TECHNICAL DESCRIPTION OF GALVANIZED STEEL EARTH WIRE.

TECHNICAL DESCRIPTION OF GALVANIZED STEEL EARTH WIRE

Details of Earth Wire

The galvanized steel earth wire shall generally conform to the specification of ACSR core
wire as mentioned in IS: 398 (Part-II)-1976 except where otherwise specified herein.
The
(i) details of the earth wire for 220 kV are tabulated below:
(a) Stranding and wire : 7/3.35 mm steel diameter
(b) Number of strands
− Steel core :1
− Outer steel layer :6
(c) Total sectional area : 73.65 sq mm
(d) Overall diameter : 10.05 mm
(e) Approximate weight : 550 kg/km
(f) Calculated D.C. resistance : 2.5 Ohms/km at 20 deg. Centigrade
(g) Minimum ultimate tensile : 68.4 kN strength
(h) Direction of lay of : Right hand outer layer

Workmanship

General

All steel strands shall be smooth, uniform and free from all imperfections, such as spills and
splits, die marks, scratches, abrasions and kinks after drawing and also after stranding.
The finished material shall have minimum brittleness as it will be subjected to appreciable
vibration while in use.
The steel strands shall be hot dip galvanized and shall have minimum, Zinc coating of 275
gms/sq m after stranding. The zinc coating shall be smooth, continuous, of uniform
thickness, free form imperfections and shall withstand three and half dips after stranding in
standard Preece test. The steel wire rod shall be of such quality and purity that, when drawn to
the size of the strands specified and coated with zinc, the finished strands shall be of
uniform quality and have the same properties and characteristics as prescribed in ASTM
designation B498-M.
The steel strands shall be preformed and post formed in order to prevent spreading of
strands while cutting of composite earth wire. Care shall be taken to avoid damage to
galvanization during preforming and postforming operation.
To avoid susceptibility towards wet storage stains (white rust), the finished material shall be
provided with a protective coating of boiled linseed oil.

Page 4.1.6A–1
 Joints in Wires

There shall be no joints of any kind in the finished steel wire strand entering into the
manufacture of the earth wire. There shall be no strand joints or strand splices in any length of
the completed stranded earth wire.

6A.2.3 Tolerances

The manufacturing tolerance to the extent of the following limits only shall be permitted in the
diameter of the individual steel strands and lay length of the earth wire:

–
(ii)for 7/3.35 mm size Earth wire:
Standard Maximum Minimum
Diameter 3.35 mm 3.43 mm 3.31 mm
Lay length 181 mm 198 mm 165 mm

Materials
(a) Steel
The steel wire strands shall be drawn from high carbon steel rods and shall conform to the
following requirements as to the chemical composition:

Element % Composition
Carbon Not more than 0.55
Manganese 0.4 to 0.9
Phosphorous Not more than 0.04
Sulphur Not more than 0.04
Silicon 0. 15 to 0.35

(b) Zinc
The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity. It shall
conform to and satisfy all the requirements of IS: 209.

Standard Length
The standard length of the earth wire shall be 2000 meters. The tolerance on length shall be
± 5% on the standard length.
Random length will be accepted provided no length is less than 70% of standard length and the
total quantity of random lengths is not more than ten (10) percent of the total quantity in each
shipment.

Page 4.1.6A–2
Tests and Standards

Type Tests

Type Tests on Earth wire

The following tests shall be conducted once on a sample of earth wire.

(a) UTS test

As per Sub-
(b) DC resistance test Clause 6A.8

6A.5.2 Acceptance Tests on Earth wire

(a) Visual and dimensional check on

drum
(b) Visual check for joints scratches etc.
and lengths of earth wire
As per Sub-
(c) Dimensional check
Clause 6A.8
(d) Lay length check
(e) Galvanizing test
(f) Torsion test
(g) Elongation test
IS: 398 (Part-II)
(h) Wrap test
(i) DC resistance test
IS: 398 (Part-II)
(j) Breaking load test
(k) Chemical Analysis of stee As per Sub-
Clause 6A.8

Routine Tests

Routine Tests on earth wire shall be:

(a) Check for correctness of stranding
(b) Check that there are no cuts, fins etc. on the strands. (c) Check that drums are as per
Specification.

6A.5.4 Tests During Manufacture

(a) Chemical analysis of zinc used for

galvanizing As per Sub-
Clause 6A.8
(b) Chemical analysis of steel

Page 4.1.6A–3
 Testing Expenses

The break-up of the testing charges for the type tests specified shall be indicated separately.
Tenderer s shall indicate the laboratories in which they propose to conduct the type tests.
They shall ensure that the tests can be completed in these laboratories within the time
schedule guaranteed by them.
In case of failure in any type test the Contractor is either required to manufacture fresh
sample lot and repeat all the tests successfully once or repeat that particular type test three
times successfully on the sample selected from the already manufactured lot at his own
expenses. In case fresh lot is manufactured for testing then the lot already manufactured
shall be rejected. The decision of the Engineer in this regard shall be final and binding on
Contractor.
The entire cost of testing for the acceptance and routine tests and tests during manufacture
specified herein shall be treated as included in the quoted unit price of earthwire except for the
expenses of the Employer's/Engineer's representative.
In case of failure in any type test, repeat type tests are required to be conducted, then all the
expenses for deputation of Employer's/Engineer's representative shall be deducted from the
contract price. Also if on receipt of the Contract's notice of testing the Employer's/Engineer's
representative does not find ‘materials and facilities’ to be ready for testing, the expenses
incurred by the Employer/Engineer for redeputation shall be deducted from the contract
price.

Additional Tests

The Employer/Engineer reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Contractor’s premises, at site, or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
materials comply with the Specifications.
The Employer also reserves the right to conduct all the tests mentioned in this specification at
his own expense on the samples drawn from the site at Contractor’s premises or at any other
test center. In case of evidence of non compliance, it shall be binding on the part of
Contractor to prove the compliance of the items to the technical specifications by repeat
tests, or correction of deficiencies, or replacement of defective item all without any extra cost to
the Employer.

6A.5.7 Sample Batch for Type Testing

The Contractor shall offer material for selection of samples for type testing only after
approval of the Quality Assurance Plan. The sample shall be manufactured strictly in
accordance with the Quality Assurance Plan approved by Engineer.
The Contractor shall offer at least three drums for selection of sample required for
conducting all the type tests.
The Contractor is required to carry out all the Acceptance tests successfully in presence of
Employer’s/Engineer's representative before sample selection.

Page 4.1.6A–4
6A.5.8 Test Reports

Copies of type test reports shall be furnished in at least six copies along with one original.
One copy will be returned duly certified by the Engineer only after which the commercial
production of the material shall start.
Record of routine test reports shall be maintained by the Contractor at his works for periodic
inspection by the Employer's/Engineer's representative.
Test Certificates of tests during manufacture shall be maintained by the Contractor. These
shall be produced for verification as and when desired by the Engineer.

6A.5.9 Inspection

The Employer's/Engineer's representative shall at all times be entitled to have access to the
works and all places of manufacture, where earth wire shall be manufactured and
representative shall have full facilities for unrestricted inspection of the Contractor’s works,
raw materials and process of manufacture for conducting necessary tests as detailed herein.
The Contractor shall keep the Engineer informed in advance of the time of starting and of the
progress of manufacture of earth wire in its various stages so that arrangements can be
made for inspection.
No material shall be despatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the Engineer in
writing. In the latter case also the earth wire shall be despatched only after satisfactory
testing for all tests specified herein have been completed.
The acceptance of any quantity of material shall in no way relieve the Contractor of any of his
responsibilities for meeting all requirements of the Specification, and shall not prevent
subsequent rejection if such material is later found to be defective.

6A.5.10 Test Facilities

The following additional test facilities shall be available at the Contractor’s works:
(a) Calibration of various testing and measuring equipment including tensile testing
machine, resistance measurement facilities, burette, thermometer, barometer etc.
b) Standard resistance for calibration of resistance bridges.
(c) Finished Earth wire shall be checked for length verification and surface finish on
separate rewinding machine at reduced speed (variable from 8 to 16 meters per
minute). The rewinding facilities shall have appropriate clutch system and free of
vibrations, jerks etc., with traverse laying facilities.

6A.6 Transportation of Earth Wire

6A.6.1 Packing

The Earth wire shall be supplied in non-returnable, strong, wooden drums and provided with
lagging of adequate strength, constructed to protect the Earth wire against all damage and
displacement during transit, storage and subsequent handling and stringing operations in the
field. The Contractor shall be responsible for any loss or damage during transportation

Page 4.1.6A–5
handling and storage due to improper packing. The drums shall generally conform to IS:
1778-1980, except as otherwise specified hereinafter.
The drums shall be suitable for wheel mounting and for letting off the earth wire under a minimum
controlled tension of the order of 5 kN
The general outline of the drum for Earth wire shall be as per annexed drawing. The
Contractor should submit their proposed drum drawings along with the bid. For Earth wire, two
standard lengths shall be wound on each drum.
For Earth wire, each strand shall be individually welded to prevent parting of two lengths at a
tension less than 15 kN. The two ends where the first length finishes and the second length
starts, shall be clearly marked with adhesive tape and no weld should be present outside
these marks. The length between the two marks shall be treated as scrap and will not be
taken into account for measurement purposes.
All wooden components shall be manufactured out of seasoned softwood free from defects
that may materially weaken the component parts of the drums. Preservative treatment shall be
applied to the entire drum with preservatives of a quality which is not harmful to the earth wire.
The flanges shall be of two ply construction with each ply at right angles to the adjacent ply
and nailed together. The nails shall be driven from the inside face flange, punched and then
clenched on the outer face. The thickness of each ply shall not vary by more than 3 mm
from that indicated in the figure. There shall be at least 3 nails per plank of ply with maximum nail
spacing of 75 mm. Where a slot is cut in the flange to receive the inner end of the earth wire
the entrance shall be in line with the periphery of the barrel.
The wooden battens used for making the barrel of the earth wire shall be of segmental type.
These shall be nailed to the barrel supports with at least two nails. The battens shall be
closely butted and shall provide a round barrel with smooth external surface. The edges of the
battens shall be rounded or chamfered to avoid damage to the earth wire.
Barrel studs shall be used for the construction of drums. The flanges shall be holed and the
barrel studs shaft be threaded over a length on either end, sufficient to accommodate
washers, spindle plates and nuts for fixing flanges at the required spacing.
Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the
inner surface of the flanges and the drum barrel shall be counter sunk. The ends of barrel
shall generally be flushed with the top of the nuts.
The inner cheek of the flanges and drum barrel surface shall be painted with a bitumen
based paint.
Before reeling, cardboard or double corrugated or thick bituminous waterproof bamboo
paper shall be secured to the drum barrel and inside of flanges of the drum by means of a
suitable commercial adhesive material. After reeling the earth wire, the exposed surface of the
outer layer of earth wire shall be wrapped with water proof thick bituminous bamboo paper
to preserve the earth wire from dirt, grit and damage during transport and handling.
A minimum space of 50 mm for earth wire shall be provided between the inner surface of the
external protective lagging and outer layer of the earth wire.
Each batten shall be securely nailed across grains as far as possible to the flange, edges
with at least 2 nails per end. The length of the nails shall not be less than twice the thickness of
the battens. The nails shall not protrude above the general surface and shall not have exposed
sharp edges or allow the battens to be released due to corrosion.

Page 4.1.6A–6
The nuts on the barrel studs shall be tack welded on the one side in order to fully secure
them. On the second end, a spring washer shall be used.
Outside the protective lagging there shall be minimum of two binder consisting of hoop
iron/galvanized steel wire. Each protective lagging shall have two recesses to accommodate the
binders.
The earth wire ends shall be properly sealed and secured on the side of one of the flanges to
avoid loosening of the earth wire layers during transit and handling.

6A.6.2 Marking

Each drum shall have the following information stencilled on it in indelible ink along with
other essential data
(a) Contract/Award letter number.
(b) Name and address of consignee. (c) Manufacturer’s name and address. (d) Drum
number
(e) Size of earth wire
(f) Length of earth wire in meters
(g) Gross weight of drum with earth wire & lagging
(h) Weight of empty drum with lagging
(i) Arrow marking for unwinding
(j) Position of the earth wire ends
(k) Distance between outer most layer of Earth wire and the inner surface of lagging
(l) Barrel diameter at three locations and an arrow marking at the location of measurement

6A.7 Verification and Standards

6A.7.1 Verification of Earth Wire Length

The Engineer reserves the right to verify the length of earth wire after unreeling at least ten
(10) percent of the drums in a lot offered for inspection.

6A.7.2 Standards

The earth wire shall conform to the following Indian/ International Standards, which shall
mean latest revisions, amendments/changes adopted and published, unless otherwise in the
Specification.
In the event of the supply of earth wire conforming to standards other than specified, the
Contractor shall confirm in his tender that these standards are equivalent to those specified. In
case of award salient features of comparison between the standards proposed by the Contractor
and those specified in these documents will be provided by the Contractor to establish their
equivalence

Page 4.1.6A–7
 International
Indian Standards Title
Standards
IS: 209-1992 Specification for Zinc BS: 3436-1986
IS: 398-1990 Specification for Aluminium Conductors IEC: 1089-1991
for Overhead- Transmission Purposes BS: 215-1970

IS: 398-1998 Part-II Aluminum Conductor Galvanised Steel BS-215-1970

Reinforced IEC: 1089-1991
IS: 398-1996 Part-IV Aluminum Alloy stranded conductor BS- 3242-1970
IEC: 1089-1991
ASTM-8399 M86
IS: 398-1992 Part-V Aluminium conductor Galvanised Steel- IEC:1089-1991
Reinforced for- BS: 215-1970
Extra High Voltage (400 KV) and above

IS: 1778-1997 Reels and Drums for Bare Conductors BS: 1559-1949
IS: 1521-1991 Method of Tensile Testing of Steel ISO: 6892-1984
Wire
IS: 2629-1997 Recommended Practice for Hot Dip
Galvanising of Iron and Steel
IS: 2633-1990 Method of Testing Uniformity of
Coating on Zinc Coated Articles
IS: 4826-1991 Galvanized coating on Round Steel IEC 888-1987
Wires BS: 443-1969
IS: 6745-1991 Methods of Determination of Weight of BS: 433-1969
Zinc Coating of ISO: 1460-1973
Zinc Coated Iron and Steel Articles
IS: 8263-1983 Method of Radio Interference Tests on 1EC: 437-1973
High Voltage Insulator NEMA: 107-1964
CISPR
IS: 9997-1991 Aluminium Alloy Redraw Rods IEC: 104-1987
Zinc Coated steel wires for stranded IEC: 888-1987
Conductors
Hard drawn aluminium wire for IEC: 889-1987
overhead line conductors
IS: 5714 Method of measurement of resistivity of
metallic materials
IS: 12776 Specification for galvanized strand for
earthing

Page 4.1.6A–8
6A.8 Tests on Earth wire

6A.8.1 UTS Test

Circles perpendicular to the axis of the earth wire shall be marked at two places on a sample of
earth wire of minimum 5 m length suitably compressed with dead end clamps at either end.
The load shall be increased at a steady rate up to 50% of UTS and held for one minute. The
circles drawn shall not be distorted due to relative movement of strands. Thereafter the load
shall be increased at steady rate to 100% of UTS and held for one minute. The earth wire
sample shall not fail during this period. The applied load shall then be increased until the
failing load is reached and the value recorded.

6A.8.2 DC Resistance Test

On a earth wire sample of minimum 5m length two contact clamps shall be fixed with a
predetermined bolt torque. The resistance shall be measured by a Kelvin double
bridge/digital micro meter by placing the clamps initially at zero meter and subsequently one
meter apart. The test shall be repeated at least five times and the average value recorded.
The value obtained shall be corrected to the value at 20oC. The resistance corrected at
20oC shall conform to the requirements of this Specification.

6A.8.3 Chemical Analysis of Zinc

Samples taken from the zinc ingots shall be chemically/ spectrographically analyzed. The
same shall be in conformity to the requirements stated in the Specification.

6A.8.4 Chemical Analysis of Steel

Samples taken from the steel ingots/coils/strands shall be chemically,/spectrographically

analyzed. The same shall be in conformity to the requirements stated in this Specification.

6A.8.5 Visual and Dimensional Check on Drums and Barrel Strength Test

The drums shall be visually and dimensionally checked to ensure that they conform to the
requirements of this Specification. The details regarding barrel strength test will be
discussed and mutually agreed to by Contractor and Engineer in the quality assurance
programme.

6A.8.6 Visual Check for Joints, Scratches etc. and Length of Earth Wire

Ten percent drums from each lot shall be rewound in the presence of the Engineer. The Engineer
shall visually check for scratches, joints etc. and see that the earth wire generally conforms to
the requirements of this Specification. The length of earth wire wound on the drum shall be
measured with the help of counter meter during rewinding.

Page 4.1.6A–9
6A.8.7 Dimensional Check

The individual strands shall be dimensionally checked to ensure that they conform to the
requirement of this Specification.

6A.8.8 Lay Length Check

The lay length shall be checked to ensure that they conform to the requirements of this
Specification.

6A.8.9 Galvanizing Test

The test procedure shall be as specified in IS: 4826-1979. The material shall conform to the
requirements of this Specification. The adherence of zinc shall be checked by wrapping
around a mandrel four times the diameter of steel wire.

6A.8.10 Torsion Test

The minimum number of twists which a single steel strand shall withstand during torsion test
shall be eighteen for a length equal to 100 times the standard diameter of the strand. In
case test sample length is less or more than 100 times the stranded diameter of the strand the
minimum number of twists will be proportioned to the length and if number comes in the
fraction then it will be rounded off to next higher whole number.

UTK Lot 4_V4.1-Sec06A_GSW_122402

Page 4.1.6A–10
 OPTICAL EARTH (GROUND) WIRE (OPGW)

Table of Contents
Page

6B.1 Scope of Work .............................................................................................. 1

6B.1.1 General ............................................................................................................... 1

6B.1.2 Works to be Provided by the Contractor.............................................................. 1

6B.1.3 Works to be Provided by Employer ..................................................................... 1

6B.2 Codes and Standards................................................................................... 2

6B.2.1 General ............................................................................................................... 2

6B.3 Technical Requirements .............................................................................. 3

6B.3.1 Description of Services ....................................................................................... 3

6B.3.2 Design Requirements ......................................................................................... 4

6B.3.2.1 General
.......................................................................................................................... 4
6B.3.2.2 Basic
Construction......................................................................................................... 4
6B.3.2.3 Central Fibre Optic Unit
................................................................................................. 5
6B.3.2.4 Optical Fibre
.................................................................................................................. 6
6B.3.2.5 Buffer Construction
........................................................................................................ 6
6B.3.2.6 Marking of
Fibres........................................................................................................... 6
6B.3.2.7 Maximum Working Tension and Ultimate Tensile Strength
.......................................... 7
6B.3.2.8 Splice
Box...................................................................................................................... 7
6B.3.2.9 Dead End Clamp Assembly
.......................................................................................... 8
6B.3.2.10 Suspension Clamp Assembly........................................................................................
8
6B.3.2.11 Damping System ...........................................................................................................
8
6B.3.3 Materials and Workmanship................................................................................ 9

6B.3.4 Stress-Strain and Creep Data ............................................................................. 9

6B.3.5 Sag/Tension Data ............................................................................................... 9

6B.3.6 Tools ................................................................................................................... 9

6B.3.7 OPGW Reels .................................................................................................... 10

6B.3.8 Preparation for Shipping and Storage ............................................................... 10

6B.3.9 Quality Assurance Requirements ...................................................................... 11

6B.3.10 Other Technical Requirements for OPGW ........................................................ 12

6B.4 Installation................................................................................................... 12

6B.5 Tests ............................................................................................................ 12

6B.5.1 General ............................................................................................................. 12

6B.5.2 Cable Tzests ..................................................................................................... 12

6B.5.2.1 Design
Tests................................................................................................................ 12
6B.5.2.2 Routine Tests
.............................................................................................................. 14
6B.5.3 Fibre Tests........................................................................................................ 15
6B.5.3.1 Design
Tests................................................................................................................ 15
6B.5.3.2 Routine Tests
.............................................................................................................. 15
6B.5.4 Field Tests ........................................................................................................ 17

6B.5.5 Test Reports ..................................................................................................... 17

6B.6 Data and Documentation Requirements................................................... 17

6B.6.1 General ............................................................................................................. 17

6B.6.2 Data and Information to be Submitted with the Tender ..................................... 18

6B.6.3 Data and Information to be Submitted After Award of Contract ......................... 18

6B.6.3.1 Data Submission Schedule
......................................................................................... 19
SECTION 6B T-S06-2A OPTICAL EARTH (GROUND) WIRE (OPGW)

6B.1 Scope of Work

6B.1.1 General

This specification covers the technical and associated requirements for Composite
Overhead Earth (Ground) Wires with Optical Fibres (OPGW) and their accessories, attachments,
splice materials and splice installation tools, for the use on overhead transmission
lines rated 110 kV and above.
It is not the intent to specify all technical requirements nor to set forth those requirements
adequately covered by applicable codes and standards. The Contractor shall furnish high
quality materials meeting the requirements of this specification and applicable industry
standards.
The Contractor shall bear the full responsibility that the OPGW have been designed and
manufactures in accordance with all standards and applicable regulations and perform under the
condition and to the standards specified herein.
No deviations shall be made from this specification and standards unless waived or modified in
writing by the Engineer. The Contractor shall obtain from its sub-contractor a statement as to
compliance with this specification without exception and/or if there are any exceptions, these
shall be described in detail and included in the Contractor’s Tender. The Contractor shall add
a statement that no other exceptions are taken to this specification.

6B.1.2 Works to be Provided by the Contractor

The Contractor shall provide the equipment, accessories and services specified in the Data
Sheets.

6B.1.3 Works to be Provided by Employer

The Employer shall provide the materials and services listed in the Data Sheets and Price
Lists.
The recommended optical earth/ground wire should comply with the physical properties
given in the table below.

Table 6B.1.3.1 Optical Earth Wire Properties

Specification Earth wire

Tension Wires ACS (Aluminium Clad Steel):
Suspension optical fibre wires Aluminium tubes, stainless steel or slotted
core
Minimum static bend diameter: 350 mm
Minimum Ultimate strength, Ref. UTS ACS Conventional ground wire
reference:
Minimum delivery length per drum: 4.0 km
 Specification Earth wire
Normal temperature range: 0 – 45 oC
Maximum temperature < 1.0 oC
180
second:

The Fibre Cable should comply with the physical properties in Table 6B.1.3.2 below.

Table 6B.1.3.2 Optical Fibre properties

Specification Earth wire

Fibre type Stand. single mode (ITU-T G652)
Coating diameter 245 ±10 µm
Coating concentricity error < 12.5 µm
Coating non-circularity <6%
Finished cable attenuation < 0.40 dB/km at 1310 nm
< 0.23 dB/km at 1550 nm
Minimum number of fibres 24
Normal temperature range 0 ... 45 oC
Maximum temperature < 1.0 sec. 160 oC
Lifetime expected 40 years

6B.2 Codes and Standards

6B.2.1 General

The OPGW furnished shall be in accordance with, but not limited to, the latest issues of the
following applicable standards and recommendations, including all addenda, in effect at time of
purchase order unless otherwise stated in this specification.

IEC - International Electrotechnical Commission Publications

60104 Aluminium-Magnesium-Silicon Alloy Wire for Overhead Line Conductors
60888 Zinc-Coated Steel Wires for Stranded Conductors
60889 Hard-Drawn Aluminium Wire for Overhead Lines
61089 Round Wire Concentric Laid Overhead electrical Stranded Conductors
61232 Aluminium-clad steel wires for electrical purposes
61395 Overhead electrical conductors - Creep test procedures for stranded conductors
62219 Overhead electrical conductors - Formed wire, concentric lay, stranded conductors
61284 Overhead lines - Requirements and tests for fittings
60304 Standard Colours for Identification and Coding
 60793 Optical Fibres. Measurement methods and test procedures
60794 Optical Fibre Cables. Specifications

ITU - International Telecommunication Union

G.650 Definitions and test methods
G.652 Characteristics of single-mode optical fibre and cable

ISO - International Standards Organization

Quality System Model for Quality Assurance in Design/ Development, Manufacture
9001
and Testing
Quality System Model for Quality Assurance in Production, Installation and
9002
Servicing

These codes and standards set forth minimum requirements which may be exceeded by the
Contractor if, in the Contractor's judgment and Engineer's acceptance, superior or more economic
designs or materials are available for successful and continuous operation of the Contractor's
materials as required by this specification.
In addition to the applicable standards, the Contractor shall comply with applicable national and
local laws, codes, regulations, statutes and ordinances.
The materials and services furnished shall comply with and not prevent compliance with all
applicable standards of the local codes.
It is the intent of this specification to allow supply of optical earth wires according to
International Standards (IEC, ISO, etc.). If the Contractor customarily produces the specified
optical earth wires of national standards other than mentioned, the Contractor shall describe the
equivalences and/or differences of such standards with his Tender. For any such
standards, which are not written in the English language, the Contractor shall make available
copies of an English translation thereof. In any event, the Contractor shall list all those
standards he proposes to use in the supply of the specified optical earth wire.
In the event of any apparent conflict among standards or theses specifications, the
Contractor shall refer the conflict to the Engineer for written resolution.

6B.3 Technical Requirements

6B.3.1 Description of Services

The composite fibre optic overhead ground wire covered by this specification shall be made up
of buffered flexible glass optical telecommunications fibres contained in a protective central
fibre optic unit surrounded by concentric-lay stranded metallic wires either in single or multiple
layers as required in the Data Sheets. It has a dual purpose of providing the electrical and
physical characteristics of conventional overhead ground wire and the optical transmission
properties of optical fibre. The supply of OPGW shall include all the required cable
accessories, hardware and components necessary for proper installation and operation
of the OPGW.
6B.3.2 Design Requirements

6B.3.2.1 General
The OPGW cable construction shall comply with the requirements set forth in the relevant
IEC publications.
The OPGW shall meet both the construction and performance requirements such that the ground
wire function, the optical fibre integrity and optical transmissions characteristics are suitable for
intended purpose.
The cable shall consist of multiple optical fibre units as stated in the Data Sheets. There
shall be no factory splices within the cable structure of a continuous cable length.
The OPGW shall withstand lightning, short circuit currents, induced currents and voltages
from the power conductors, and expected abnormal external conditions, as well as normal service
conditions, without impairment to the optical signal transmission or degradation of the optical
fibre specification for the lifetime of the project.
The complete OPGW shall have a design lifetime of at least 40 years of service.
The OPGW shall be grounded at each tower through jumper assemblies and approved
clamps to be used for connections.
The Contractor shall provide a written guarantee that the proposed OPGW to be supplied
shall be able to carry the specified fault current and its specified duration without causing
annealing, deformation degradation or damage to the stress carrying steel strands, the aluminium
protective coating, the aluminium-alloy wires if any, the central fibre optic unit encasing the
optical fibre and the supporting and guiding assembly (and any inserts and filling compounds
used) and the optical fibres.
The number, diameter and cross-section areas of the aluminium-clad steel wires and the
number of optical fibres shall comply with the requirements listed in the Data Sheets.

6B.3.2.2 Basic Construction

(a) General
The cable construction shall conform to the applicable requirements of this specification as
well as applicable clauses of IEC 1089 related to stranded conductors.
The basic construction shall have bare concentric-lay stranded metallic wires with the outer
layer having left-hand lay unless otherwise specified in the Data Sheets. The stranded wires
may be of multiple layers with a combination of various metallic wires within each layer. The
direction of lay shall be reversed in successive layers with the direction of the external layer
being left hand. The type of metallic wire that will be used shall be as stated in the Data
Sheets.
The overhead ground wire shall be so stranded that when the complete OPGW is cut, the
individual wires can be readily regrouped and then held in place by one hand. For multilayer
wires, the wires in each layer shall be evenly and closely stranded around the underlying
wire(s). The tension in individual wires in a layer shall be sufficient to hold each wire firmly in
place with only enough strand separation to prevent crowding at the time of stranding and
during installation.
The completed cable shall be uniformly cylindrical and shall withstand all handling during
manufacture, shipping and installation without being deformed from its cylindrical form in
such a way as to cause detrimental forces and stresses and/or damage to the encased
optical fibres.
The make-up and lay of wires shall be such as to produce a cable essentially free from a
tendency to untwist or spring apart when cut.
The completed composite overhead ground wires with optical fibre (OPGW) shall be smooth,
free from nick, burrs, aluminium, zinc or steel particles, dirt and excessive die grease. The
wire shall be absolutely free of copper dust and copper particles.
The finished wires shall contain no joints or splices unless otherwise approved by the
Engineer.

(b) Breaking Strength

The rated breaking strength of the completed OPGW shall be taken as no more than 90% of the
sum of the rated breaking strengths of the individual wires, calculated from their nominal
diameter and the specified minimum tensile strength.
The rated breaking strength shall not include the strength of the optical unit. The fibre optic
unit shall not be considered a load bearing tension member when determining the total rated
breaking strength of the OPGW.

6B.3.2.3 Central Fibre Optic Unit

(a) General
The central fibre optic unit shall be designed to house and protect multiple buffered optical
fibre units from damage due to forces such as crushing, bending, twisting, tensile stress,
moisture and water ingress. The central fibre optic unit and the outer stranded metallic conductors
shall serve together as an integral unit to protect the optical fibres from degradation
due to vibration and galloping, wind loading, wide temperature variations, lightning and
fault current, as well as environmental effects, which may produce hydrogen.
Depending on the requirements stated in the Data Sheets, the central fibre optic unit
encasing the optical fibres should be an aluminium tube, channelled aluminium rod or a
stainless steel tube.
For an aluminium and/or stainless steel tube, it may be fabricated as a seamless extruded
tube, seam welded or a tube without a welded seam.
For an aluminium rod, it may be fabricated with one or more channels or grooves and
formed into a helix to house the optical fibres. An outer protective shield may be applied
around the rod such as an aluminium tube or a helically applied overlapping aluminium tape to
provide an additional mechanical and environmental barrier.

(b) Filling Compound

The interstices of the fibre optic unit and cable shall be filled with a suitable compound to
prohibit any moisture ingress from outside or any water longitudinal migration along the fibre
optic unit or along the fibre optic cable. The water tightness of the cable shall meet or
exceed the test performance criteria as per IEC 60794. The filling compound to be used
shall be compatible with all the components it may come in contact with and shall absorb
and/or inhibit generation of hydrogen within the cable.
The filling compound shall not affect the colour of the primary or secondary coating, or
encapsulates commonly used in splice enclosures, shall be easily removed from the
secondary coating with a non-toxic cleaning solvent. The filling compound used shall be non-
toxic homogenous waterproofing gel that is free of dirt and foreign matter, non-hygroscopic,
electrically non-conductive, non-nutritive to fungus, free from all smell and shall not affect
human skin.

The filling compound shall remain stable for ambient temperatures between –20oC and
+80oC and shall not drip, flow or leak with age or at high temperature during short duration
lightning strikes and short circuit currents.

(c) Central Structural Member(s)

Structural member(s), if necessary may be used to limit the stress on the fibres inside the
central fibre optical unit

6B.3.2.4 Optical Fibre

(a) Fibre Core and Cladding

The fibres shall comply with the geometrical data given in the Data Sheets. Generally,
single-mode fibres, dispersion-unshifted and multi-mode fibres with 50/125 µm and 62.5/125
µm core/clad diameters are considered in this specification..
The core and the cladding shall consist of all glass, which is predominantly silica (SiO2).
Factory splicing of fibre is not allowed.
The Contractor shall present a graph showing the typical reflective index profile of the fibre.
The Contractor shall also present a tension test and give the stress corrosion factor value
and typical plot of variables over tension and probability for break.

(b) Primary Coating

The bare fibre shall be primary coated with UV-cured acrylic material for protection from abrasion
during subsequent handling or manufacturing.
The primary coated fibres shall be proof tested for a time longer than 1.0 s with a strain of
minimum 1.0 %. The Contractor shall state the applied strain force.

6B.3.2.5 Buffer Construction

A buffer for protection from physical damage shall surround the individually coated fibres
during fabrication, installation and performance of the OPGW. Depending on the
requirement specified in the Data Sheets, the buffer construction that may be used to isolate the
fibres, can either be a loose buffer or a tight buffer construction.
For loose buffer construction, it shall consist of a tube that surrounds each fibre or fibre
group, such that the inner diameter of the tube is greater than the outside diameter of the
fibre or fibre group. The interstices inside and outside the tube may be filled with a filling
compound.
The tight buffer construction shall consist of suitable materials that come in contact with the
coated fibre.

6B.3.2.6 Marking of Fibres

The Contractor shall give information about:
• Number of tubes
• Number of fibres in each tube
• Colour codes
The colour shall have good-fast property and shall comply with the colours specified in IEC
60304. The colour coding method shall be submitted to the Engineer for approval.
The original colour coding system shall be visible or discernible throughout the design life of the
OPGW.
Colouring utilized for colour coding optical fibres shall be integrated into the fibre coating and
shall be homogenous. The colour shall not bleed from one fibre to another and shall not fade
during fibre preparation for termination or splicing. The optical fibre colour code to be used
shall be as stated in the Data Sheets.

6B.3.2.7 Maximum Working Tension and Ultimate Tensile Strength

Maximum working tension (MWT) shall be calculated for maximum allowable sag of 2% on
nominal span lengths and under the wind conditions specified in the Data Sheets.
Ultimate Tensile Strength (UTS) of the optical fibre cable shall be designed to exceed 2.5
times the maximum working tension.
Associated Hardware and Fittings

6B.3.2.8 Splice Box

The fibre optic cable (OPGW) shall be joined in splice boxes located on the tower legs or
pole body at the locations where the OPGW is dead ended. The fibre optic leads shall be
brought down and up the towers/poles on the inside of the tower legs supporting the splice
box.
The splice box shall be of the corrosion resistant metallic material and watertight. The box
shall be able to contain trays for the required number of fibres specified in the Data Sheets.
The splice box shall be equipped with locker and shall be designed for direct mounting to the
tower.
The splice box shall include the mounting hardware, optical fibre splice kits, OPGW and/or
cable entry seals and all accessories for a permanent optical joint.
Splice boxes for transmission line towers/poles shall be designed for connection of two
optical fibre ground wires. Splicing boxes for the gantry towers of the substation shall be designed
for connection of one optical fibre ground wire and one optical fibre feeder cable.
The OPGW leads shall be attached to the tower/pole at 1.0 m interval by double groove
aluminium alloy clamps specifically designed to accommodate the diameter of the composite
fibre optical ground wire.
The splice box shall be installed on the towers/poles at a height of approximately 5 meters
(min.) from the ground. The OPGW leads shall be laid in a loop at the tower/pole side. The
length of the OPGW leads shall be such that the splicing can be made on the ground 10
meters from the tower/pole.
The splicing shall be made by fusion welding. The attenuation in any single splice shall be
less than 0.20 dB at 1550 nm with an average value of maximum 0.15 dB and at 1310 nm
less than 0.25 dB and 0.20 dB, respectively.
The Contractor shall submit with the bid complete information regarding the splice boxes and the
method and equipment to be used for mounting, splicing and testing.
6B.3.2.9 Dead End Clamp Assembly
The Contractor shall furnish a complete assembly to dead end the OPGW to the
transmission dead end and terminal structures consisting of an approved dead end clamp, the
necessary hardware components to link the dead end clamp to the supporting structure and
the jumper assembly to bond and ground the OPGW to the structure.
Dead end clamps shall be of the type specified in the Data Sheets and shall be of such
design and material capable of developing after installation a minimum of 95% of the rated
breaking strength of the OPGW and shall not permit slippage of the shield wire in the
gripping section.
The dead end clamps shall be capable of carrying the maximum current for which the
OPGW is designed without causing overheating or loss of mechanical strength.
Dead end clamps shall allow the OPGW to be continuous through the clamp without cutting
and splicing.
The hardware linkage to connect the dead end clamp to the supporting structure shall be
galvanized steel with stainless steel centre bolt with nut, stainless steel cotter key and galvanized
steel connecting plate.
The grounding jumper assembly shall be provided with a tight-fit aluminium alloy parallel
groove bolted clamp for the OPGW end and one-bolt galvanized steel clamp for the structure
end.

6B.3.2.10 Suspension Clamp Assembly

Contractor shall furnish a complete assembly to support the OPGW at the transmission
suspension structures consisting of an approved suspension clamp, armour rod set, the
necessary hardware components to link the suspension clamp to the supporting structure
and the jumper assembly to bond and ground the OPGW to the structure.
Suspension clamp shall be free-centre bolted type and shall be provided with aluminium
alloy armour rod for mechanical protection of the OPGW. The body and keeper of the suspension
clamp shall be made of aluminium alloy, the centre bolted pin and cotter key shall be of
stainless steel and the U-bolts shall be either galvanized steel or stainless steel.
The hardware linkage to connect the suspension clamp to the supporting structure shall be
galvanized steel with stainless steel bolted pins and nuts provide with stainless steel cotter
keys.
The grounding jumper assembly shall be provided with a tight-fit aluminium alloy parallel
groove bolted clamp for the OPGW end and one-bolt galvanized steel clamp for the structure
end.

6B.3.2.11 Damping System

The Contractor shall recommend the type, number and location of dampers for vibration
control of the OPGW, based on the prevailing wind velocity, wire tension and low average
temperature data. The recommendation together with supporting calculations shall be
submitted by the Contractor for Engineer’s review and approval.
Aeolian vibration dampers shall be of the Stockbridge type of high efficiency damping
characteristics extending to the range of frequencies that may produce wire strand and
central core tubing fatigue damage.
Dampers shall be of such design and construction that when installed and working within the
OPGW design loads and operating environment, they will not become loose, twisted or
cause abrasion and/or fatigue to the strands at the clamping area. Damper clamps shall be
provided with torque-control bolts of the breakaway type.

6B.3.3 Materials and Workmanship

The materials shall conform to the applicable Standards, of recent manufacture and unused.
Workmanship shall conform to industry standards and good practices.

6B.3.4 Stress-Strain and Creep Data

Contractor shall supply Stress-Strain data for the specified cable(s) as stated in the Data
Sheets. The data shall be in the form of coefficients and, additionally, in the form of stress -
strain curves. Contractor's stress-strain and creep data shall be obtained from stress-strain
tests on the cable(s) produced under this contract, if so required in the Data Sheets.
Stress-strain tests shall be performed according to IEC 61089 or Engineer approved
equivalent.
If no stress-strain test is required in the Data Sheets, Contractor shall provide the stress-
strain data based on his own new tests, or based on previous tests on a cable identical to the
specified or based on a cable constituted of the same materials and number of strands as
specified, approximately the same lay (in function of cable outer diameter).

6B.3.5 Sag/Tension Data

The Contractor shall furnish the initial and final Sag Tension Charts and data for the
specified OPGW based on the Stress-Strain and Creep test conducted under this
specification. Calculations shall be submitted to the Engineer for approval.
The OPGW sag shall not exceed 80 percent (theoretically calculated sag) of the final sag of the
conductor at the no wind loading condition. In addition, if a companion standard
overhead earth wire is installed in the same tower, the sags of both the optical ground wire
and standard overhead earth wire shall match the same no wind final condition, within one (1)
wire diameter tolerance.

6B.3.6 Tools

The Contractor shall furnish a list of special tools aside from those mentioned in the Data
Sheets, identifying the function of each tools and the specific items for which it is used.
Contractor shall a l s o p r o v i d e instruction for t h e p r o p e r operation, maintenance
and calibration of all tools furnished, including instruction for proper storage.
If comealongs a r e required in the installation, Co ntr ac t or s hall supply such tools and its
pertinent information. If, in the opinion of the Contractor, the specified comealongs are not
adequate to properly hold the specified cable(s), Contractor shall offer the appropriate
comealongs a n d p r o v i d e a n e x p l a n a t i o n i n t h e D a t a S h e e t s . Contractor s h a l l
p r o v i d e instruction for the proper use, maintenance and storage of the comealong.
6B.3.7 OPGW Reels

The OPGW cables shall be supplied on reels as specified in the Data Sheets. If returnable
metal reels are specified, they will be returned to the Contractor on or before a time period
elapsed as indicated in the Data Sheets, after the cables are received at the contract- designated
destination.
The OPGW shall be packed for export and the reels shall be sturdy enough to withstand
rough, but normal and customary, handling during loading, transport, unloading, field
deployment and installation. The inside surfaces of the drum and flanges shall be smooth
and without protrusions so that the conductor is not damaged during winding and unwinding.
The OPGW shall be protected by plastic or other suitable material against dust and sprays
(particularly salt spray). Steel-banded lagging is required on the outside of wooden flanges
and between the flange I-beams of metal reels.
Reels shall be marked with arrows showing the direction in which the reel should be rolled and in
which the outer end of the wire points.

6B.3.8 Preparation for Shipping and Storage

(a) General
The Contractor shall prepare the OPGW, splicing material and special installation tools for
shipment to protect them from damage during shipment, inland transport and subsequent storage
not exceeding one year, unless otherwise specified in the Data Sheets.
The storage of the OPGW will be in an environment similar to the installed location. The
splicing materials and tools shall be stored in a warehouse or similar location.
The C o n t r a c t o r shall p r o v i d e , at E n g i n e e r ’ s request, the C o n t r a c t o r ’ s
recommended instructions for long-term storage.

(b) Packing and marking of splicing materials and tools

Splicing materials and tool shall be packed in individual boxes. Individual boxes may be
shipped in larger shipping units such as containers or pallets. For shipping limitations,
length, width, weight, etc. reference is made to the Data Sheets.
Such shipping units shall be plainly marked by stencil or with a firmly fastened metal tag with the
following information as a minimum:
• Name of the Employer
• Name of the Contractor
• Name of the Project
• Project/order number
• Destination
• Name of Supplier
• Case Number
• Shipping Unit (e.g., 1 of 3, etc.)
• Dimensions
• Handling instructions
• Gross weight (kg)
• Net weight (kg)
• Tare weight (kg)
(c) Marking of OPGW reels
Reel numbers shall be painted in clear and legible manner in two locations on the outside of
each flange and on two opposite locations on the lagging.
Each reel shall be tagged with two shipping tags. One tag shall be attached to the outside of
one of the reel flanges and the second tag shall be attached to the inside of the reel flange.
Tags shall be weather resistant metal tag containing the following information as a minimum:
• Name of the Employer
• Name of the Contractor
• Name of the Project
• Project/order number
• Destination
• Name of Supplier
• Case Number
• Shipping Unit (e.g., 1 of 3, etc.)
• Reel No.
• Dimensions
• Handling instructions
• OPGW length on reel (m)
• Gross weight (kg)
• Net weight (kg)
• Tare weight (kg)
The tags should clearly indicate OPGW in the description.
The outer end of the OPGW shall be fastened to the inner surface of the reel flange a
minimum of 25 mm below the wood lagging. The cable end shall be securely fastened to
prevent the cable from becoming loose during shipment. A minimum of 4 m of the inner end of
the OPGW shall be accessible for connection to optical measuring equipment without removing
wood lagging or outer layer of protection. This length of cable shall be securely fastened and
protected during shipment.
A seal shall be applied to each end of the OPGW to prevent the entrance of moisture into the
optical fibres or the escape of filling compound during shipment and storage. Two extra seals
shall be shipped with each reel and should be accessible without removing lagging.
Each reel shall be marked on the outside flange to indicate the direction the reel should be
rolled during shipment in order to prevent loosening of the cable on the reel.
The Contractor shall furnish at the time of shipment, a certified record of final quality control
measured values for each fiber on each reel. This certification s h a l l be attached to the
outside flange of the reel in a weatherproof package.

6B.3.9 Quality Assurance Requirements

The Contractor shall have methods to assure that items and services, including
subcontracted i t e m s and services, c o m p l y with this specification. The provisions o f the
Contract shall apply.
6B.3.10 O t h e r Technical Requirements for OPGW

Other requirements and features for the optical ground wire, if required by the Engineer are
stated in the Data Sheets.

6B.4 Installation
Installation will be by Employer or Contractor as specified in the Data Sheets and monitored by
Engineer.
When the installation is by the Contractor such as for turnkey contracts, complete details of
installation and stringing methods, proper handling and storage, stringing methods and performance
records, etc. shall be furnished for Engineer’s review and approval.

6B.5 Tests

6B.5.1 General

The OPGW and its accessories shall comply with test criteria, and Engineer acceptance of the
OPGW a n d its accessories s h a l l not relieve the Contractor o f his responsibility f o r meeting
all the requirements of this specification. All routine tests required herein should be witnessed b y
the Engineer o r his authorized r e p r e s e n t a t i v e u n l e s s waived in writing or specified in the
Data Sheets and no OPGW shall be shipped until released for shipment by the Engineer or his
authorized representative.
The test equipment, test methods, measurements and computation shall be in accordance with
the latest applicable requirements of the IEC Publications in cases where otherwise set forth and
shall be subject to the approval of the Engineer.

6B.5.2 Cable Tests

6B.5.2.1 Design Tests

The OPGW shall be subjected to the design (or Type) tests in accordance with the Test
Methods mentioned in the IEC publications. However, design tests may be waived at the option
of the Engineer if the OPGW of identical design has been previously tested to demonstrate the
capability of the manufacturer to furnish cable with the desired performance characteristics. As a
minimum, the following tests shall be performed on the cables:

(a) Water ingress test

No water shall leak through the open end of the 1 m sample. If the first sample fails, one
additional 1 m sample, taken from a section of cable adjacent to the first sample shall be
tested for acceptance.

(b) Seepage of flooding compound

The seepage of flooding compound tests shall be done in accordance with the IEC test
specification.

The filling and flooding compound shall not flow (drip or leak) at 65oC.

Bid No: BEPL/PKG-4: EPC Execution of Electromechanical Works 1