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SOP & Manual On OPGW Stringing
SOP & Manual On OPGW Stringing
WORKING METHODOLOGY FOR
OPGW STRINGING & TESTING
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
REVISION CONTROL SHEET
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
CONTENTS
SL NO. DESCRIPTION PAGE NO.
I Cover Sheet 1
II Revision Control Sheet 2
III Contents 3
IV Abbreviations 4
1.0 Purpose 5
2.0 Scope 5
3.0 Exclusions 5
4.0 Applicability 5
5.0 Reference Documents 5
6.0 Responsibility 5
9.0 Safety Measures / Precautions 9
10.0 Acceptance Criteria 9
11.0 Records 9
ABBREVIATIONS
FQP ‐ Field Quality Plan
PM ‐ Project Manager
QA ‐ Quality Assurance
QCE ‐ Quality Control Engineer
OPGW ‐ Optical Ground Wire
OTDR ‐ Optical Time Domain Reflectometer
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
1.0 PURPOSE :
This document describes the step wise work methodology to carry out the installation work & Testing of
OPGW Cables in 132 / 220 / 400 / 765 KV Transmission Line work in planned and controlled manner with
reference to the technical specification and standards to determine the suitability of the site for the proposed
project.
2.0 SCOPE :
It includes detailed installation methodology & testing of OPGW Cable true to lines & levels. The work shall be
carried out in accordance with the specification and corresponding approved drawings.
3.0 EXCLUSION :
In case of very specific & mandatory customer’s need their processes & formats can be followed as a part or in
full. However in case of any conflict most stringent norms must be followed.
4.0 APPLICABILITY:
This working methodology is primarily developed for Transmission & Distribution works & applicable to the
same, at sites across all locations as per specification
5.0 REFERENCE SPECIFICATION / STANDARDS :
Following Documents / Drawings / Codes have been referred for the preparation of this work methodology :
1. IEEE 1138: 2009
2. IEC 60793‐1‐40
3. IEC 61089
4. IEC 61284
6.0 RESPONSIBILITY:
Responsibility of implementation of this methodology rest with below mentioned officials
1. PRIMARY: Stringing In‐Charge, Section‐In‐Charge, Site Supervisor
2. SECONDARY: Project Manager, Quality Control Engineer
7.0 PREREQUISITE:
1. Generic Contract Documents (as applicable)
2. Field Quality Plan
3. Availability of documents listed under Para 5.0.
4. Availability of tested handling equipment’s, tools, tackles.
5. Availability of skilled manpower.
8.0 METHODOLOGY FOR OPGW STRINGING:
A) SURVEY OF THE LINE:
Prior planning for installation of the OPGW cable is performed by monitoring the line, taking into account
the following parameters:
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
a) LENGTH OF EACH DRUM:
The OPGW drum lengths are determined based on the following considerations: position of the
tension towers, tower access, distance between supports and crossing with other lines, roads,
railways, routes, services and other obstacles.
b) SPLICES:
The position of the splices depends on the maximum available length of OPGW, on the position of the
towers and the tower access.
B) GENERAL INSTRUCTIONS BEFORE INSTALLATION:
a) TRANSPORT, LOADING, UNLOADING AND STORAGE:
The following procedures are recommended to prevent the cable from suffering damage during
handling, transport and storage:
i) The drums should always be transported in vertical position with the cable ends fixed to prevent
cable from slackening. All of the staves and safe guards should be maintained until the drums are
situated for immediate installation.
ii) After the transport, the drums should be inspected to verify that they have not been damaged and
that none of the staves and / or safeguards is broken.
iii) The drums should never, in any case, be thrown from the lorry during unloading, or moved by
uncontrolled rolling.
iv) Loading and unloading are performed so that the drum remains in vertical position and the sides of
the drum are not damaged by using suitable method.
v) The direction of the drum turns should follow the instruction of the mark on the drum.
vi) In any case the drum should not be stored horizontally.
vii) The ends of the cable should be sealed to prevent water penetration.
viii) The drums can be moved by rolling a short distance ensuring that there are no objects that may
damage the staves. The direction in which the drum turns should be the same as that in which the
cable is wound during manufacture.
ix) The drum should not be stored on its side under any circumstances whatsoever.
x) The ends of the cable should be sealed to prevent water penetration.
xi) The drums should be stored on flooring that is strong enough to prevent sinking.
xii) The drums should be stored to facilitate handling and loading. They should be located far from any
activity that may damage them.
C) PREPARATION FOR INSTALLATION:
a) POSITIONING THE EQUIPMENT:
i) DRUM:
The drum is placed at the selected site (with the space required for its location) so that the cable
outlet is on the upper part and aligned with the planned laying direction.
The drum must be located at a distance of 2 or 3 metres from the tensioner. The lifting components
usually used are hydraulic jacks and a bar with the suitable dimensions inserted in the central
opening of the drum. The drum must be located at a height of 10 to 15 cm from the ground.
ii) PULLER AND TENSIONER:
Either the puller or the tensioner must be placed at a minimum distance from the tower equal or
more than twice of the tower’s height. The tensioner as well as the puller should be placed aligned
with the conductors.
iii) TOOLS & TACKLES:
All the tools & tackles i.e. Pulleys, Anti‐Twisting devices, swivel, pulling grip, clamps & suitable
pulling ropes used must be checked for any damages / defects prior to usage.
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
iv) INSPECTION ON BREAKAGE OF OPTICAL FIBERS (DRUM TEST):
Inspection on breakage of optical fibers / drum can be made before installation of the OPGW for site
by using Optical Time Domain Reflectometer (OTDR) setup.
1) First of all, check the appearance and marking of the drums
2) Check the sealing of the cable ends and spare cable caps
3) Carry out the physical inspection of cable assembly and check the continuity and attenuation of
optical fibres by OTDR.
4) The attenuation of the fibres shall be distributed uniformly throughout its length such that there
are no point discontinuities in excess of 0.1dB. The overall optical fibres attenuation should be
less than 0.21dB/km at 1550nm and 0.35dB/km at 1310nm.
b) INSTALLATION OF OPGW:
Important factors to be taken into account during stringing:
a) BASIC CONTROLS:
i) Strict controls must be established during installation to ensure that it is performed correctly,
without excess tension, twist of the OPGW, regulating a correct sagging. Neither the fibres nor
the tube will be damaged.
ii) The tensioner and the puller should be placed at a distance from the first tower pulley which is
equivalent to at least twice the height of the tower.
iii) Intermediate control points should be established, with the necessary precautions that are
required at critical points during installation (beginning / end of drum, angles, etc.).
iv) During installation, the OPGW cable should not strike nor graze any objects other than the
pulleys.
v) No obstacles must prevent the pulleys from rotating in the correct way.
b) STRINGING SPEED:
The maximum permissible stringing speed is 40 meters/minute with subject to depends on the
stringing conditions and must be reduced to avoid damages to the optical fibres, the tube and the
OPGW cable. Recommended Puller speed should be less than 1.5 Ton.
c) PULLING TENSION:
Recommended pulling tension to be < 1.5 times the weight (kg) of 1 km OPGW cable length.
d) COMMUNICATIONS DURING STRINGING:
The personnel located at the puller, the tensioner, the pulley crossings and the cable ends are in
communication at all times by communication system (Walkie ‐ Talkie).
e) BLOCK ATTACHMENT:
i) The tensile strength shall be added to block attachment wire for stringing.
ii) The pulley block on each tower must be earthed and grounding roller to be used on drum side
to ensure grounding of any induction current developed during installation.
f) SAGGING OF THE OPGW CABLE:
The specific recommendations f or OPGW are as follows:
i) Sagging is performed by a preformed fitting or tension clamp.
ii) At the time of sagging, the attachment fittings are also installed to prevent damage to the
OPGW cable.
iii) While holding of OPGW wire, exact size groove type clamp should be used for holding the rough
sag load of the OPGW wire.
iv) Over sagging for OPGW wire should not be done, as per sag chart only load should be taken to
avoid damage to the fibre inside & earth peak bend.
v) Once completed final sagging of each span, rollers shall be pulled down from tower through PP
rope arrangements.
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
vi) After completion of sagging and clipping, the surplus OPGW is to be laid temporary in the tower
body in coil (Diameter of coil is approximately 1.0 ‐ 1.5 m) and fixed on the tower. It is important
that precautions must be taken to prevent any damage of OPGW.
vii) While connecting the OPGW to down lead clamp bending radius should be maintained as
mentioned above otherwise fibres inside OPGW may get damage.
viii) Sealing of both ends to be done properly of OPGW cable, if Splicing / jointing work is not under
progress.
The sag measured span in the sagging area shall be basically decided to the following table:
i) Ensure that the 15‐20 meter extra cable should be kept at both end in addition to the tower
height for easy splicing / jointing work of OPGW in later stage.
NUMBER OF SPAN FOR NUMBER OF
SELECTION OF MEASURABLE SPAN
SAGGING SELECTION MEASURING SPAN
Longer span of center area
Less than 7 spans Not less than 3
& the span of both end
g) INSTALLATION OF FITTINGS A ND ACCESSORIES:
The fittings: tension clamps, suspensions, earthing clamps, dampers etc. should be installed in
accordance with the approved drawings and using the appropriate tools immediately after
completion of the final sagging, ensure that the OPGW cable should not bend more at clamping
portion.
NOTE: BE SURE TO INSTALL AND TIGHTEN THE BOLT OF HARDWARE FITTINGS BY USING A TORQUE WRENCH.
h) SPLICES:
After stringing and the optical measurements after installation the OPGW cable will be Spliced by
using splicing instrument. Proper care shall be taken to avoid misalignment of the fiber continuity.
i) SPLICES MEASUREMENT:
After splicing, each joint is optically verified using OTDR in order to ensure that the attenuation
values are within the required margins.
j) DOWN LEAD TO JOINT BOX POSITION:
Surplus length of OPGW is necessary to lead down from the strain clamp on the top of tower to
the joint box along with the arm and tower structures. The position of joint box is near the
bottom cross‐arm and excess OPGW shall be coiled in such a way that the OPGW remains above
the bottom cross‐ arm of the tower
D) SPLICING & POST INSTALLATION TEST:
a) After stringing and the optical measurements after installation the OPGW cable will be spliced.
b) For Measurement of attenuation, it should be ensure that dummy fibre length should not be less than
2Mtr for fine & good values.
c) MEASUREMENTS BEFORE OPGW CABLE INSTALLATION: Prior to OPGW cable installation / Store issue,
each optical fibre is verified using OTDR. Results of attenuation should be as per below
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
E) FINAL ACCEPTANCE TEST AT SITE:
After installation, a final measurement of the transmission characteristics is and the values are duly
recorded, the attenuation result should be as per estimated line attenuation.
a) End to End test through OTDR.
a) Maximum Attenuation @ 1550 nm : (0.21 dB/KM x Total KMS) +( 0.05 dB / Splice x No. of Splices) + (0.5 dB /
Connector x No. of Connectors)
b) Maximum Attenuation @ 1310 nm : (0.35 dB/KM x Total KMS) +( 0.05 dB / Splice x No. of Splices) + (0.5 dB /
Connector x No. of Connectors)
9.0 SAFETY / PRECAUTIONS:
Basic precautions shall be taken care during OPGW stringing:
a) Loading and unloading of OPGW drums shall be done using suitable arrangement / crane.
b) Ensure water shall not penetrate in to the OPGW cable.
c) Shutdown shall be arranged during paying out and till completion of final sagging activity.
d) Earthing shall be done at both the sides of phases before fixing the roller.
e) Both sides of the winch machine shall be earthed.
f) Once again cross verify the earth peak members before starting the stringing activity.
g) Grounding cable must be connected to the ground source first then to the object being grounded. When
removing grounds the ground must be removed from the grounded object first and then from the ground
source.
h) All site workers must follow the safety procedure while working at site. They must use safety belts, safety
shoe, safety helmet and other safety items required.
i) Equipment like OPGW, existing ground wire and pulley block are to be connected to Individual copper
cable and connect to the tower earthing. Grounding clamp shall be cleaned well and ensure proper
contact. Grounding is to be perfectly done to ensure safe level of working. Proper grounding is to be
ensured during operation like clamping work to avoid fault current likely to be encountered.
10.0 ACCEPTANCE CRITERIA
Conformity of Sag
Conformity of Attenuation before & after laying.
Conformity of Attenuation after Splicing.
Conformity of Attenuation after Completion of 60KM (Approx.) Stringing & Splicing.
Conformity of End to End Test by Power Meter.
11.0 RECORDS
OPGW Stringing Checklist
Attenuation Test Report (Drum Test, Before & after Splicing)
End to End Trace analysis (After completion of complete Line)
Link Test Report (End to End Report)
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
12.0 EQUIPMENTS :
Tensioner
Puller (3 to 5Mtr.)
Splicing Machine
Power Meter
Talk Kit
Other Tools & Tackles for Stringing
OTDR
13.0 COMPETENCE MATRIX :
Specialised Stringing Team
Expert Splicing Team
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
PROJECT NAME :
LOA NO. & DATE :
NAME OF EPC : M/s KEC INTERNATIONAL LTD.
OPGW STRINGING CHECKLIST
LOCATION NO. : ……..…… TO LOCATION NO. : …………..
SECTION LENGTH : …………………………………….
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
OPGW STRINGING CHECKLIST
CHECK LIST NO. : …………………………………
DATE : .………………………………..
1. PRE‐STRINGING CHECKS:
a) OPGW drum is being checked using OTDR & details recorded before laying / before dispatch Yes / No
from Store recorded as per as per annexure CF‐I.
b) All the materials, T&P, safety equipment’s and relevant drawings available for Stringing Yes / No
c) Necessary Protection / Scaffolding / Warning Signals provided for Railway / Power Line Yes / No
/ Road Crossing.
2. PAYING OUT & FINAL SAG CHECKS OF OPGW CABLE :
a) Work is being carried out as per safety guide lines. Yes / No
b) Paying out is carried out as per approved drum schedule. Yes / No
c) Effective communication exist s through Walkie ‐ Talkie between workmen Yes / No
available at towers.
d) Details of Hardware / fitting are recorded As per annexure CF ‐ II, Yes / No
e) All the accessories of jointing box are provided as per approved drawings Yes / No
through persons on towers.
f) Optical ground wire is being checked using OTDR after final sag & details recorded \ Yes / No
Before splicing as per annexure CF‐III.
g) Optical ground wire is being checked using OTDR after final sag & details recorded \ Yes / No
After splicing as per annexure CF‐IV.
h) Optical ground wire is being checked using OTDR after final sag & details recorded \ Yes / No
as per annexure CF‐V. (After 60 KM Approx.)
i) Spare cable are properly coiled & clamped on tower. Yes / No
FOR M/S
FOR M/S KEC INTERNATIONAL LTD.
SITE ENGINEER QA / QC SITE ENGINEER QA / QC
NAME NAME
SIGNATURE SIGNATURE
DESIGNATION DESIGNATION
DATE DATE
Certificate: ‐ Stringing is completed in all respects as per specification.
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
(ANNEXURE CF ‐ I)
OTDR DRUM TEST REPORT
REPORT NO. : KEC / STORE / OTDR / IR / --- DATED:
Name of Contractor : M/s KEC International Ltd. (T & D Division)
Name of Client :
Project Details :
Drum No. / Actual Drum Length :
Date of Testing :
Test Equipment Details :
Actual
Spool Attenuation
Tube Fiber Fiber Length Fiber ` @1310
Length @ 1550 Remarks
Colour Number Colour (Meter) Length (db / km)
(Meter) (db / km)
(Meter)
1 BLUE
2 ORANGE
3 GREEN
4 BROWN
5 GRAY
BLUE
6 WHITE
7 RED
8 BLACK
9 YELLOW
10 VIOLET
11 PINK
12 AQUA
13 BLUE
14 ORANGE
15 GREEN
16 BROWN
17 GRAY
ORANGE
18 WHITE
19 RED
20 BLACK
21 YELLOW
22 VIOLET
23 PINK
24 AQUA
(ANNEXURE CF ‐ II)
DETAILS OF HARDWARE FITTINGS
SR. NO.: ………..
DATE: …………….
a) MAKE :
b) BATCH NO. :
DETAILS OF TENSION CLAMP / FITTINGS
SR. QUANTITY
LOCATION NO. REMARKS
NO. (IN SETS)
DETAILS OF SUSPENSION CLAMP / FITTINGS
SR. QUANTITY
LOCATION NO. REMARKS
NO. (IN SETS)
Page 1 of 2
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
DETAILS OF VIBRATION DAMPER
SR. QUANTITY
LOCATION NO. REMARKS
NO. (IN SETS)
c) All Components of clamps have been provided as per approved drawings. YES / NO
Dimensions and galvanizing are Ok clamp is cleaned and there is no damage
to any component.
d) All Nuts & bolts have been properly tightened. YES / NO
e) Spilt pins have been properly fixed. YES / NO
FOR M/S KEC INTERNATIONAL LTD. FOR M/S
SITE ENGINEER QA / QC SITE ENGINEER QA / QC
NAME NAME
SIGNATURE SIGNATURE
DESIGNATION DESIGNATION
DATE DATE
PAGE 2 of 2
STANDARD WORKING METHODOLOGY DOCUMENT NO. KEC‐Q‐SOP‐020
(ANNEXURE CF ‐ III)
OTDR SITE TEST REPORT POST INSTALLATION (BEFORE SPLICING)
6 WHITE
7 RED
8 BLACK
9 YELLOW
10 VIOLET
11 PINK
12 AQUA
13 BLUE
14 ORANGE
15 GREEN
16 BROWN
17 GRAY
ORANGE
18 WHITE
19 RED
20 BLACK
21 YELLOW
22 VIOLET
23 PINK
24 AQUA
(ANNEXURE CF ‐ IV)
OTDR SITE TEST REPORT POST INSTALLATION (AFTER SPLICING)
6 WHITE
7 RED
8 BLACK
9 YELLOW
10 VIOLET
11 PINK
12 AQUA
13 BLUE
14 ORANGE
15 GREEN
16 BROWN
17 GRAY
ORANGE
18 WHITE
19 RED
20 BLACK
21 YELLOW
22 VIOLET
23 PINK
24 AQUA
(ANNEXURE CF ‐ V)
OTDR SPAN TESTING (AFTER 60KM.APPROX. STRETCH SPLICING)(END TO END)
6 WHITE
7 RED
8 BLACK
9 YELLOW
10 VIOLET
11 PINK
12 AQUA
13 BLUE
14 ORANGE
15 GREEN
16 BROWN
17 GRAY
ORANGE
18 WHITE
19 RED
20 BLACK
21 YELLOW
22 VIOLET
23 PINK
24 AQUA
(ANNEXURE CF ‐ VI)
END TO END LINK TEST TRPORT