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TECHNIQUE FOR DETECTING CORROSION PART OF OPGW

F.MINOURA* K.ADACHI
Tokyo Electric Power Co., Inc.

(Japan)

SUMMARY

Composite Fiber-Optic Ground wire (OPGW) has a risk that communication faults may be
caused by corrosion of their pipes. We have discovered the signal losses caused by the
hydrogen generated by the corrosion of installed OPGW can be measured by means of an
Optical Time Domain Reflectometer (OTDR). And we have developed, based on this finding,
a method to detect corroded parts of OPGW.
The use of this method on a transmission line in which a communication fault has occurred
allows corroded parts to be detected accurately and thus allows an effective maintenance plan
to be developed which does not overlook any part that requires repair or replacement. This
method is also useful as a mean of preventive maintenance. For example, this method can be
used for regular monitoring of OPGW in healthy transmission lines and to detect signs of
corrosion before the corrosion causes a communication fault.

KEYWORDS

Composite Fiber-Optic Ground Wire (OPGW) - Corrosion - Communication - Fault - Optical

Time Domain Reflectometer (OTDR) - Hydrogen-Induced Loss

Email:fumito.minoura@tepco.co.jp
1. Introduction
We have been developing optical fiber cable networks to expand its communications-related
businesses and upgrade its network of transmitting information for circuit protection.
Transmission lines are more robust and stable and require less facility maintenance than
distribution lines. This is why electric power companies mainly use optical fibers on
transmisstion lines as trunk communication lines and as power relaying system. Therefore
optical fiber cables are used as highly reliable long-distance information routes. Presently in
Japan, overhead ground wires are mainly used when installing optical fibers on towers[1]. A
prerequisite for installing optical fiber cables in an overhead ground wire is that the overhead
ground wire must withstand heat and arcs. To satisfy these requirements, we have been using
OPGW, a ground wire that contains optical fiber in core sections which is coated with heat-
resistant synthetic resin . However, corrosion has been found in the aluminum pipes for
optical fiber cables in some of our OPGW in recent years. The major cause of this corrosion is
the development of a small hole in the aluminum pipe, which causes the infiltration of water
into the aluminum pipe. The infiltrated water may freeze and swell, or cause the formation of
a corrosion product, and the ice or corrosion product may press itself against the optical fiber
cables and consequently cause communication faults. To solve these problems, we have
developed a method to detect corroded parts.

2. Causes of OPGW Faults

Because transmission lines are exposed to severe weather and natural environmental
conditions, it is a severe condition for optical fiber cables. In addition, because optical fiber is
a fragile material, signal losses and cable breakage faults may occur. The major causes of
OPGW faults are as follows:

* Significant signal loss resulting from poor manufacturing (for example, slight bending of
the optical fiber over a long distance due to uneven winding of the tape that binds the
optical fibers)
* Damage to optical fiber resulting from poor installation work (for example, physical
bending of the optical fiber inside the joint box and collapse of the aluminum pipe due to
excessive tightening of the cleat and clamp)
* Significant signal loss resulting from aging degradation (for example, when the aluminum
pipe is damaged by corrosion, water infiltrates into the aluminum pipe, freezes and swells
inside and corrosion products generate pressure) (See Fig.1,2.)
Alminum-clad steel wire Aluminum pipe

Optical fiber cable Spacer

Fig.1 Cross-Section of an OPGW

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 Aluminum pipe

Spacer

Fig.2 An Aluminum Pipe Damaged by Corrosion

3. Conventional Maintenance Method and Its Problem

So far, communication faults have traditionally been dealt with by detecting the fault points
after the detection of faults by means of measurements at the communication wavelengths
using OTDR and replacing the fault section.
In the case of communication faults due to manufacture or installation-related problems, the
parts that need to be replaced or repaired are easy to be detected unfailingly, because such
faults occur immediately after the emergence of the causal conditions and in the places where
the causes are present.
However, communication faults due to problems associated with aging deterioration may
occur gradually in the following sequence:

(1)A hole develops in the aluminum pipe as a result of corrosion and water infiltrates into the
pipe through the hole.
(2)The infiltrated water freezes and swells, or causes the formation of a corrosion product on
the inside surface of the aluminum pipe.
(3)The ice or corrosion product presses itself against the optical fiber cables and consequently
causes significant signal losses.

This means that communication faults may occur intermittently as a result of the intermittent
icing of the infiltrated rain water due to temperature drops, or corrosion may progress without
causing a communication fault until the corrosion product presses itself against the optical
fiber cables. In particular, corrosion will progress slowly and will not disappear unless an
effective countermeasure is taken. Therefore, there is a risk with the conventional approach of
only looking at communication fault points, that the corroded parts cannot be found
completely and consequently some of the parts requiring replacement or repair may be
overlooked.

4. The Working Principle of the Method to detect Corroded Parts

To solve this problem, we have developed a method to detect corroded parts of OPGW by
measuring signal losses (reductions in the signal transmissivity) caused by the absorption by
optical fiber cables of the hydrogen generated by corrosion of the aluminum pipe.
It is considered that corrosion of an aluminum pipe causes the generation of hydrogen in the
aluminum pipe through the corrosion reactions shown below. Results from examinations of
disassembled aluminum pipes also show that Al(OH)3 is present in the pipes.(See fig.3.)

Al→Al3++3e- ・・・(1)
3+ -
Al +3Cl +3H2O→Al(OH)3+3HCl ・・・(2)
Al+3H++2Cl-→3/2H2↑+AlCl2+ ・・・(3)

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 Optical fiber Aluminum pipe

Al(OH)3

Fig.3 A Corroded Part of an Aluminum Pipe

The hydrogen generated in the aluminum pipe absorbs certain wavelengths of signal and
consequently reduces the signal transmissivity (hydrogen-induced losses). Measuring
hydrogen-induced losses by OTDR method using wavelengths that are sensitive to such
losses(See fig.4.), the locations where hydrogen-induced losses have occurred can be
detected accurately. And thus not only the parts where communication faults have occurred
but also the parts where aging deterioration of the aluminum pipe has occurred (corroded
parts) can be detected.

1.24μm
12.0 1.24μm

1.17μm
10.0
損失(dB/km)

1.08μm
Loss (dB/km) 8.0

Fiber that absorbed hydrogen

6.0
水素吸収ﾌｧｲﾊ ﾞ
1.625μ m
4.0
Fiber under
normal conditions
1.55μm
1.31μm
2.0

健全ﾌｧｲﾊ ﾞ
0 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6
波長(μm)
Wavelength (µm)

Fig.4 Loss Wavelength Characteristic of Single-mode Optical Fiber[2]

5. Selection of Wavelengths for Measuring Losses

The OTDR measurement is a method in which a laser incident beam of a certain wavelength
is applied from the end of optical fiber. After the scattered light generated in the optical fiber
cable is received by using a photo-detector, the signal light losses and the distances from the
locations where the losses have occurred are calculated based on the measured amounts of
received signal light and times to reception. Because the laser beam must reach the end of the
measurement section of the optical fiber for a measurement to be completed, the measurable
distance is limited by the signal output capacity of the measuring equipment and the amount
of losses at the measurement wavelength. That is, the loss that occurred at a location can be
evaluated without cutting the optical fiber cable as long as the location is within the
measurable distance as which is determined by the luminous energy of the laser beam.
However, it is important to select the correct measurement wavelength, because the one-

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wavelength measurement approach means that selecting an inappropriate wavelength can
result in a misjudgment in determining the cause of the loss.
Losses in an optical fiber can be divided into two types; one caused by material-related causes
and the other loss caused by external causes [3]. It can be said that signal loss increases after
installation are caused by external causes. In particular, past data on signal loss increases
shows that most of the signal losses caused by external causes are ones caused by bending.
Because losses caused by bends (such as micro bends) require different measures from
corrosion ones, it is necessary to discriminate between such losses and hydrogen-induced
losses. The longer-wavelenghth become, the more bending loss increase.(See fig.5.)
Therefore, corroded parts can be detected accurately by using the 1.24µm wavelength, which
is a short wavelength that is sensitive to hydrogen-induced losses.
Optical fiber in
a bending state

Loss(dB)

Wavelength(µm)

Fig.5 Bending-Induced Losses of Single-Mode Optical Fiber

6. Verification Testing
This section describes the results of measurements made on an actual overhead OPGW. No
communication fault had occurred in this OPGW. To verify the adequacy of the method, the
inside surface of the aluminum pipe which is examined for corrosion by dismantling and
disassembling OPGW.(See table 1.)

Table 1 Overview of the Tested OPGW

Optical fiber Cross-Section area Number of external
Line name Year of installation
(Single-mode) (mm2) AC layers
Line MS 18-cables 60 1 1987

Fig. 6 shows the measured loss increases from the initial losses (i.e. the losses measured at the
time of installation) at 1.24µm. It can be seen from the figure that there have been loss
increases in sections other than No. 10 – No. 22. Fig.7 shows the measured loss increases
from the initial losses (i.e. the losses measured at the time of installation) at 1.31µm, which is
the common communication wavelength. It can be seen from the figure that loss increases
have occurred in sections other than No.20 – No.22.

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 8.0

7.0

6.0

損失増加値　(dB /km )
Loss increase
5.0
(dB/km)
4.0

3.0

2.0

1.0

0.0
N o.10-13 N o.13-20 N o.20-22 N o.22-24 N o.24-28 N o.28-35 N o.35-44 N o.44-53
区間
Section
Fig.6 Loss Increases at 1.24µm

0.5

0.4
損失増加値　(dB /km )

Loss increase
0.3
(dB/km)

0.2

0.1

0.0
N o.10-N o.13 N o.13-N o.20 N o.20-N o.22 N o.22-N o.24 N o.24-N o.28 N o.28-N o.35 N o.35-N o.44 N o.44-N o.53
区間
Section
Fig.7 Loss Increases at 1.31µm

After the OTDR measurement, the sections of OPGW that are shown in the above figures are
dismantled and disassembled to examine the inside surface of the aluminum pipe for
corrosion. It was confirmed through the examinations that the inside surface of the aluminum
pipe was corroded in No.22 – No. 53 and there was no corrosion in No.10 – No.22.(See table
2.) These examination results are consistent with the results of the measurements at 1.24µm,
which means that the precision of the method is good enough. In No.10 – No.20, bending-
induced losses due to micro bends were observed.

Table 2 Results of Disassembled Examinations Section

Loss measurement result in terms of whether the Corrosion on the inside
Section degree of loss is normal or abnormal surface of the aluminum
1.31µm 1.24µm pipe
No. 10 – No.20 Abnormal Normal Not corroded
No. 20 – No.22 Normal Normal Not corroded
No.22 – No.24 Abnormal Abnormal Corroded
No.24 – No.53 Abnormal Abnormal Corroded

7. Measurement Procedure
The measurement procedure can be summarized as follows:

(1) An investigation is carried out to confirm the initial loss at a wavelength of 1.24µm (In
the case of single-mode optical fiber cables being used by us, the initial loss values are
around 0.5dB/km).

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(2) OTDR measurement is made at 1.24µm from the end of the line to be measured
(telecommunication building) (See fig.8). If OTDR laser beam does not reach the terminal
end of the measurement section of the optical fiber, measurement from the other end or
from relay station between the end is made so that all of the line to be measured can be
covered.

(3) The sections with measured losses that are larger than the initial loss are the sections in
which hydrogen-induced losses have occurred, which means that they are the sections in
which corrosion has occurred.
　OPGW
substation substation

OTDR
Optical tower tower Optical
plugboard plugboard

Fig.8 Schematic Diagram of the Measurement Configuration

8. Application Case
The measurement method was applied to 14 OPGW installed in highly corrosive
environments such as coastal areas. As a result, hydrogen-induced losses were detected in
four of the 14 lines and the corroded parts were identified. Several months after the
measurement, we found the communication fault on one(Line MY) of the four lines where the
hydrogen-induced losses were detected.(See table3.) It showed the validity of this
measurement.

Table 3 Results of Examinations Section

Number of hydrogen-
Optical fiber Cross-Section Year of
Line name external induced
(Single-mode) area (mm2) installation
AC layers losses
Line KM 18-cables 60 1 1994 No
Line KA 24-cables 170 2 1987 No
Line KJ 24-cables 170 2 1990 Yes
Line MY* 24-cables 170 2 1988 Yes
Line KG 18-cables 60 1 1993 No
Line OY 18-cables 60 1 1996 Yes
Line FJ 24-cables 170 2 1997 No
Line HF 18-cables 60 1 1995 No
Line NK 18-cables 60 1 1995 No
Line KM 18-cables 60 1 1991 No
Line AK 18-cables 60 1 1988 No
Line GK 24-cables 170 2 1995 No
Line HK 30-cables 290 2 1989 No
Line AS 18-cables 60 1 1989 Yes
* :The communication fault was observed on Line MY.

9. Conclusions
A method that effectively detects corroded parts of OPGWs through OTDR measurement
using a wavelength of 1.24µm was presented.
This method allows parts that have deteriorated as a result of corrosion to be detected in a
transmission line in which a communication fault has occurred. In addition, the method can

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also be used as a means of preventive maintenance, including the detection of signs of
corrosion before the corrosion causes a communication fault.

BIBLIOGRAPHY
[1]Electric Technology Research Association,“Optical fiber grounding wire”, Vol. 46, No.1,
1990.
[2]Yoshitaka Namihira et al.,“Hydrogen-Induced Problems in Optical Fiber Cables”,Institute
of Electronics, Information and Communication Engineers, CS84-46, pp27-34, 1984.
[3] Shojiro Kawakami et al.,“Optical Fiber and Optical Fiber-Based Devices”,Baifukan Inc.,
1996.