, 10M (5/8) pole mounting hardware is

For transmission applications higher loads and tensions must be

Pole Line Hardware and Guying should be matched to a minimum of

Guying Rules same as for messenger supported cable or power

Basic aerial line construction rules are applicable

ADSS and OPGW Cable Installation

OPGW Attachment Hardware

ADSS and OPGW Cable Installation

Fiber Optic Cable Attachment Hardware Important

ADSS and OPGW Cable Installation

OPGW Deadend Choices

Tension Points of segment

Different choices available for different

Hardware is matched to specific cable

Used for wide angles, splice points, reel

ADSS and OPGW Cable Installation

OPGW Deadend Choices Formed Wire

Tension Points of segment

MRDT and UTS

ADSS and OPGW Cable Installation

OPT-GW Tangent/Suspension Choices

ADSS and OPGW Cable Installation

OPT-GW Suspension Choices

ADSS and OPGW Cable Installation

OPT-GW Grounding Choices

Grounding of OPT-GW at each

ADSS and OPGW Cable Installation

OPT-GW Tower/Pole Guides

Tower Guide Clamp

Wood Pole Clamp

ADSS and OPGW Cable Installation

OPGW Vibration Dampers

ADSS and OPGW Cable Installation

ADSS Attachment Hardware

ADSS and OPGW Cable Installation

Attachment Hardware Important Considerations

ADSS attachment hardware must be matched to a specific cable.

ADSS and OPGW Cable Installation

ADSS Deadend Choices

Tension Points of segment

Hardware is matched to specific cable

Also Temporary Tension Grips

Different choices available for different

Formed Wire Deadend

ADSS and OPGW Cable Installation

Medium length spans

Formed Wire Deadends

Medium and long spans

ADSS and OPGW Cable Installation

Medium/Long Span Formed Wire DE

ADSS and OPGW Cable Installation