Materials System Specification

18-SAMSS-005 22 July 2012

Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications
Document Responsibility: Communications Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Specifications................................................. 3
5 Testing............................................................ 5
6 Markings……………….……………….………. 7

Previous Issue: New Next Planned Update: 22 July 2015

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Primary contact: Nufaii, Abdullah Sufran on 966-3-8801359

Copyright©Saudi Aramco 2012. All rights reserved.

Document Responsibility: Communications Standards Committee 18-SAMSS-005
Issue Date: 22 July 2012
Next Planned Update: 22 July 2015 Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications

1 Scope

This Material Specification specifies the minimum technical requirements for design,
engineering, manufacture, inspection, testing, performance, and acceptance criteria of a
composite overhead optical fiber-ground wire (OPGW) that is installed as part of the
electrical transmission system. For the metallic part specifications and testing, it shall
be referred to Electrical Systems Division of CSD.

2 Conflicts and Deviations

Any deviations, providing less than the mandatory requirements of this standard require
written waiver approval as per Saudi Aramco Engineering Procedure SAEP-302. For the
metallic part, any deviation shall be referred to Electrical Systems Division of CSD.

3 References

The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this specification shall comply with the
latest edition of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standards

SAES-T-624 Telecommunications Outside Plant-Fiber Optics
SAES-P-100 Basic Power System Design Criteria

3.2 Industry Codes and Standards

International Telecommunications Union (ITU-T)

ITU-T G.652 Characteristics of a Single-Mode Optical Fiber
Cable
ITU-T G.655 Characteristics of Non-Zero Dispersion-Shifted
Single-Mode Optical Fibers
ITU-T G.656 Characteristics of a Fiber and Cable with Non-Zero
Dispersion for Wideband Optical Transport

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Document Responsibility: Communications Standards Committee 18-SAMSS-005
Issue Date: 22 July 2012
Next Planned Update: 22 July 2015 Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications

Institute of Electrical and Electronics Engineers

IEEE 1138 Standard Construction of Composite Fiber Optic
Overhead Ground Wire (OPGW) for use on
Electric Utility Power Lines

International Electrotechnical Commission (IEC)

IEC 60794-4-10 Optical fiber cables – Part 4-10: Aerial Optical
Cables along Electrical Power Lines – Family
Specification for OPGW (Optical Ground Wires)
IEC 60794-1-2 Optical Fiber Cables – Part 1-2: Generic
Specification – Basic Optical Cable Test
Procedures
IEC 60793-1 Series Optical Fibers: Generic Specification

Electronic Industries Association

ANSI/TIA/EIA-598-A Color Coding of Fiber Optic Cables

4 Specifications

4.1 The IEEE-1138 “IEEE Standard for Testing and Performance for Optical
Ground Wire (OPGW) for Use on Electric Utility Power Lines” and IEC 60794-
4-10 “Aerial optical cables along electrical power lines-Family specification for
OPGW (Optical Ground Wire)” are hereby adopted as Saudi Aramco Material
Specifications for OPGW. Deviations and exceptions are outlined below.

4.2 General

4.2.1 The composite OPGW shall be designed in which the integral optical
fibers are used for transmission of optical signals, and in which the
metallic materials are used for conduction of surge currents attributed to
lightning and electrical faults.

4.2.2 The cable shall meet the site environmental conditions.

4.2.3 For the fiber optic specifications, refer to the Communications &
Computer Networks of P&CSD.

4.3 Fiber Optical Unit

4.3.1 The fiber optical unit shall operate continuously up to ambient outdoor
temperature of +70°C without any degradation of cable guaranteed
performance.

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Document Responsibility: Communications Standards Committee 18-SAMSS-005
Issue Date: 22 July 2012
Next Planned Update: 22 July 2015 Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications

4.3.2 The fiber optical unit shall be a metallic tube to house the fiber strands.

4.3.3 Filling compound shall be used to prohibit any moisture ingress from
outside or any water migration along the fiber optic unit. The filling
compound shall be able to withstand normal service conditions and shall
remain flexible (not to harden) throughout the entire expected life of the
fiber.

4.3.4 Fiber Color Coding

4.3.4.1 When buffer tubes or binders are used, the ANSI/TIA/EIA 598
shall be used.

4.3.4.2 Exception: When more than 12 strands are combined together

in one group, the black strand shall be Nature color
(Uncolored). Black ring (tracer) shall be used to mark fiber
count above 12. Use the color scheme in the table below to
identify the color and ring tracers for 48 strands or less:

Table (1) – Fiber Strands Colors

Number of Black
Fiber No. & Color
Rings/Tracers
1 2 3 4 5 6
Blue Orange Green Brown Gray White
Without
7 8 9 10 11 12
Red Black Yellow Violet Pink Aqua
13 14 15 16 17 18
Blue Orange Green Brown Gray White
1
19 20 21 22 23 24
Red Nature Yellow Violet Pink Aqua
25 26 27 28 29 30
Blue Orange Green Brown Gray White
2
31 32 33 34 35 36
Red Nature Yellow Violet Pink Aqua
37 38 39 40 41 42
Blue Orange Green Brown Gray White
3
43 44 45 46 47 48
Red Nature Yellow Violet Pink Aqua

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Document Responsibility: Communications Standards Committee 18-SAMSS-005
Issue Date: 22 July 2012
Next Planned Update: 22 July 2015 Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications

4.3.5 Optical fibers shall comply with one of these standards based on the end
communication equipment:
(a) ITU-T G.652, Characteristics of a Single-Mode Optical Fiber and
Cable.
(b) ITU-T G.655, Non-zero Dispersion-shifted Single-Mode Optical
Fiber and Cable.
(c) ITU-T G.656, Characteristics of a fiber and cable with non-zero
dispersion for wideband optical transport.

4.3.6 The optical fibers shall comply with IEC-60793-1 series.

5 Testing

5.1 The OPGW shall successfully pass the tests specified in the IEEE 1138 or
IEC 60794-4-10. The relevant tests are subdivided into three categories:
Type Tests, Routine Tests and Factory Acceptance Tests.

5.2 Qualification or Type Tests

Type tests are usually conducted on new cable design. Manufacturer shall
provide Saudi Aramco with the results of these tests confirming that the cable
has passed successfully these tests according to Table (2).

Table (2) – Qualification (Type) Tests

IEEE 1138
Test IEC Procedure Note
Procedure
Cable characteristics tests 6.4.1
Creep Test 6.4.1.1 IEC 60794-4-10; 9.6 *
Stress-Strain-Test 6.4.1.2 IEC 60794-4-10; 9.2 *
Strain-Margin-Test 6.4.1.3 IEC 60794-4-10; 9.1 *
Ultimate Tensile strength 6.4.1.4 IEC 60794-4-10; 9.3 min. 95% RTS
DC-Resistance Test 6.4.1.5 IEC 468 2m sample
Installation Tests 6.4.2
Sheave Test 6.4.2.1 IEC 60794-4-10; 9.4 MAOC ≤ 10%
Crush Test 6.4.2.2 IEC 60794-1-2; E3 criteria acc. IEEE
In Service tests 6.4.3
Aeolian Vibration Test 6.4.3.1 IEC 60794-4-10; 9.5 10x106 cycles
Short-Circuit-Test 6.4.3.3 IEC 60794-4-10; 9.9 *
Lightning Arc Test 6.4.3.4 IEC 60794-4-10; 9.10 *
Water Ingress Test 6.4.3.5 IEC 60794-4-10; 9.8 *
Seepage of Flooding Compound 6.4.3.6 IEC 60794-1-2; E14 *
Temperature Cycle Test 6.4.3.7 IEC 60794-4-10; 9.7 *
ASTM B117/
Salt Spray Corrosion Test 6.4.3.8 1000h/35°C/5% Salt fog
EIA/TIA-455-16A
‘*’: Denotes that the test can be done according to the IEEE or the IEC without any modifications.

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Document Responsibility: Communications Standards Committee 18-SAMSS-005
Issue Date: 22 July 2012
Next Planned Update: 22 July 2015 Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications

5.3 Routine Tests

Manufacturer shall conduct routine tests on all production cable lengths to

demonstrate their integrity. Test results shall be provided to Saudi Aramco
confirming that the cable has passed successfully these tests according to
Table (3).

Table (3) – Routine Tests

IEEE 1138
Test IEC Procedure Note
Procedure
Mechanical and electrical tests on 6.5.1 IEC 60479-4-10; 11 sample test
the wires before stranding
a) Tensile test
b) Elongation at failure
c) Diameter
d) Resistance
e) Thickness of aluminum layer
f) Twist test
g) Bending test
Test on complete cable 6.5.3 IEC 60794-4-10; 11 *
Lay length measurement 6.5.3.1 IEC 60794-4-10; 11 *
Optical attenuation measurement 6.5.3.2 IEC 60794-4-10; 11 *
‘*’: Denotes that the test can be done according to the IEEE or the IEC without any modifications.

5.4 Factory Acceptance Tests (FAT)

FAT test shall be conducted on all cables. Witness tests on 10% of cables of
delivery lot as a minimum. Manufacturer shall demonstrate that the cable being
tested is exactly same as the one requested and tested during Qualification
(Type) and Routine tests. For each FAT and Type tests, individual Inspection &
test plan shall be prepared and agreed with Saudi Aramco prior to the test.

Table (4) – FAT Test

Test Note
Bedding -
Number and diameter of wires (inner layer) -
Lay ratio and direction of lay (inner layer) -
Number and diameter of wires (outer layer) -
Lay ratio and direction of lay (outer layer) -
Attenuation at operational wavelength and Fiber point defects -
Chromatic dispersion and Polarization mode dispersion 10% of fibers
Diameter -
d.c. resistance at 20°C -

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Document Responsibility: Communications Standards Committee 18-SAMSS-005
Issue Date: 22 July 2012
Next Planned Update: 22 July 2015 Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications

Test Note
Constructions Verify that the cable matches
the one tested under the
Qualification (Type) tests

5.5 The Optical Time Delay Reflectometer (OTDR) testing shall be conducted
(1) after manufacturing, (2) after receiving the cable at the site and (3) after
installation.

5.6 After “Lightning Arc” test and “Short-Circuit” tests, the remaining tensile
strength shall not be less than 75% RTS. The tensile strength can be calculated
by the tensile strength of the unbroken wires.

5.7 During the “Seepage of Flooding Compound Test”, the chamber shall be
preheated to at least 70°C. The filling compound shall not leak or drip at 70°C.

5.8 Test on complete OPGW cable for rated strength is required.

6 Markings

6.1 Composite OPGW reels shall be marked with a drum label in legible and
indelible letters providing the following particulars:
a) Manufacturer's name and country of origin
b) Year of manufacture
c) Type of cable, number of fiber strands and type
d) Serial number / supplier ID no.
e) Length and weight of composite OPGW on reel
f) Gross weight
g) Direction rolling of reel
h) BI Number/Contract Number
i) Purchase Order & Consignee Address

6.2 All markings shall appear on both sides of the reel. See Figure (1) for reel
marking location.

6.3 Composite OPGW reel identification shall include any additional information as
required by the SAUDI ARAMCO shipping instructions.

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Document Responsibility: Communications Standards Committee 18-SAMSS-005
Issue Date: 22 July 2012
Next Planned Update: 22 July 2015 Composite Overhead Fiber Optic Ground Wire (OPGW) Specifications

Figure (1) – Reel Markings

Manufacturer’s Name Cable & Reel Data

& Country of Origin as in Section 6.1

Purchse Order Number

BI / JO /Contract Nubmers
Consignee Address

Serial Number of Reel

Revision Summary
22 July 2012 New Saudi Aramco Materials System Specification.

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