Opgw Installation Manual-Megatro

QINGDAO MEGATRO HOLDING CO.
, LIMITED OPGW INSTALLATION MANUAL
OPGW INSTALLATION MANUAL

Contents
1) General Rules
2) Installation Preparation of OPGW
a) Establishment of OPGW installation and engineering
b) Preparation of installation tools
c) Transportation and storage of optical cable reels
d) On-the-spot checking before acceptance of OPGW and Hardware and Accessories
e) Staff training
3) Installation of OPGW
a) Frequently-used installation of OPGW
b) Laying preparation of OPGW
c) Laying process control of OPGW
d) Tightening and observation of suspension arc
4) Installation of Hardware and Accessories of OPGW

a) Installation of tension clamp
b) Installation of suspension clamp
c) Installation of vibration damper
d) Installation of earth wire
e) Installation of downlead clamp, cable tray and joint box
5) Optic Fiber Splice and Whole Process Test of OPGW

a) Optic fiber splicing of OPGW
b) Whole process test
6) Main Points of Quality Control and Special Attentions during Installation

a) Main points of quality control
b) Special attentions during installation
7) Documents on File
Add.: No. 82 East shuangzhu Road, Huangdao District, Shandong Province, China Page 1
Website: www.megatro.cc ; E-mail: karl@megatro.cn
QINGDAO MEGATRO HOLDING CO., LIMITED OPGW INSTALLATION MANUAL
1. General Rules
The handbook is formulated on IEEE 1138-2008 and IEEE 524-1992 etc. OPGW has two functions:
electric aerial ground wire and fiber communication. It is constituted of AS wire, AA wire and
stainless steel tube op-unit. The installation rules of OPGW are almost the same as the engineering
and installation modes of traditional aerial electric power wire, referring to electric power company's
aerial transmit circuitry installation skills, management and other related files. In order to guarantee
the installation of OPGW and avoid the waste of personnel and material resources, we compile the
handbook as the reference, not instead of any other manufacturers' installation instructions.
OPGW is usually installed on the top of pole of the electric power aerial wire. The following
disadvantages should be considered: vibration caused by wind, hurricane, ice thickness, unsteady
operation caused by temperature, and possible thunder attack, short circuit ere. Therefore, detailed
engineering program should be formulated according to different structures of OPGW and specific
route conditions. According to design requirement, OPGW should be allotted correctly; every tray of
optical fiber cable should he installed in the appointed part of route and should be laid according to
engineering chart operation file.
2． Installation Preparation of OPGW
2.1 Establishment of OPGW installation and engineering
In principle, the tension pay-off method is adopted. Suitable

tension should be maintained to keep OPGW hanging in the air
to avoid abrasion of the OPGW cable on the ground.
Meanwhile, it can reduce green shoots compensation, mitigate
physical labor and increase the speed of engineering. Every
project can be allocated with suitable equipments and tools according to project capacity. The
design part should send the design drawing to the engineering, which should compile the
engineering program (or operation guide including striding chart and time limit table) of OPGW cable
according to the route, the length and the pre-remaining splice place and check on related data.
Master the ingredients and the distribution of the whole communication system and fix the detailed
allocation and patterns of joining of different sub-stations including patterns of installation and
specific position from termination pole to termination generator room. Nail down the structure, the
quantity and the accessory allocation. Put forward suitable erecting pattern according to the special
condition of particular area. Master the parameters such as mechanic property, transmission
properly and splice loss etc. of OPGW according to its design rules and report before acceptance
and other data to prepare for the test on the spot and checking on the delivery.
2.2 Preparation of installation tools
2.2.1 Main operation equipments and transportation tools recommended (one team)
No Name Quantity Specification Notes
1 Tension Machine 1 3.5t Flexible Range
2 Traction Machine 1 3t Flexible Range
3 Pay-off Machine 2 5t
Diameter of the groove
4 Pulley 20
is 600/800mm
Match with Diameter of
5 Tensionless Steel Wire 7000
the cable
Match with the Number
6 Traction Net Several Match with the cable of
the cable
7 Torsion Releaser 2 Match with the cable
8 Anti-torsion Whip 2 Optional
Match with the Number
Tightening Pre-stranding Match with the cable
9 Several of
Wire diameter
the cable
10 Interphone 20 Advised Amoun
11 Radio Station 2 Advised Amount
12 Sag Board 4 Advised Amount
13 Theodolite 1 Advised Amount
Determined by
14 Hand Chain Block Several
Constructer
15 Telescope 2 300times
Notes: auxiliary facilities like transportation instruments, crane,

climbing board, safety helmet, safety belt, earth wire, electroscope,
rope, red and white flags, bamboo, protection net, safety warning
signboard etc should be prepared before engineering.
2.2.2 Main points about engineering equipments

(1)Traction and tension machine operation
Traction and tension machine should have tension instructions and

limiting device which can adjust
tension and pay-off speed at all times so that OPGW can operate at specific tension value. Tension
and traction machine should have flexible brake apparatus that can keep OPGW at original tension
when paying off the cable momentarily. Self-protection brake apparatus should be used in principle
(see picture 2 and 3).
Tension machine's groove should he semi-round, of which the
suggested depth should be nut less than 50% of OPGW. The
angle of the wall and middle vertical line should he between 5“-15'.
The diameter should be more than 70 times but not less than
1200 mm the diameter of OPGW. In order to prevent outside
stranding wire from damage, chlorine robber should be wrapped in the groove at least to avoid
abrasion and OPGW should be wrapped at least 6 circles and fastened on the tension pulley. The
end of OPGW can’t be directly wrapped on the tension machine after being pulled from the
drum; we should firstly use a tightrope to wrap on the tension machine and then draw the
cable to avoid man-made cable torsion.
(2) Pulley
The minimum allowed bending radius should be about 20D during the process of installation and
splicing. The diameter of the pulley is advised to use 600mm and 800mm so as to promise no
damage to the cable. The width of the pulley groove shouldn’t be less than the diameter of the cable
and should be as large as possible. At no times can it be less than the minimum dynamic bending
radius. In order to increase abrasion and prevent OPGW from rotating in the groove, pulley groove
should be coated with chlorine robber elastic buffer layer.
Pulley stents edge should be smooth or cab be protected by colloid, and the gap of the pulley should
be less than 10mm so as to prevent damages to cable surface or cable blocking (see picture 4).
Picture 4: Pulley
Pulley should be in good state and lubricated properly in order to ensure OPGW smooth operation
without extrusion and lessen the abrasion of OPGW outer stranded string. The cushion layer cannot
be dilapidated or aging and desquamated. Pulley is often grounded when cutting the electricity to
install OPGW; Al least, pulleys at the two towing sections should he grounded with tower at the
same time.
Pulley is usually connected with tower, hook etc. Besides, application of thimble clevis, which is
being used to hang hoop and other accessories, guarantees its free movement. However, the
tension and the type of pulley often decide the application of the thimble.
(3) Pull-off net
Pull-off net is used to tow the OPGW ca61e through
pulley smoothly and should be made up of two or three
decked stranded hollow tube (see picture 5). Its inside
diameter should be corresponding with the cable. During
the process of towing, traction should be identical with

Picture 5: Pull-off Net
pay off tension. Application of pull-net should obey the
instructions of manufacturer strictly. It is not allowed to
adjust tension with pull-off net or hold the cable when
adjusting tension.
(4) Anti-torsion whip
Anti-torsion whip (see picture 6) is often used with
pull-off net at the same time (see picture 7). Its weight
Picture 6: Torsion Releaser
length should be above 5N.m so as to prevent OPGW
from revolving on the process of traction and protect extra fiber length from damage. Meanwhile, it
also can avoid torsion release and ungluing and sign of bird caging. Besides, it can protect the cable
from damage. Pull-off torsion releaser is used to protect pull-off rope from knotting.
(5) Pre-stranding wire for tightening
Temporarily pretension pre-stranding wire for tightening is used to adjust tension and arc. Its
repetitive times can reach more than 3 times.
2.3 Transportation and storage of optical cable reels
OPGW cable should be packaged with wooden or iron-wooden drums which contain wooden
materials. The following matters should be paid attention to during transportation and storage for the
essential factors of wooden materials:
(1) Cable should be stored at indoor venues which are dry and ventilative, if indoor venues are not
accessible, then the venue to place the cable should be flat, solid and with good drainage facilities.
(2) When in seasons with too much rain, then waterproof cloth should be covered on the cable so as
to avoid deformation and rot after being got wet in the long-term rain.
(3) When in dry season, after being laid for a long time, the wooden materials would shrink. The
drum should be checked before laying, the cable can have water immersing one say before laying if
it is accessible.
(4) Effective measures should be taken to prevent moth and other harmful insects.
(5) Cable drum can’t be rolled for more than 5m, and it should be rolled according to the stamped
rotate arrow on the drum in short distance.
(6) The cable must be transported, loaded and unloaded by special-purpose vehicles (cranes and
forklifts), during the process, the cable drum must be vertical so as to avoid damaging the wooden
lagging, and it can’t be pushed from cars to the ground by manpower.
(7) During transportation process, the cable drum must be vertical; the cable end should be fastened
so as to prevent the cable from loosening. After the cable drum arrived at the installation site can the
wooden lagging and other protective facilities be dismantled.
(8) Cable drums are forbidden to be piled and placed upside down, and other materials are
forbidden to be laid on the drum.
2.4 On-the-spot checking before acceptance of OPGW and Hardware and Accessories
After OPPC and hardware and accessories having arrived construction materials warehouse,
construction unit should carry out unpacking acceptance inspection together with the owner,
supervisor and supplier representative. Check the attenuation of OPPC cable, the number of
hardware and accessories, the type and the appearance etc. After on-the-spot inspection is qualified,
all the participants fulfill the signature handover procedure.
(1) Opening test of OPPC
Check out the continuity, length and attenuation of optic fiber by using optical time domain
reflectometer (OTDR), generally check out 1550nm wavelength. Write down and keep the results
tested (optical fiber backscattering curve).
After the cables are tested qualified can they be set up.
(2) Checking of hardware and accessories
Each construction section should carry out checking, classification and trial erection of hardware
and accessories according to design drawing and technical agreement, change the product when
there are problems as soon as possible. Material store keeper should issue the materials in
accordance with the requirements of design drawing.
2.5 Staff training
Carry out electric power industrial technology management rules, electric power security regulations,
on the spot overhauling rules. Train the engineering operator and laboratory technician effectively
with this handbook.
Engineers should study and communicate with each other before construction. Technicians or
supervisory should explain the structure, property, quality criteria, engineering procedure,
requirements of installation tools, special attentions during installation and using method of
hardware and accessories etc. Operation demonstration and trial erection can be used when there
is necessary (such as tension clamp, suspension clamp). Discuss the installation method under
special circumstance.
3. Installation of OPGW
3.1 Frequently-used installation of OPGW

The method of OPGW installation is tension payoff. Tension payoff can make OPGW receive
constant tension in the whole payoff process through payoff system which remains enough spare
from obstacles and other objects and avoid friction, so as to protect OPGW. And it also can lighten
physical labor and improve the speed of the project.
3.2 Laying preparation of OPGW
3.2.1 Dealing with pay-off channel, obstacles, cross agreement and safeguard procedures
We usually carried out with power line construction according to
relevant provisions in “Overhead Transmission Lines Design
Technology procedures” and “Power Line Construction and
Acceptance Interim Technical Specifications”. Before construction,
pay-off channels would be made out in the areas where lines go
through to ensure unblocked transport. Find out obstacles,

Picture 11:
Protection Frame specific location of cross, make cross agreement, build protection
frame (see picture 11) measures in advance for crossing railways, expressways, rivers,
uninterrupted lines, communications radio lines, streets, fruit-bearing forest and so on, try hard not
to damage surrounding crops. When operated crossing other liners, we should avoid any touch and
pulled by load-carrying insulation rope so as to avoid short-circuit accident. Streets and bridges that
tension stringing equipment passes must be prospected and should be repaired when necessary.
3.2.2 Arrangement of traction site and tension site
(1) Tension site usually choose a field of width: 10m and
length: 25m and should be convenient for the storage
and transportation for tension machine, cable reels
and other materials and facilities. Traction site can be
chosen as the tension site (see picture 12).
(2) Tension site and traction site should be located at the outside of the tension tower of two ends
of the erection section and should be in the line direction. It can also be chosen in the inner side
when confined to geography. If traction site can’t be placed in the line direction, we can use a
pulley with large diameter, please be careful not to slide during pay-off.
(3) The distance between traction machine and tension machine to the first fundamental tower
should be at least 3 times the height of the tower, and the distance between tension machine and
the spool of pay-off stand shouldn’t be less than 5m.

(4) The force direction of traction machine wheel, tension machine pulley, cable pay-off stand,
pulling rope and pulling rope drum should be perpendicular to the axis, and avoid direction
change in the pulley.
(5) The traction machine, tension machine and cable pay-off stand should be anchored according
to the requirement.
3.2.3 Hang the pay-off pulley
Hang a pulley that meets dimensional requirement on each tower according to OPGW construction
technical requirements.
First fundamental tower, corner tower that close to traction site and tension site and the tower that
makes cable can’t meet the requirement of pulley’s envelope angle for the large height difference,
we should hang a pulley whose tank bottom diameter is more than 800mm (or can use combined
type pulley block with a diameter of 600mm).

For the pay-off in corner tower, during pay-off period, the pulley has a period that leans from vertical
direction to corner inside, this period is unstable, especially the impact force of anti-torsion whip from
the pulley ad it is easily to cause the cable leaping from the groove which leads to thread jamming.
In order to avoid this, we can put the pulley to pre-leaning inside.
3.2.4 Laying and levitation of pulling rope
Pulling rope is laid in section by manual work according to their drum length, and then connected by
bending resistance connector and this process must have a responsible specialist; after this, to
check whether the fair line of the pulling rope is intact.
Before using pulling rope connector, check whether there is fracture, formation and it is strictly
prohibited to use nonconforming product.
After the laying of pulling rope is finished, it should be raised up to the groove of pay-off pulley.
3.2.5 Traction end connection
During pay-off period, fibers in the OPGW can easily be effected and damaged for extra torsion of
OPGW, so the traction end need to be made well to make sure OPGW won’t have torsion during
pay-off period.
The end of the cable can’t be directly wrapped on the tension machine after being pulled
from the drum; we should firstly use a tightrope to wrap on the tension machine and then
draw the cable to avoid man-made cable torsion. The connection method of cable with pulling
rope after the cable passes through tension machine is: cable—traction net pipe—bending
resistance connector-- anti-torsion whip (optional)—spiral connector—traction rope.
If OPGW is stranded type, anti-torsion whip is not necessary, while we use two spiral connectors to
connect in series through steel wire rope (See picture 13.1).
If OPGW is center type, suitable anti-torsion whip is a must (See picture 13.2). It can’t be installed
reversed and should slow down when it passes through the pulley.
Traction net pipe must match with the outer diameter of the cable so as to guarantee the tightness
between the net pipe and cable. It is better to wrap the net pipe end with iron wire (not less than 30
turns) and then it should be wrapped in black tape.
3.3 Laying process control of OPGW
3.3.1 Check up and requirement before laying
(1) Check the location, width, length, structure firm degree and overall stability degree of the
cross frame.
(2) Check the arrangement of traction site and tension site and machine anchoring situation.
(3) Whether all staff is in place, whether the communication is smooth and whether there is
fault along the lines.
(4) Traction machine and tension machine should be normally operated, and the
brake equipment and safety device should be reasonable; central shaft of pay-off stand should
be horizontal. Whether the traction ends are firm.
(5) Before paying off, mails should be removed and sundries along the pay-off stand should
be cleared.
(6) Stern line should be fastened and checked during laying process at all times.
3.3.2 OPGW laying process
(1) Adjust and control the tension according to the parameters from technical department,
the tension is controlled less than 10%RTS, any tension put on the cable during the process of
installation should be no more than 20%RTS.
(2) Traction should be controlled according to the value given by technical department.
(3) The speed of payoff at the beginning is 5m/min, after the cable arrives at the first base
tower
can it be speeded up to about 30m/min. The maximum speed should be no more
than 40m/min. The speed should be constant, abrupt acceleration or slowdown is
forbidden, and vibration is forbidden during payoff.
(4) During pay-off process, each corner tower top and cross point should have a specialist to
look after so that they can report instantly when thread clamp happens or other circumstances. The
cable traction end should pass through the pulley under surveillance of
construction personnel.
(5) Tension machine operator should care the tension control during installation. In the
traction process, it is normal that the traction is suddenly increased by a big margin or hard
strings of suspended payoff pulley are excessively leaned.
(6) When cable end and anti-torsion whip is close to the pulley especially the corner tower
pulley, the traction speed should be slow down so as to let the scourge pass the pulley
successfully.
After that, we can speed up to the original traction speed.
(7) The cable can fall to the ground during laying process, and make sure that the cable has a
safety distance of 3-5m with across things. All personnel should observe the laying conditions
at all times and informs to adjust the tension so as to avoid collision between cable and
conductor and across frame or other obstacles that lead to abrasion and torsion.
(8) The minimum bending radius of cable should be more than o.5m, when the set up process
temporarily discontinues, we should stop the cable keeping going by hand brake, or it can
easily cause damages and at the same time avoid torsion on the cable.
(9) After the laying of cable is finished, stern line should be kept and the length shouldn’t be less
than the height of the tension tower (or door model structure height) and add 15m as a joint or
follow-up spare. Stern line shouldn’t touchdown and the bending radius should be more than
0.5m. Hard bend and gold hooks are forbidden.
(10) Cable drums can’t be placed in two stets, if limited by geography, cable can be placed in
two sets after being confirmed by relevant respects and detailed plan should be made out.
3.3.3 OPGW temporary fixation and anchor end
(1) If the cable can’t be laid out in one day, pulling rope and cable in traction end and tension end
should be anchored. Cable relaxation degree from tension end to tension machine should be
advisable to remove the tension of traction machine and tension machine and it shouldn’t be
too loose, and the cable can’t touch the ground.
(2) If the cable can’t be tightened or hung after laid out, it should be anchored. At this time, anchor
lines should be made at the end of the cable, special cable yarn trapper should be placed
about 3-5m at the tail end of the cable.
(3) When anchoring lines, related torsion resistance measures can be taken. Heavy stuff can be
hung on U-type shackle which connects with the yarn trapper.
3.4 Tightening and observation of suspension arc
(1) Tightening payoff shouldn’t be more than 20%RTS, so as to make sure optical fiber properties
are not affected.
(2) High altitude soft hang can be done at one end of tension section, and then slowly loosen the
anchor to make tension string get force, remove this anchor, tightening can be done at the
other end.
(3) When tightening, the traction speed should be stable and the direction should be the same as
the lines. If limited by geography that the direction needs to change, pulleys should be
installed. When tightening in short section, cable sag raises fast, so the speed should be slow.
Parallel hang line method is suitable to tightening the lines when there is large height
difference and flip angle.
(4) Tightening preformed armor rods is advised as a tool to tension OPGW or adjust tension sag.
Tension clamp can be used as tightening tool for the first time, but it must be used as
installation materials for the second time. It should be stressed through thimble when used as
tightening tool, while pulling outer preformed armor rods is not allowed, try best not to make it
deformation. Yarn trapper is forbidden to hold OPGW, for it can cause too much side pressure
that could cause damage to op-unit (see picture 14).
(5) When the sag is close to the design requirement, stop tightening, use spanner bottle gourd to
tighten the cable sag to the design value, then use a marking pen to sign it .At last, install the
tension clamp.
(6) During tightening operation, keep the signal clear.
(7) Straight-through type tension tower sag should be controlled according to the following
principles: when the cable passes below the earth wire stand, the sag is usually controlled
about 400±100mm; When the cable passes over the earth wire stand, the sag is usually
controlled about 150~200mm. The jumper wire should satisfy not only the minimum bending
radius but also without collision with fittings and tower materials.
(8) After tightening is finished, make downlead clamp as soon as possible according to design
requirement. Spare cable reel with a diameter of about 1.2m is laid flat on conductor cross
arm and is fastened with nylon cord which is used for later joint.
4. Installation of Hardware and Accessories of OPGW
Install the fittings and accessories in 48 hours after tightening the cables in the tension section to
avoid unnecessary damage to the fibers caused by overfatigue of the cable, for the cable could be
easily abraded or vibrates in the pulley. Fittings and accessories of OPGW usually include: tension
clamp, suspension clamp, special earth wire, vibration damper, armor rods, downlead clamp, joint
box and so on.
4.1 Installation of tension clamp
Tension clamp is the key hardware to install OPGW which not only fixes the cable on the pole and
tower and affords much pressure but also grips the cable tightly while not exceeds the side pressure
intensity of OPGW. Tension clamp is usually used in the termination tower, corner tower of over 15°,
the cabling tower or pole tower of large altitude difference. The standard pre-stranding tension
clamp is constituted of inner stranding wire, outer stranding wire, thimble, bolt, nut and so on (see
picture 15).
Steps of installation:
A. Fix the hardware in the tower after the cable arc is adjusted with putt-off equipments.
B. Pull the outside stranding wire of tension set through heart-shaped loop of the transit hardware.
Make the stranding wire parallel with the cable and mark the cable in the place of coloring on the
wire.
C. Correspond the inside stranding wire with mark on the cable, and then, reel the first group of
pre-stranding wire on the cable. Reel the other pre-stranding wires or insert the grounding flake by
the coloring mark to ensure all the pre-stranding wires reeling together tightly and the ends are trim
and well-proportioned. Prevent pre-stranding wire from transmutation by overexerting so as not to
influence the distance of bolts
D. Put the pre-stranding wire into the thimble and correspond the cross-section mark of outside
stranding wire with the coloring earmark of inside stranding wire. And then, reel the outside
stranding wire. Keep the space symmetrical no matter reel from one part or two parts.
4.2 Installation of suspension clamp
Pre-stranding suspension clamp is used to hang the cable in the lower, which is constituted of inside
stranding wire, outside stranding wire, rubber clamp, alloy ingot crust, bolt, nut and gasket
(see picture 16).
Steps of installation:
A. Mark the suspension fixed point on the OPGW cable and reel the inside stranding wire from the
middle part, which has been marked. Use hands not tools to reel the termination part after reeling all
the inside stranding wires.
B. Put the center of the inside stranding wire to the center of rubber clamp and fixed with the insulted
tape, And then, reel the outside stranding wire on the robber clamp along with the curve or insert the
grounding Hake. Keep the space symmetrical and avoid intersecting.
C. Put the center of the crush to the center of the stranding wire end rip the bolt and fix it. And then
connect with suspension staple, rip the bolt and hang on the tower.
4.3 Installation of vibration damper
Vibration damper is used to eliminate or loosen the vibration caused by all kinds of factors during
OPGW operation so as to protect OPGW cable and prolong the life of the cable.
4.3.1 Installation number allocation principle:
The number of vibration damper is allocated according to the following principle: span≤250m: 2 sets;
span: 250~500m (including 500m), 4 sets; span: 500~750m (including 750m), 6 sets; when the span
is over 1000m, allocation plan should be changed according to line situation.
4.3.2 Installation position
(1) Computational formula:
:
cable
diameter (mm)
T : cable annual average stress (kN), generally 20% RTS
M: cable unit weight (kg/km)
(2) Starting point of vibration damper installation: the starting point of L1 is the center line of
suspension clamp and the center line of tension clamp thimble; the starting point of L2 is the center
of the first vibration damper, the starting point of L3 is the center of the second vibration damper, and
so on.
(3) The first vibration damper should be installed on the inner stranding wire of accessories, and
others are installed on special armor rods from second vibration damper.
4.4 Installation of earth wire
The earth wire is mainly used to supply access to short cut electricity when the OPGW is grounding.
It is stranded by alloy wire and connected with accessories with parallel groove clamp or illustration
and the other end is connected to tower grounding hole. The installation of earth wire should be
aesthetic, with suitable length, without bend or twist. Connection points should have good contacts
and keep unified in all lines.
4.5 Installation of downlead clamp, cable tray and joint box
Cable at the splicing point on the tower should be spliced after being lead to the ground. Along two
sides of earth wire stand of the tower to the tower body and then lead along the inside of the tower
body.
Bending radius of the route where downlead passes through shouldn’t be less than 1m, and the
minimum bending radius should be promised during operation, generally more than 0.5m.
After the cable is lead to the ground, downlead clamp is used to fasten
the cable on principle material or other material of the cable. Anchor ear
type downlead clamp should be used when it is lead along concrete pole
(such as converting station, power plant structure).
Cable downlead should be straight and beautiful.
Joint box and cable tray should be installed at suitable place on the tower,
and about 8~10m above the datum surface of the tower. The installation
should be firm and all the lines should be unified (see picture 17).
5. Optic Fiber Splice and Whole Process Test of OPGW
5.1 Optic fiber splicing of OPGW
After the lightening of OPGW, fittings and accessories, downlead clamp and cable tray are all
installed, OPGW is almost in the state for normal operation, then optic fibers should be spliced and
at the same time, attenuation should be tested on the fibers to make sure whether any damages has
caused during laying process. Attenuation usually tested at 1550nm, record and store the test
results.
5.2 Whole process test
5.2.1 Bidirectional whole test should be carried out after the installation of cables finished. Test items
include unidirectional fiber splicing loss, bidirectional average loss and average attenuation etc. Test
results should be in accordance with the contract.
(1) Cable unidirectional loss is tested by OTDR. At the same time, back scattering signal curve and
schedule list should be provided. And calculate bidirectional whole process average loss according
to test results.
(2) Carry out repeat test of total loss of the whole process by light power method and check out the
order of fiber core.

5.2.2 Drum list of cable route
Check out ODF from A to B of the drum list. Parameters such as length of leading cable, erected
length of each pallet and place of connecting box etc should be labeled.
5.2.3 Fiber reel list for splicing list of cable route
Check out fiber reel list for splicing list of all connecting points from A to B end of ODF.
6. Main Points of Quality Control and Special Attentions during Installation
6.1 Quality control points
(1) Transportation and storage control points
Whether OPGW, fittings and accessories get abraded during transportation or get damp and
corroded during storage.
(2) Lightening and laying control points
The bending radius of optical cable during laying process should be effectively guaranteed to
avoid “gold hooks” and avoid too much tension, abrasion and too many times of twists and turns.
(3) Fittings and accessories installation control points
To avoid too much tighten torque of bolts and avoid abrasion, twist and unreasonable pressure
to the optical cable.
6.2 Special Attentions during Installation
(1) Before construction, calibrations should be made on frequency and sensitivity of the interphone;
during laying process, take physical truth and former experience into account and subject to
unified scheduling command.
(2) During construction, OPGW and accessories must reliable grounding, thus avoiding damage to
personnel and facilities caused by capacitance and inductive coupling.
(3) The end of the cable can’t be directly wrapped on the tension machine after being pulled from the
drum; we should firstly use a tightrope to wrap on the tension machine and then draw the cable
to avoid man-made cable torsion.
(4) The installation of OPGW must be operated during power off in principle and can’t be operated
during gale and thunderstorm; we should strictly conform to “Electricity Safety Rules”, fill out
work sheet, carry out organization measure of aerial transmission line safety work and follow
related work procedures of power system.
(5) Although the structure of OPGW is sturdy and durable, we should be careful to avoid wrong
operations that cause unnecessary damage to the cable; during the laying of OPGW, sudden
vibrations, pull and jump should be avoided.
(6) When operating on streets and expressways, the direction of OPGW should be in consistent with
traffic flow, special person should be arranged to direct the traffic, warnings and traffic guide
signs can be used to delimit the work area, we can also ask the public security police to ease
traffic when necessary.
7. Documents on File
7.1 Original record documents on the spot should be collected and assembled according to
provisions and hand them to installation units before schedule time. When in cases of system
transformation and critical situation, they can be referred to solve problems.
7.2 The following on-the-spot documents are suggested to be classified.
(1) The measuring method of test with the project process, project arc and crossing span organized
by the representatives on the installation site, who are dispatched by the construction company;
the qualified record of secret project; the checking and acceptance of system open.
(2) The relief map for the system: the detailed form of pole tower, junction site, crossing span
diagram etc.
(3) System integral diagram: mark the cable drum numbers, drum length, optical fiber cable and the
type, length, data and quantity of fiber, the color spectrum arrangement for fiber connection,
patch cord materials, which have been used in every junction or branch of every point, terminal
equipment, the main road.
(4) Installation of data form: record the actual equipment devices, tower installation, dimension, the
pre-remained length of every junction or terminal, ground connection and fixture etc used in
every pole tower.
(5) Checking and acceptance of data form: including input light power, receivable light power, fiber
average attenuation, the input loss of junction and patch cord, the length of the optical fiber
cable, etc.
7.3 Requirements:
(1) Project files should be collected, organized and filed with original copy (document).
(2) Written materials should be intact, legible, icon neat and with complete signatures. The
damaged file materials should be repaired.
(3) The files shouldn’t be written or drawn with easy fade materials, copies should be made on
illegible and easy fade files.

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QINGDAO MEGATRO HOLDING CO.

, LIMITED OPGW INSTALLATION MANUAL

OPGW INSTALLATION MANUAL

b) Preparation of installation tools

c) Transportation and storage of optical cable reels

d) On-the-spot checking before acceptance of OPGW and Hardware and Accessories

b) Laying preparation of OPGW

c) Laying process control of OPGW

d) Tightening and observation of suspension arc

4) Installation of Hardware and Accessories of OPGW

b) Installation of suspension clamp

c) Installation of vibration damper

d) Installation of earth wire

e) Installation of downlead clamp, cable tray and joint box

5) Optic Fiber Splice and Whole Process Test of OPGW

b) Whole process test

6) Main Points of Quality Control and Special Attentions during Installation

b) Special attentions during installation

engineering chart operation file.

2． Installation Preparation of OPGW

2.1 Establishment of OPGW installation and engineering

In principle, the tension pay-off method is adopted. Suitable

2.2 Preparation of installation tools

Notes: auxiliary facilities like transportation instruments, crane,

2.2.2 Main points about engineering equipments

Traction and tension machine should have tension instructions and

(see picture 2 and 3).

Tension machine's groove should he semi-round, of which the

1200 mm the diameter of OPGW. In order to prevent outside

cable to avoid man-made cable torsion.

should be coated with chlorine robber elastic buffer layer.

(3) Pull-off net

Pull-off net is used to tow the OPGW ca61e through

pulley smoothly and should be made up of two or three

decked stranded hollow tube (see picture 5). Its inside

diameter should be corresponding with the cable. During

the process of towing, traction should be identical with

pay off tension. Application of pull-net should obey the

instructions of manufacturer strictly. It is not allowed to

adjust tension with pull-off net or hold the cable when

(4) Anti-torsion whip

Anti-torsion whip (see picture 6) is often used with

(5) Pre-stranding wire for tightening

essential factors of wooden materials:

rotate arrow on the drum in short distance.

lagging, and it can’t be pushed from cars to the ground by manpower.

wooden lagging and other protective facilities be dismantled.

forbidden to be laid on the drum.

all the participants fulfill the signature handover procedure.

(1) Opening test of OPPC

tested (optical fiber backscattering curve).

(2) Checking of hardware and accessories

accordance with the requirements of design drawing.

2.5 Staff training

with this handbook.

3.1 Frequently-used installation of OPGW

physical labor and improve the speed of the project.

3.2 Laying preparation of OPGW

We usually carried out with power line construction according to