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Fiber Optic Installation and Maintenance

S V Deshmukh, H A Atre, Santosh Wangde, D B Rane

Tata Power Co. Mumbai, India

Abstract-- The paper deals with the installation and

maintenance of Optical Guard Wire (OPGW) laid on Extra High
Voltage (EHV) Transmission Lines of a major utility in Mumbai,
India i.e. Tata Power. Since teleprotection of EHV transmission
lines through reliable communication significantly improve the
reliability of power supply to consumers, the optical guard wire
network needs to be installed on the transmission lines. The
paper also covers the practical experience of the authors and
shares the best installation and maintenance practices and
measures to reduce the down time of the network.
Index Terms- OPGW, Attenuation, Chromatic Dispersion,
Cladding, Dispersion, Radius of Curvature, Bonding, Cleating.

I. INTRODUCTION
Tata Power Company is in the field of Generation,
Transmission and Distribution of Electric Power since 1916 in
Mumbai, India. It has an overhead transmission network of
about 1200 circuit kms of 22 kV, 110 kV and 220 kV lines. It
was the first utility in India to install Fiber Optic in year 1987
on its 220 kV Trombay Carnac lines for SCADA operations.
Since then there is a rapid growth in the fiber optic network
and OPGW is now widely installed on Transmission Lines.
Tata Power has a fiber optic network of about 350 kms having
two to ninety six fibers in guard wire of same diameter.
Optical Guard Wire consists of optical fibers and is covered
by steel conductor. Optical fiber consists of Glass Core of
about 9 microns in diameter surrounded by a coating called
Cladding. It gives a secured communication channel with
large traffic capacity, free from electromagnetic interference,
induced voltages and atmospheric disturbances which are
normally experienced in utility operational environment.
OPGW serves a dual purpose of shielding the overhead line
and also as a communication / Information Expressway
because of its capacity to transmit high volume of data with
the available Right of Way of overhead lines. This
expressway is used for automation of electrical network and
business IT applications to improve overall efficiency of
business. These applications require 99.99% availability of
communication system for better and quick decision making.
To achieve this level of availability, one needs to build
reliability aspect of communication infrastructure during all
three stages of the system i.e. Design, Installation and
maintenance.
Redundancy of fibers & circuits, selection of right
equipments (OPGW and end equipments) and proper jointing
techniques are major aspects which need to be emphasized in
design stage for best results in long run.

978-1-4577-0567-0/11/$26.00 2011 IEEE

The key area for OPGW is the installation technique during

which utmost care is to be taken to prevent any damage to the
OPGW, adequate tension as per the sag tension charts is
applied and all the accessories are properly installed. Any
deviation to the construction methodology affects the
performance of the OPGW.
The maintenance of OPGW is also to be carried as per the
specified norms.
The OPGW is exposed to various
atmospheric conditions hence in saline and polluted
atmosphere the rate of deterioration is very rapid which results
in unwarranted failure and disruption.
II. OPTICAL FIBER CONSTRUCTION
An optical fiber is composed of two basic parts; the core and
cladding made of an optically transparent material (e.g. fused
silica glass) and the coating.
The core is in the centre of the optical fiber and is used to
guide the light due to difference in refractive index of core
and cladding. At their interface (core / cladding) the modes
are kept in the core of the optical fiber by total internal
reflection.
The coating is the layer applied directly to the cladding
surface during production. It must be removable for light
coupling in and out of the fiber or for jointing fibers. It can be
composed of several layers of plastic and must be applied
evenly over the entire length without bare spots or variations
in thickness. The coating may be colored and if necessary
may have additional ring markings for identification. It has a
refractive index higher than that of the cladding hence the
undesirable light launched into the cladding is absorbed in the
plastic within a few meters.
Mechanically the coating should protect the optical fiber
from external influences and absorb shear forces which might
bend the fiber in the micro range and thereby cause additional
attenuation.
Following Reliability Centric Design Practices for Optical
Fiber based network Infrastructure are recommended:
a) Room Condition: High Speed digital device requires
controlled operating condition.
Design of
communication room should be done to take care of
system heat load, dust proofing, cable inlet and trays.
b) Fan less Devices: Having high operating temperature
range (about 500C) are preferred for critical nodes
and links.
c) Adequate margin of transmission signal level and
input power supply (minimum +/- 10% typical
voltage) needs to be specified in design.
d) Redundancy in important sections like control unit
section (CPU), trans receiver section and power

supply section shall be built in for important critical

backbone nodes
e) Proper termination for field cable system and panel
ground shall be studied as part of panel design.
f) Device hardware configuration (like CPU speed,
Backplane capacity memory & buffer sizes etc.) and
software architecture needs to be studied for
reliability aspects during device selection.
g) Common failure point in network link devices and
modules shall be studied and network shall be
designed and configured to avoid communication
services failure
III. OPGW INSTALLATION
Prior to installation of OPGW, following prerequisites are
to be performed.
A. Visual Inspection
OPGW cable drum should be visually inspected after
receiving to ensure that no damage has occurred during
transportation. Nameplate information such as reel numbers,
length, outer diameter and other details should be checked to
ensure that the materials delivered are as per the requirement.
B. Handling
The reels should be removed from the delivery vehicle by
means of safe and proper lifting practices employing the use
of forklift trucks, cranes or hoists adequate for handling of the
reel(s) from a weight and size perspective.

Handling should be accomplished such that the

equipment used does not come in contact with the
cable surface.
Straps, chains or cables must never be wrapped
around the lagging.
The reels should not be rolled or dragged off the
transport vehicle. Rolling of reels on a flat surface for
a short distance can be permitted, but direction of
rolling should be same as winding direction of
OPGW.
The forks of the lift truck must never be used to push
the reels. The forks should be positioned under both
flanges from the side of the reel and must be long
enough to extend across the complete width of the
reel.
The cable ends should always be kept sealed to
prevent moisture ingress.
If cranes or hoists are used, either a cradle supporting
the reel flanges or a solid steel shaft through the
arbor hole should be used in conjunction with a
spreader bar to prevent the chains/cables from
crushing the reels. Only one reel should be lifted at a
time.
Reels must be transported and stored in an upright position
on the edges of the flanges at all times. The reels must never
be laid with the face of the flange flat against the ground. In
case the reels are required to be stored for a long time before

installation starts, it is recommended that the reels should be

kept indoors for protection of the cable as well as the reels.
C. Pre-installation (OTDR) Testing
It is recommended that the continuity / attenuation of all
fibers for each reel be checked upon receipt of the material.
Both ends of the cable are readily accessible on each reel. The
OTDR testing should be bi-directional (from both ends).
After completion of this test, the cable ends should be resealed against water entry. This practice should be observed
after each subsequent test at each stage of the installation.
Plastic caps are supplied for this purpose with each reel and
these should be secured using PVC tape.
D. Positioning of equipments for installation
a) Drum
Drum is always positioned in such a way that the cable
outlet is on the upper side of the drum & aligned with
the planned laying direction. Drum is placed at a
distance of about 2-3 meters from tensioner. The reel
diameter should be at least 80 times the diameter of
cable.
b) Tensioner & Puller
The tensioner and puller should be kept aligned with
the conductor and at a distance equal to or greater than
twice the height of the tower.
c) Rollers and Pulleys
All rollers and pulley grooves should be protected with
Neoprene or similar protective coating. Minimum
diameter of rollers should be 800mm in following cases
i) For change in laying direction greater than 150.
ii) On first and last tower in a pull.
iii) If the distance between two towers is greater than
600m.
iv) In all other cases roller with diameter of 600m can be
used.
d) Other Accessories
The pulling grip for OPGW pulling should be
minimum 1.5m long and specifically designed for
OPGW stringing.
E. Optical Fiber Guard Wire Stringing
a)Pilot wire paying out
The pilot wire / PP rope drums are kept on one end of
the section where paying out is to be carried out. The
pilot / PP rope is pulled either by hand or tractor till it
reaches the tower. It is then lifted and put in the aerial
roller. This process is repeated till the pilot reaches
the end of the section. One end of the pilot is fixed to
the puller and the other to the articulated joint
(swivel), which in turn is connected to the pulling
socks.
b)OPGW paying out
The OPGW is passed through the Tensioner drums.
The OPGW is inserted into the pulling socks. Both the
puller and the Tensioner are started simultaneously.
Constant communication is essential during the paying
out. The pulling tension should not exceed 1,000 Kgs.
during paying out. Before starting the paying out, a

mark is put on the OPGW to identify the length of the

OPGW leading down the tower body.
c)Final Sagging
After paying out is completed, final sagging operation
is carried out. Suitable length of OPGW is kept on
both the sides for joint purpose. OPGW is fixed with
the help of protection spiral and tension grip. The
OPGW is pulled with the help of sagging winch /
puller till the required sag is obtained. Sag boards are
fixed before final sagging is carried out.
d)Clipping
After final sagging is completed, clipping work is
started. Necessary suspension fittings are fixed on the
OPGW and hooked on the tower peak. Vibration
dampers are provided at a specified distance and
tightened with the help of torque wrench.
e)Cleating & Bonding
At all the locations i.e. Suspension & Tension, the
OPGW is bonded to the tower part. This helps in
reducing the tower footing resistance and also the
impact of fault current during line tripping. The
OPGW on joint locations is required to be cleated
through down lead clamps in order to avoid swinging
of OPGW and protect from damage. Any loose contact
with tower structure should be avoided.
F. General Guide Lines/ Precautions to be Observed During
OPGW Stringing
a) The minimum bending radius of OPGW is 40 times its
diameter. Hence all rollers utilized for running of
OPGW needs to have a diameter of 600 mm.
b) OPGW is required to be strung with tension stringing
equipment only, for which, Tensioner bull wheel
diameter should not be less than 1,000 mm with instant
braking available. Also the Tensioner available should
have maximum pulling tension up to 3,000 Kgs. and
auto trip for exceeding the tension set at predetermined value. The speed of the paying out should
not exceed 60 meter / min.
c) OPGW conductor is manufactured as per the lengths
based on the span chart for the line, and therefore, it is
essential to check the drum lengths corresponding to
the span lengths prior to its shifting to site. OPGW
drums should be loaded / unloaded with the help of
crane.
d) Rollers installed on the tower peaks should be friction
free and should not touch the tower body at any point.
It may, therefore, be necessary to provide gin poles of
suitable height to install the rollers, so that OPGW will
not rub and get damaged against any metallic part.
e) A suitable braid on braid rope / polypropylene rope /
swedge type messenger (10 / 12 mm dia.) wire rope
will be run, which should be in good condition and
tested for tension up to 5,000 Kgm.
f) The rope / messenger wire will be attached to OPGW
conductor with suitable sock and swivel with free
movement. The sock used will be of proper size and
secured firmly.

g)

h)

i)
j)

VHF (walkie-talkie) communications at Tensioner and

puller end is a must to co-ordinate proper pulling.
Also VHF sets minimum two numbers in spans should
be provided.
Tensioner and puller should normally be positioned in
the straight line alignment. OPGW drums lifting jacks
and axle to be of suitable capacity and size and must
be positioned in time with the Tensioner. The puller
and Tensioner should be kept at least 2H meters from
the tower, where H is the height of the tower.
When OPGW pulling end reaches the end tower, it
should be pulled sufficiently to reach the ground + 5
Mtrs. additional.
OPGW to be tensioned as per tension stringing chart
provided and with the help of tension grip only. No
come along clamps of any type shall be used on
OPGW.

G. Installation / Commissioning of Fibers Based Network

If Proper installation is not done, network made up of best
devices are prone to failure. Following aspects need to be
considered during installation / commissioning
a)
b)
c)

d)
e)
f)

Jointing of fibers should be of high quality. The fiber

should be cut at exactly perpendicular to its axis so as
to reduce losses.
Proper grounding of device / equipment and panels
must be done. Separate earth pit for electronic system
is preferred.
Termination of all signal cable with proper connectors
/ lugs as specified by OEM need to be done. For high
speed Ethernet based network proper structural cabling
needs to be installed. It is preferred to have all cabling
components from same manufacturer to get best
performance.
For inter panel and inter room proper armoured cables
must be used.
All cabling should be tagged and harnessed properly
for faster identification and isolation during fault.
All panel inlets and room inlets must be sealed to
avoid any failure due to rodents.
IV. OPGW MAINTENANCE

A properly designed and constructed OPGW network will

require minimum maintenance. However the basic function of
OPGW is to shield the Transmission lines, hence OPGW and
its accessories are prone to withstand the transmission line
faults and hence should be inspected after any line tripping /
lightning surges and also during routine patrolling of overhead
lines.
A. Probable defects
a)

Failure in bonding connection at the conductor and / or

tower end due to improper bonding, atmospheric
corrosion etc.
b) Damage to OPGW due to discharge of induced voltage,
direct lightning stroke corrosion inside down lead
clamps, as in Figure 1

c) Damage to suspension & tension fittings, as in Figure 2

d) Theft of joint box and OPGW conductor in the loop.

Fig. 1. Damage to OPGW

d)

In case the OPGW is damaged in the mid span it is

required to be lowered for inspection. OPGW is
released from the joint locations where spare
conductor is available. In such case all precautions as
taken during installation are to be taken. If the aldrey
alloy strands are damaged (only one or two) then we
can apply quick setting epoxy material to prevent
water penetration but if the damage is more it is
advisable to replace the OPGW in that span with two
additional joints.

C. Maintenance of Optical Fiber Equipment

Following aspects need to be considered during
maintenance of Optical Fibers Equipment
a) All devices which are more prone to dust
like fan based devices; frequent periodic
preventive maintenance is required.
b) Keeping adequate spares at site to restore
the system faster and reduce the down time
c) Use of Network Management System for
remote management analysis of network
level problems and to maintain schedule
back up.
V. CONCLUSION

Fig. 2. Damage to tension grip.

Tata Power Company has a wide experience of maintaining
OPGW to achieve maximum reliability for last twenty three
years. However, following problems were experienced
wherein damage to OPGW was noticed. There were about
three failures during the past twenty three years wherein at
two occasions there was attempted theft where the restoration
time was about two hours and at one occasion when the
conductor had parted the restoration time was about eight
hours.
B. Attending Defects
a) The normal defects reported are corrosion of hardware
fittings used for bonding the OPGW to the ground.
This is be attended by cleaning and polishing the
connections and replacing the damaged components
like PG Clamps, bonding conductor and connection at
tower end.
b) The suspension / tension assembly components cotter
pins / rivets if corroded are replaced.
c) The cleat bolts at joint locations also become loose due
to wear & tear the same can be tightened.

OPGW installation and maintenance is a challenge to the

utility which can be well accepted if the basic design,
installation and commissioning is executed in a focused
manner. The protection to the transmission lines with fiber
optic based equipments can give desired performance. The
fiber optic based communication network and broadband
efficiency depends upon the high end quality of design,
installation and maintenance of the equipments provided to
serve the customers. This paper has tried to briefly cover the
practical hands on aspects of fiber optic installation and
maintenance.

VI. REFERENCE:
Books:
[1]

Fundamentals Cable Technology Installation Practice Gnter Mahlke

and Peter Gossing

Technical Reports:
[2]

S. A. Deshmukh (2010, Apr.) report on OPGW stringing on Bhivpuri

Headworks lines.

Standards:
[3]

IEC 60794-4-1 Optical fiber cables Aerial optical cables for high
voltage power lines.
[4] IEC 60793-1 Optical fibers - Part 1 Generic Specifications
[5] IEC 60793-2 Optical fibers - Part 2 Product Specifications
[6] IEC 60104 An Aluminium-Magnesium-Silicon alloy wire for overhead
line conductors.
[7] IEC 61232 Aluminium clad steel wires for electrical purposes.
[8] IEC 61089 Round wire concentric lay overhead electrical stranded
conductors.
[9] IEEE Std. 1138 IEEE standard construction of composite fiber optic
overhead ground wire.
[10] ITU-G 652D Characteristics of a single mode optical fiber cable.

VII. BIOGRAPHIES

Sandeep Deshmukh was born in India, on December,

17 1961. He completed his LEE from Victoria Jubilee
Technical Institute,
Mumbai, India.He has an
employment experience of 29 years with Tata Power Co.
Ltd. Mumbai. His special interest is in the field of
Transmission Line Design, Engineering, Construction
and Maintenance. He has contributed technical papers at
IEEE & CIGRE forums.

Santosh Wangde was born in India, on March 26, 1976.

He graduated from the Thadomal Sahani Engineering
College, University of Mumbai, India.His employment
experience included the Tata Power Co. Ltd. Mumbai as
Telecom engineer. His special fields of interest included
Network planning.

H. A. Atre was born in India, on October 16, 1964. He

completed Diploma in Elecrical Engineering from Shree
Bhagubhai Mafatlal Polytechnic, Mumbai. He has an
employment experience of 25 years with Tata Power
Company in the fields of thermal generating station and
operation and maintenance of overhead transmission
lines.

D B Rane was born in India , on Jan 4, 1953. He

graduated from College of Engineering Amaravati and
studied at the University of Nagpur. He completed his
Post Graduation in Electrical Engineering from Indian
Institute of Science-Bangalore. His employment
experience of 35 years in Tata power includes Testing
and commissioning of Power Plants, Engineering Design
of EHV switch yard, Transmission schemes, GIS and
associated equipments, Projects, Consumer Engineering
and Consumer management, Regulation. His special fields of interest are in
EHV power transmission.