Dobbins Opgw

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities
Patrick Dobbins Director Technology Applications
Agenda
Industry Standards Structure Hardware Cable Attachment Hardware ADSS Cable Attachment Hardware OPGW Installation Apparatus OPGW Installation Methods ADSS Installation Methods Key Installation Issues
IEEE 534 2003 Guide to Installation of OH Transmission Line Conductors IEEE 1138-2009 Standard for Testing and Performance of Optical Ground Wire (OPGW) for Use on Electric Utility Power Lines IEEE 1222 2011 Standard for Testing and Performance for All-Dielectric SelfSupporting (ADSS) Fiber Optic Cable for Use on Electric Utility Power Lines IEEE 1591 2011 Standard for Testing and Performance of Hardware for Optical Ground Wire Recognized as the best practices Working groups from Power Engineering Society
Structure and Pole Line Attachment Hardware

For most distribution applications, 10M (5/8) pole mounting hardware is used (eye nuts, bolts, etc). For transmission applications higher loads and tensions must be considered and appropriate hardware selected Pole Line Hardware and Guying should be matched to a minimum of fiber optic cable UTS or 2X maximum rated operating tension (MRCL/MRDT). Guying Rules same as for messenger supported cable or power conductors. Basic aerial line construction rules are applicable Use company current safety rules on hardware standards
OPGW Attachment Hardware
Fiber Optic Cable Attachment Hardware Important Considerations

OPGW and ADSS attachment hardware must be matched to a specific cable type and manufacturer. Cable diameter, cable design type, loading factors and cable UTS are considered Key element is the Maximum Rated Design Tension (MRDT) of OPGW Cable or Maximum Rated Cable Load (MRCL) of ADSS cable. Do not match based on diameter alone Hardware must be certified by hardware and cable manufacturer as an integrated system
OPGW Deadend Choices

Tension Points of segment Used for wide angles, splice points, reel ends, road, river, and railroad crossings. Different choices available for different OPGW cable designs Hardware is matched to specific cable design
Cable Diameter MRDT and UTS Cable Construction Type
OPGW Deadend Choices Formed Wire

Tension Points of segment Used for wide angles, splice points, reel ends, road, river, and railroad crossings. Different choices available for different OPGW cable designs Hardware is matched to specific cable design Heliformed deadend
Reinforcing rods
Cable Diameter MRDT and UTS Cable Construction Type
Aluminu Aluminum m or copper ground ground wire clamp
FiberLign deadend
OPT-GW Tangent/Suspension Choices

Hi-Bus Suspension 0 to 20 Line Angle Slip rating to 20% for UTS under 25Klbs Can be configured with double yoke plate to 40
Hi-Bus Suspension
Hi-Bus Trunion 0 to 20 Line Angle Slip rating to 20% for UTS under 25Klbs Top Mount Style Superior Vibration Resistance
Hi-Bus Trunnion
OPT-GW Suspension Choices

Single Mechanical Suspension 0 to 30 Line Angle Slip rating to 1500 lbs Vertical load at 25Klbs Suspension Mount Style
Single Suspension
Double Mechanical Suspension 31 to 60 Line Angle Slip rating to 3000 lbs Vertical load at 25Klbs Yoke Plate/Anchor Shackle
Double Suspension
OPT-GW Grounding Choices

Bonding Clamp
Grounding of OPT-GW at each

tower Difference Grounding Harness depending on current carrying requirements
Bonding Clamp
OPT-GW Tower/Pole Guides

Tower/Pole Guide Clamp Used at splice points Guides cables down structure Lattice steel structures or wooden poles
Tower Guide Clamp

Pole Guide Clamp Used at splice points Guides cables down structure Used on wooden poles
Wood Pole Clamp
OPGW Vibration Dampers
Damper System Used to control Aeolian Vibration Engineered to cable diameter, tension, and span Software analysis program provides specific recommendation of number of dampers and locations OPGW MFGR provides recommendations
Stockbridge Damper
Spiral Dampers
ADSS Attachment Hardware
Attachment Hardware Important Considerations
ADSS attachment hardware must be matched to a specific cable. Cable diameter, jacket material and cable UTS are considered Do not match based on diameter alone Hardware must be certified by hardware and cable manufacturer
ADSS Deadend Choices

Tension Points of segment Also Temporary Tension Grips Used for wide angles, splice points, reel ends, road, river, and railroad crossings. Torque-balanced design Different choices available for different ADSS cable designs Hardware is matched to specific cable design
Mechanical Deadend
Cable Diameter MRCL and UTS Jacket Type
Formed Wire Deadend

Deadend Choices
Mechanical Deadened
Medium length spans Fast Installation Limited tension applications Standard PE Jackets Only
Formed Wire Deadends
Medium and long spans Special designs Higher tension applications Standards and Tracking Resistant Jackets

Deadend Choices
Medium/Long Span Formed Wire DE
Tangent/Suspension Choices
< 600 feet (180 m) Heavy Loading to 1200 feet (365m) Light Loading, angles < 22 degrees. (15 deg for installation pulls)
Tangents are used for span lengths
Tangent (Trunion)
span lengths > 600 feet (180 m), angles < 30 degrees.
Suspensions are used for
Suspension
Formed Wire Suspension
EHV ADSS Corona Rings
For EHV ADSS Applications
Protects cable from discharge off of

Formed Wire Hardware
Under SRL layer of DE or SU units Typical for applications above 230kV Follow manufactures recommendation
Corona Ring
Vibration Dampers
Aeolian Vibration Control
Distribution Applications Spiral Vibration Damper Transmission Applications Spiral Vibration Dampers Stockbridge Dampers
Stockbridge Vibration Dampers
ADSS in EHV (>230Kv) environments may require Stockbridge damper Due to Tracking potential on SVD Damper Solution must be engineered by AFL Damper must attach over armor rods
Cable Reel - Visual Inspection

Visually inspect all reels for any damage that may have occurred during transit. Be particularly alert for damage if:
A reel is laying flat on its side (flange). Reels are stacked on top of each other. Other freight is stacked on the reel. Nails have been driven into the flange or lagging. A reel flange is damaged or lagging is damaged. The end seals of the cable have been removed or damaged, allowing potential moisture ingress into the cable.
Cable Preparation Prior to Install

The wood lagging or flexwrap should be the last thing removed before installation. The inside end tail should be loosened on the reel prior to pulling. This allows the inner layers of the reel to shift and grow out if they need to.
Installation Equipment
Reel Stands
Reel stands are designed to be used with tensioners to supply the necessary hold-back tension to the cable Reels are not designed to withstand the forces developed by braking during high tension stringing operations Direct tension stringing from the reel at cable installation stringing tensions should not be attempted
Bullwheel Characteristics
Recommended guidelines
Semicircular grooves with depths of 50% or more than the cable diameter, and with a flare angle of 5 to 15 from the vertical center line reference The minimum radius at the bottom of the groove should be at least 35 times the diameter of the cable Elastomer lined grooves or other smooth surface finish
Puller Characteristics
The system should be capable of maintaining a constant and even tension Equipped with tension indicating and limiting devices Braking system to maintain a constant holdback tension at various pulling speeds Positive braking systems are required for pullers and tensioners to maintain cable tensions when pulling is stopped Fail safe braking systems are recommended
Travelers/Blocks
Lined Blocks Recommended Large Diameter for:
First position after payoff Final position before take-up Heavy Angles (25 or greater)
Smaller Diameters
Tangent 12 minimum sheave diameter
At minimum, the first and last traveler should be grounded to the structure
Running Ground
Safety device for personnel protection Protects personnel from induced voltages and transients Requited at pay-out and at take-up locations Must be tied to a made ground of multiple grounding rods
Sheave Groove Configuration

The minimum radius of the sheave groove (Rg) should be 55% greater than the diameter of the cable The minimum depth of the groove should be 25% greater than the diameter of the cable The sides of the groove should between 15 to 20 from the flare vertical
Bending Radius for Equipment/Hardware

Equipment/HW Bull Wheel 1 and Last Structure Stringing Block Angle Structures (> 20 ) Tangent Structures (< 20 )
st
Diameter (minimum) 70 X cable OD
40 X cable OD Cable Manufacturers Recommendation Typically < 30 X cable OD
Pull Rope
Torque Balanced High Dielectric Low Elongation High UTS Abrasion Resistance
Grips and Swivels

Rated for max pull tension 2 Stage Double weave to single Double Clevis Swivel
Rated for Load Non-Breakaway
NEVER use the wire mesh grip to tension or to hold cable under tension
Anti-Rotation Device
The use of the ARD depends upon the construction of the cable. This device is utilized to avoid cable twisting during the pulling operation.
Tension Hoist
Rated for 2 X max sag tension Ratchet type Easy release mechanism Take up length appropriate for sag operation
OPT-GW Temporary Tension Device
Tension Grip is also called a comealong or pocketbook grip Specifically engineered to each cable design Maximum tension rating is 5000 lbs If higher tension is required then two grips can be used in tandum
ADSS Temporary Tension Grip
Rated for 2 X max sag tension or 2500 lbs Easy release mechanism Used with thimble clevis in bail Alternative is to use a regular DE temporary Cannot be used on TrackingResistant Jackets.
ADSS Formed Wire FIT Tool

Used to properly install formed wire deadends and suspensions Snaps armor rods into place without damaging the cable jacket Screwdrivers/Pliers will cut the jacket and lead to failure
Dynamometer
Utilized for final tensioning process Must be rated for 2X the maximum sagging tension Typical accuracy is 0.5% of full scale reading of dynamometer
OPT-GW Installation Process
Pre-Pull Checklist
Verify power system outage and key power company contacts for call outages Verify fiber integrity by testing reels and comparing to factory readings Inspect pull location for best setup of payout end verses the pulling end or the direction Identify key concern areas such as heavy line angle changes, road crossings or elevation changes Verity length of pull verse length of cable. Be sure to plan for extra needed for payout and pulling set up location. Account for sag requirements. Frame tower or pole attachment hardware ahead of pull Set up all travelers on tower structures Verify communications of payout and pulling technicians
Installation Diagram
Pay-out end.
Pay-out in line with first two structures. 4 to 5 wraps on BW. Reef per mfgr. Payout min.15 from BW. 3:1 lead-to-height ratio. Breaking mechanism. Proper traveler sizes. ADR if required.
Take-up end.
Take-up in line with last two structures. Low elongation pull rope or verify integrity of existing static wire. 3:1 lead-to-height ratio. Aerial double clevis swivel (rated) and wire mesh grip. Watch for bird cage. Max pulling speed < 250 ft/min.
OPT-GW Stationary Reel Method

Complete make-ready prior to pull
Poles framed Trees trimmed Hazards identified
Payout pull rope through travelers of entire reel segment (+6km) Attach cable to pull rope with wire mesh grip and clevis swivel Establish 3 to 1 set up on both ends (payout and take-up) Set up in-line with first 2 and last 2 structure Load cable and pull rope, start pull process Sag deadend segment to deadend segment
OPT-GW Helicopter Installations

Similar to Stationary Reel but no pull rope payout Complete make-ready prior to pull
Structures framed Road crossings prepared

Attach cable to helicopter leader rope (150) with wire mesh grip and clevis swivel Load cable and pull rope, start payout process with Helicopter Transfer at last structure to puller and presag to maximum installation tension Target sag deadend segment to deadend segment
12-7
OPGW Sag and Tension Considerations

OPGW Sag and Tension
Catenary Curve Analytic Method Base on AE value of composite cable Commercial Software like SAG10 and PLSCAD
Key Input Parameters

Diameter (in.) Modulus (kpsi) Weight (lbs/ft) Maximum Rated Design Tension (MRDT) (lbs) Rated Tensile Strength (RTS) (lbs) Span ranges Critical spans
SAG-10 Output
46
Sag and Tension Rules

Target Sag (visual sag method)
Establish Soft Side DE on first structure Sag on worse case span of DE segment Establish reference at frame location on both critical structures Measure down to installation sag requirement Flag both structures at sag height with visible surveyor flagging Tension DE segment while observing sag from one of the structures As sag of span is in-line with both flags the cable is at the prescribed sag. Deadend the segment
Tension Sag (measured sag method)

Establish Soft Side DE on first structure Go to next deadend location on the hard side deadend Rig Temporary DE at 2X length of DE from DE structure. Rig Dynamometer in line with temporary DE and hoist Tension segment to requited sag tension Verify sag visually on critical span segment Deadend the segment
12-22
What Not to Do During OPGW Installation

1. 2. 3. 4. 5. 6. 7. Do not use a tensioner with undersized bull wheels. Do not utilize tensioner bull wheels without neoprene lining. Do not reeve OPGW on the tensioner bull wheels from the wrong side. Do not locate the reel of OPGW too far from the tensioner. Do not allow the OPGW cable to sag down between the reel and the tensioner. Do not install or string fiber optic cable without good communications. Do not utilize travelers without neoprene groove lining.
48
12-22,23

8. 9. 10. 11. 12. 13. Do not install travelers on tangent structures with groove diameter less than 30x the cable diameter Do not install travelers on heavy angle structures with groove diameters less than 40x the cable diameter. Do not fail to install temporary grounding at the tensioner and puller. Do not fail to utilize the correct type and size of cable grips. Do not fail to install clamping devices and permanent grounding to the cable within 24 hours of sagging and dead-ending. Do not fail to install vibration dampers within 24 hours of sagging and dead-ending the fiber optic cable.
49
12-23

14. 15. Do not fail to install temporary grounding on the cable if the pull is left overnight without the installation of permanent grounds. Do not fail to check and/or test the ground resistance at the base of each tower to ensure that it has a resistance at or below 10 to 15. Do not fail to check the condition of the existing shield wire if you are planning to use the existing wire to pull in the cable. Do not fail to test the fibers immediately before the reels of cable are installed.
16. 17.
50
ADSS Installation Process
Pre-Pull Checklist
Verify power system outage and key power company contacts for call outages Verify fiber integrity by testing reels and comparing to factory readings Inspect pull location for best setup of payout end verses the pulling end or the direction Identify key concern areas such as heavy line angle changes, road crossings or elevation changes Verity length of pull verse length of cable. Be sure to plan for extra needed for payout and pulling set up location. Account for sag requirements. Frame tower or pole attachment hardware ahead of pull Set up all travelers on tower structures Verify communications of payout and pulling technicians
11-20
ADSS Installation
Back Pull Method
Pay-out end.
Pay-out in line with first two structures. 4 to 5 wraps on BW. Payout min. 15 from BW. 3:1 lead-to-height ratio. Breaking mechanism. Proper traveler sizes.
Take-up end.
Take-up in line with last two structures. Low elongation pull rope. 3:1 lead-to-height ratio. Aerial double clevis swivel (rated) and wire mesh grip. Flag pulling grip for twist. Max pulling speed < 250 ft/min.
53
11-21
ADSS Installation
Drive-off Method
Need clear right-of-way with no obstructions. Back tension control on payout for cable overrun. Slack tension stringing method but maintain ground clearance. Cable payout off top of reel. 3:1 lead-to-height ratio on payout. In-line structures strung through tangent attachments (<25). Proper traveler sizes on heavy angles. Guard road crossings. Sag each dead-end segment.
54
ADSS Helicopter Installations

Similar to Stationary Reel but no pull rope payout Complete make-ready prior to pull
Structures framed Road crossings prepared

Attach cable to helicopter leader rope (150) with wire mesh grip and clevis swivel Load cable and pull rope, start payout process with Helicopter Transfer at last structure to puller and pre-sag to maximum installation tension Target sag deadend segment to deadend segment
Sag and Tension Rules

Target Sag (visual sag method)
Establish Soft Side DE on first structure Sag on worse case span of DE segment Establish reference at frame location on both critical structures Measure down to installation sag requirement Flag both structures at sag height with visible surveyor flagging Tension DE segment while observing sag from one of the structures As sag of span is in-line with both flags the cable is at the prescribed sag. Deadend the segment
Tension Sag (measured sag method)

Establish Soft Side DE on first structure Go to next deadend location on the hard side deadend Rig Temporary DE at 2X length of DE from DE structure. Rig Dynamometer in line with temporary DE and hoist Tension segment to requited sag tension Verify sag visually on critical span segment Deadend the segment
11-8
ADSS Sag and Tension Considerations

Catenary curve analytic method of sage and tension analysis SAG10 or PLS CAD inputs of AE Value
Diameter (in. or mm) Modulus (kpsi) Maximum rated cable load (MRCL) Rated tensile strength (RTS) Deadend segment span ranges Critical span or longest span of segment
57
ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities What Not to Do During ADSS Installation
11-25
1. 2. 3. 4. 5. 6.
Do not use a tensioner with undersized bull wheels. Do not utilize tensioner bull wheels without neoprene lining. Do not locate the reel of ADSS too far from the tensioner. Do not allow the ADSS cable to sag down between the reel and the tensioner when pulling. Do not install or string fiber optic cable without good communications. Do not utilize travelers without neoprene groove lining.
58
ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities What Not to Do During ADSS Installation
7. 8. 9. 10. 11. 12. Do not pull cable through tangent supports on line angles greater than or equal to 15. Do not install travelers on angle supports with groove diameters less than 40x the cable diameter. Do not fail to install temporary grounding at the tensioner and puller. Do not fail to utilize the correct type and size of tensioning grips. Do not fail to install vibration dampers within 24 hours of sagging and dead-ending the fiber optic cable. Do not fail to test the fibers immediately before the reels of cable are installed.
11-25
59
Sheath Repair
New Utility Training Courses UTC Fiber Optic Professional (FOP) Certification Classes
UTC FOP Level 1 Installers/Technicians
Two Day Class Day 1 Instruction, Day 2 Skills Labs Technicians and Supervisors Installation, Testing and Maintaining
UTC FOP Level 2 Designer/Planner

One Day Class Instruction Designer, Planners, Supervisors Planning, System Design, Standards and Codes
UTC FOP Level 3 Advanced Designer

One Day Class Instruction Advanced Network Designers Advanced System Design, PMD, CD and DWDM Networking
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ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Patrick Dobbins Director Technology Applications

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Structure and Pole Line Attachment Hardware

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPGW Attachment Hardware

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Fiber Optic Cable Attachment Hardware Important Considerations

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPGW Deadend Choices

Cable Diameter MRDT and UTS Cable Construction Type

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPGW Deadend Choices Formed Wire

Cable Diameter MRDT and UTS Cable Construction Type

Aluminu Aluminum m or copper ground ground wire clamp

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPT-GW Tangent/Suspension Choices

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPT-GW Suspension Choices

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPT-GW Grounding Choices

Grounding of OPT-GW at each

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPT-GW Tower/Pole Guides

Tower Guide Clamp

Wood Pole Clamp

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

OPGW Vibration Dampers

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS Attachment Hardware

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Attachment Hardware Important Considerations

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS Deadend Choices

Cable Diameter MRCL and UTS Jacket Type

Formed Wire Deadend

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Formed Wire Deadends

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Medium/Long Span Formed Wire DE

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Tangents are used for span lengths

Suspensions are used for

Formed Wire Suspension

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

EHV ADSS Corona Rings

For EHV ADSS Applications

Protects cable from discharge off of

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Stockbridge Vibration Dampers

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Cable Reel - Visual Inspection

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

Cable Preparation Prior to Install

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities

ADSS and OPGW Cable Installation on Aerial Power Transmission Facilities