FIBRE-OPTIC

OVERHEAD
GROUNDWIRE
(OPGW)&FODP

2019
Engineering Department
WEST BENGAL STATE ELECTRICITY TRANSMISSION COMPANY LIMITED

Regd. Office: VidyutBhawan, Block – DJ, Sector-II, Bidhannagar, Kolkata – 700091.

CIN: U40101WB2007SGC113474; Website: www.wbsetcl.in

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 TECHNICAL SPECIFICATION FOR COMPOSITE FIBRE-OPTIC
OVERHEAD GROUNDWIRE (OPGW)

1.0 GENERAL REQUIREMENTS

The requirement includes the design, supply, stringing and splicing of OPGW cable on
400KV, 220KV & 132KV Transmission Towers.
This specification defines the design, material, performance and test requirements for
fibre optic cable to support the fibre optic telecommunication needs.
The work covered by this specification shall include the design, engineering, transfer of
technology, manufacture, factory tests, supply, transportation, training, survey,
installation, end to end field tests etc. complete for the 400KV, 220&132KV
Transmission lines under this contract.
The Contractor shall be responsible for completing a survey of the designed OPGW
cable routes, designing the fibre cable system, supplying the fibre cable and associated
equipment (including termination of the fibres, jointing boxes and all related
accessories), installing the OPGW and carrying out end to end tests on fibres for all
links.

2.0 SCOPE OF WORK:

The scope of work includes, but are not limited to the following :
a) The provision of completing operational turnkey fibre system that shall include the
overall project management, engineering design, transfer of technology, training of
Employer’s representatives, supply, testing, integration, delivery to the sites,
unloading, storing, handling and moving to the final position, installation, testing
and commissioning of the system complete. All hardware & accessories shall be
field proven and should be latest modified version.
b) Design & installation of the mechanical assemblies and accessories including
vibration dampers required for installation on the OPGW cable.
c) Development of installation guides and procedures for the stringing, mechanical
installation and splicing of the OPGW cable, including testing & documentation.
This includes termination of approach cable from OPGW at the terminal
towers/gantry structure of Sub-Station end up to Fibre Optic Distribution Panel
(FODP).
d) Supply, laying, jointing, termination etc. Fibre Optic Approach Cable from OPGW-
Cable junction point to FODP through new and/or existing cable trench with suitable
cable jacket and providing necessary cable protection from power & control cable
by arranging cable tray/suitable hanger system in co-ordination with successful
bidder of sub-station package and also with other suppliers’ equipment.
e) Supply & installation of FODP at each Sub-station where fibre optic links are to be
established.
f) Splicing required for the optical fibres.
g) Testing the fibre system end to end over several tandem paths.
h) Factory and field testing of fibre cable.

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 i) Providing documented evidence of satisfactory Type Test performance of similar
type OPGW to employer.
j) Transportation/Shipment of all equipment and documentation to employer
designated location and/or staging areas.
k) All documentation and drawings as specified.
l) All required spare parts, maintenance aid and test equipment.
m) Training of employer personnel in installation of fibre cable, splicing of fibres and
use of test equipment

3.0 Optical Fibre Cable Link Lengths

For bidding purposes the estimated optical fibre link lengths i.e. length of OPGW has
been mentioned in the bidding schedule. However, the Contractor shall supply and
install the optical fibre cable as required based on detailed site survey (and keeping
reasonable allowance for loops on Transmission Towers and splices) to be carried out
by the Contractor during the project execution. The Cable length as finalized by the
Contractor shall be duly ratified by the Employer. Contract price shall be adjusted
accordingly as per unit rate.

4.0 Fibre Optic Cabling :

This section defines the minimum requirements for Dual-window Single mode
(DWSM) telecommunications grade fibre optic cable. Bidders shall furnish with their
bids, detailed descriptions of the cables(s) proposed. As a minimum, the descriptions
shall include information on the fibre manufacturer, cable configurations, fibre grade,
optical characteristics, fault and lightning tolerances and any other pertinent information
required for an accurate evaluation.

5.0Fibre Optic Cable Construction:

Fibre optic cable shall be of Optical Ground wire (OPGW) type suitable for stringing
over 400KV, 220KV & 132KV Transmission Towers. OPGW termination at switch
yard shall be done through suitable splicing JB to be placed suitably on switch yard
Gantry structures. From splicing JB, fibre optic lead cable suitable for direct burial in
trenches/pipes having identical fibre properties as the aerial cable, shall be drawn up to
Fibre Optic Distribution panel (FODP) to be installed inside control room building.

The design of cable shall account for the varying operating and environmental
conditions that the cable shall experience while in service. All optical fibre cabling and
all associated installation hardware shall have a minimum guaranteed design life span of
25 years.

5.1 Required Optical Fibre Characteristics:

This section describes the characteristics of optical fibre to be provided under this
specification.

5.1.1Physical Characteristics:
The OPGW cable shall consist of 24/48 fibres as mentioned in BOQ, all of which shall
be of DWSM (Dual Window Single Mode) type for which optical characteristics are
defined in table 2-1.

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 5.1.2. Attenuation Variation:
This attenuation coefficient for wavelengths between 1525 nm and 1575 nm shall not
exceed the attenuation coefficient at 1550 nm by more than 0.05 db/km. The
attenuation coefficient between 1285 nm and 1330 nm shall not exceed the attenuation
coefficient at 1310 nm by more than 0.05 db/km. The attenuation of the fibre shall be
distributed uniformly throughout its length such that there are no point discontinuities in
excess of 0.10 db. The fibre attenuation characteristics specified in table 2-1 shall be
“guaranteed” fibre attenuation of any and every fibre reel. Further the typical or average
cabled fibre attenuation shall be as follows :
DWSM fibres : 0.35 dB/km @ 1310 nm
0.22 dB/km @ 1550 nm
The overall optical fibre path attenuation including all optical cable losses caused by
bending, compression, splicing and terminations shall be less than 0.25 dB/km @ 1500
nm. Excessive splice or coupling losses demonstrated as resulting from fibre mismatch
with dissimilar fibre, shall be documented and submitted to the purchaser.
Table 2-1
DWSM optical fibre characteristics
Fibre Description Dual – Window Single – Mode
As per ITU –G.652
Mode Field Diameter 9.2 ± 0.4 µm at 1310 nm
10.4 ± 1.0 µm at 1550 nm
Cladding Design Either matched or depressed
Clad Diameter 125.0 µm ± 1 µm
Core-Clad Concentricity Error ≤ 0.8 µm
Coating Diameter 245 µm ± 5 µm
Coating Concentricity ≤ 10 µm
Attenuation Coefficient @ 1310 nm: ≤ 0.35 dB/km
@ 1550 nm: ≤ 0.22 dB/km
Attenuation at water peak @ 1393 ± 3nm ≤ 2.1 dB / km
Bend Performance @ 1310 nm : (60 ± 2 mm dia Mandrel), 100 turns,
Induced Attenuation ≤ 0.05 dB/km
@ 1550 nm : (60 ± 2 mm dia Mandrel), 100 turns,
Induced Attenuation ≤ 0.05 dB/km
@ 1550 nm (32 ± 0.5 mm dia Mandrel), 1 turn,
Induced attenuation ≤ 0.50 dB/km
Temperature Dependence Induced attenuation ≤ 0.05 Db/KM (-60°c TO
85°c)
Temperature-humidity cycling –
10°C ± 85°C Induced attenuation ≤ 0.05 dB/km
(85-95% RH)
Cable Cutoff wavelength ≤ 1280 nm
Chromatic Maximum 20 ps / ( nm x km ) 1550 nm
Dispersion 3.5 ps / ( nm x km ) 1285 – 1330 nm
6.0 ps / ( nm x km ) 1270 – 1340 nm

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 Zero
Dispersion 1295 to 1325 nm
Wavelength
Zero
Dispersion 0.093 ps / (nm2 x km) maximum
Slope
Proof Test Level ≥ 100 Kpsi

5.2. Optical Fibre Identification

Colour coding is essential for identifying individual optical fibres and groups of
optical fibres. Individual optical fibres within a fibre unit, and fibre units shall be
identifiable as per IAW EIA-RS 598 colour-coding scheme. The colour coating shall
be permanent thus withstanding normal handling e.g. during termination, testing or
cable relocation throughout the design life of the cable.

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.

Each cable shall have traceability of each fibre back to the original fibre
manufacture’s fibre number and parameters of the fibre.

If more than the specified numbers of fibres are included in any cable, the spare
fibres shall be tested by the cable manufacturer and any defective fibres shall be
suitably bundled, tagged and identified at the factory by the vendor.

Each loose tube that contains 6 / 12 nos. Optical Fibres shall be of different colour.

5.3 Buffer Tube

Either loose tube or tight tube buffer construction may be implemented. The
individually coated optical fibre(s) shall be surrounded by a buffer for protection
from physical damage during fabrication, installation and operation of the cable. The
fibre coating and buffer shall be strippable for splicing and termination. Each fibre
unit shall be individually identifiable utilizing colour coding. If loose tube buffer
construction is provided, buffer tubes shall be filled with a water-blocking gel.

5.4 Optical Fibre Strain

The cable strain margin is defined as the maximum cable strain at which there is no
fibre strain.

The fibre optic cable shall be designed and installed such that the optical fibres
experience no strain under all loading conditions defined in IS 802. Zero fibre strain
condition shall apply even after a 25 year cable creep.

The Max Allowable Tension shall also be less than or equal to 0.4 times the UTS.

The everyday tension (EDT) shall not exceed 20% of the UTS for the OPGW cable.

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 The 25 year creep at 25% of UTS (creep test as per IEEE 1138) shall be such that
the 25 year creep plus the cable strain at Max Allowable Tension (MAT) is less than
or equal to the cable strain margin.

5.5 Filling Materials

The interstices of the fibre optic unit and cable shall be filled with a suitable
compound to prohibit any moisture ingress or any water longitudinal migration
within 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-794-I-F-5 up to
80°C.
The filling compound used shall be an non-toxic homogenous waterproofing
compound that is free of dirt and foreign matter, nonhygroscopic, electrically
nonconductive and non-nutritive to fungus. The compound shall also be fully
compatible with all cable components it may come in contact with and shall inhibit
the generation of hydrogen within the cable.
The filling compound shall remain stable for ambient temp between - 20°C and +
80°C and shall not drip, flow or leak with age at high temperatures during short
duration lightning strikes and short circuit currents. The filling compound shall
meet the requirements of ‘Seepage of Filling Compound test’ as per EIA / TIA 455-
81 for 80°C temperature.
The waterproofing filling materials shall not affect fibre coating, colour coding, or
encapsulant commonly used in splice enclosures, shall be dermatologically safe,
nonstaining and easily removable with a non-toxic cleaning solvent.

5.6 Outside Jacket Materials

The outer cable jacket for wrap around cable shall consist of carbon black
polyethylene resin to prevent damage from exposure to ultraviolet light, weathering
and high levels of pollution. The jacket shall conform to low density, medium
density and high density polyethylene standards as defined in ASTM D1248.
Gel filled stainless steel tube meeting the criteria to protect the fibres from exposure
to ultraviolet light, weathering, high levels of pollution etc. may also be offered

5.7Protection Tubes
The optical core, including fibres shall be contained and protected by a tube. The tube
may be made of Aluminium alloy that is continuous, fully sealed, water tight and
without mechanical joints. Both welded and unwelded tube is acceptable if the same
meets the requirement of Water Penetration Test, as per IEC-794-1-F5. The tube
shall have sufficient resistance in order to protect the Optical Fibres from radial
compression, transmitted by the metallic wires of the external layers. Under the
normal operating conditions, including aeolian vibration, sheeve pulling at Minimum
/ Maximum Temperature and Maximum Operating Tension, the tube shall not open,
fissure and shall not be deformed. The internal surface of the tube shall be smooth,
without smudges, notches, residues or roughness that may affect the Optical Fibres,
or the P.E. sheathing. The internal and external surface of the tube shall be circular
and the thickness shall remain constant, as specified earlier. No tube joints shall be
allowed in the finished OPGW. Stainless steel tube is also acceptable if the same
meets the requirements.

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 5.8 Metallic wires
a) The OPGW shall conform to the applicable Clauses of the IEC 1089 related to
standard conductors. Adjacent wire layers shall be stranded with reverse lay
directions. The direction of lay of the external layer shall be left hand.
b) Alluminium alloy / aluminium clad steel wires shall be smooth, uniform and free
from all imperfections that are visible in the naked eye, such as spills and splits,
die marks, scratches, abrasions and kinks.

5.9 Sheathing Removal

The cable sheath design shall permit easy removal without damage to the optical
fibres or fibre units.

6.0 OPTICAL GROUNDWIRE (OPGW)

The OPGW cable construction shall comply with IEEE-P 1138 and IEC publications
1396. The cable provided shall meet both the construction and performance
requirements such that the ground wire function, the optical fibre integrity and optical
transmission characteristics are suitable for the intended purpose. The cable shall
consist of optical fibre units as defined in earlier. There shall be no factory splices
within the cable structure of a continuous cable length.

The OPGW structure shall be based on the following characteristics:

The composite fibre optic overhead ground wire shall be made up of buffered optical
fibre units embedded in a water tight aluminium / aluminium alloy / stainless steel
protective central fibre optic unit surrounded by concentric-lay stranded metallic
wires in single or multiple layers. The dual purpose of the composite cable is to
provide the electrical and physical characteristics of conventional overhead ground
wire while providing the optical transmission properties of optical fibre.

Electrical characteristics of the OPGW must be equal to or better when compared to

standard ground wire. The electrical conductivity must be designed to withstand the
specified short circuit currents. The OPGW cable selected shall withstand the
temperature increase caused by the maximum short circuit current. The Bidder shall
describe the electrical parameters of the OPGW proposed.

The mechanical structure of OPGW shall be designed to withstand the wind and
other environmental conditions in the routes, which have been specified in this
document. The location of the fibres inside the structure shall be such that the
application of the OPGW in the specified routes is possible. The selected OPGW
cable shall tolerate the normal installation procedures. The Bidder shall list the
mechanical parameters of the OPGW and describe the cable structure including how
the fibres are located inside, and shall furnish the cross-sectional drawing of OPGW.

The cable structure shall be such that the fibres are protected against water, hydrogen
ultraviolet radiation and other environmental hazards encountered in India.

The metallic wires have to give the OPGW, conductivity to carry fault currents and
the strength to withstand mechanical stresses. Aluminium alloy, aluminium clad
steel wires or a combination of them shall be used. The OPGW shall withstand,
without change in its characteristics a lightning current of 150 kA (peak). The

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 minimum allowable radius of bending for OPGW within the specified temperature
range should be 20 x D, where D is the outer diameter of the OPGW.

The fibre tubes shall have a high crush resistance and minimum permanent or
temporary deformation under mechanical pressure. The fittings must be designed to
prevent these pressures. OPGW elongation under different stress situations likely
during wind loads or during ground faults shall be considered.

6.1 Basic Construction

The cable construction shall conform to the applicable requirements of applicable
clauses of IEC 1809 related to stranded conductors and Table 2.2(a) OPGW
Mechanical and Electrical Characteristics. In addition, the basic construction shall
included bare concentric-lay-stranded metallic wires with the outer layer having left
hand lay. The wires may be of multiple layers with a combination of various metallic
wires within each layer. The direction of lay for each successive layer shall be
reversed. The finished wires shall contain no joints or splices; however, in case the
contractor feels that joints or splices are absolutely necessary, it should only be done
upon obtaining approval from the Employer and conforming all applicable clauses of
IEC 1089 as they pertain to stranded conductors.
The wires 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.

6.2Central Fibre Optic Unit

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 and moisture. 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 and ice loadings, wide
temperature variations, lightning and fault current, as well as environmental effects
which may produce hydrogen. The central fibre optic unit may include an aluminium
tube/hermetically sealed stainless steel tube. If aluminium rod is used, it shall be
fabricated with one or more channels or grooves and formed into a helix to house the
buffered optical fibres. An outer protective shield shall be applied around the rod
such as an aluminium tube or helically-applied overlapping aluminium tape to
provide an additional mechanical and environmental barrier.

6.3Breaking Strength
The rates breaking strength of the complete OPGW shall be taken as no more than
90% of the sum of 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 be considered a load bearing tension member when determining
the total rated breaking strength of the composite conductor.

6.4Electrical and Mechanical Requirements

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 Table 2-2(a) provides OPGW Electrical and Mechanical Requirements for the
minimum performance characteristics. Additionally, the OPGW mechanical &
electrical characteristics shall be similar to the electrical & mechanical characteristics
of the earthwire specified such that there is no or minimal consequential increase in
stresses on towers. The standard GSS earthwire parameters are listed hereunder. For
the purpose of determining the appropriate Max. working Tension limit for the
OPGW cable, IS 802:1995 and IS 875:1987 shall be applied. However the OPGW
installation sag & tension charts shall be based on IS 802 version to which the line is
originally designed. For the OPGW cable design selection and preparation of sag
tension charts the limits specified in civil specification shall also be satisfied. The
Bidder shall submit sag-tension charts with their bids.

Table 2.2(a)
OPGW Electrical and Mechanical Requirements

1. Everyday Tension at 32°C, no wind ≤ 20% of UTS of OPGW

2. D.C. Resistance at 20°C ≤ 1.0 ohm / km
3. Diameter ≤ 12 mm for 132KV & 220KV
and ≤12.5 mm for 400KV
4. Weight in kg / km ≤ 428 kg for 132KV & 220KV and
≤455kg for 400KV
5. No. of fibre / tube 6/12
6. No. of Tubes 4/8
7. Short Circuit Current ≥ 6.32 KA for 1 second

Table 2.2(b)
Existing Galvanised Stranded Steel Wires (7/3.15mm&7/3.66mm) used as
Earthwire.

Sl. Description Tchnical Particulars

No.
132KV &220KV 400KV
1. Grade of Steel wire 1100N/sq. Mm.
2. Total weight 428 Kg/Km 583 Kg/Km
(standard) (standard)
3. Maximum working tension at 2962 Kg 3705.2 Kg
32°C with full wind
3. Maximum working tension at 1425.8 Kg 1326.4 Kg
32°C with No wind
4. Standard of compliance IS-2141/BS-183
5. Minimum breaking load 56 KN 68.34 KN
6. Overall diameter 11.7 mm 10.98 mm
7. Modulus of elasticity 787000 Kg/sq. cm. 1860000
Kg/sq.cm.
8. Co-efficient of linear expansion 11.5 x 10-6 per
17.8 x 10-6 per deg C deg C

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 6.5Operating Conditions
Since OPGW shall be located at the top of the EHV transmission line support
structure, it will be subjected to Aeolian vibration, galloping and lightning strikes. It
will also carry ground fault current. Therefore, its electrical and mechanical
properties shall be the same or similar as those required of conventional G.I. ground
conductors (7/3.15 mm&7/3.66mm).

6.6Installation
OPGW shall be installed on the top of 400KV, 132KV & 220KV Transmission
Towers. The installation shall be generally in accordance with the IEEE Guide to the
installation of Overhead Transmission Line Conductors (IEEE STD, 524 with latest
revisions), with additional instructions and precautions for live line working and fibre
optic cable handling.

6.7 Marking, Packaging and Shipping

This section describes the requirements for marking, packaging and shipping the fibre
optic cable.

a] Drum Markings : Each side of every reel of cable shall be permanently marked
in a minimum of 5cm high white lettering with the vendor’s
address, the Employer’s destination address, cable part
number and specification as to the type of cable, length,
number of fibres, a unique drum number including the name
of the transmission line and segment no, factory inspection
stamp and date.

b] Cable Drums : All optical fibre cabling shall be supplied on strong drums
provided with lagging of strong drums provided with lagging
of adequate strength, constructed to protect the cabling against
all damage and displacement during transit, storage and
subsequent handling during installation. Both ends of the
cable shall be sealed as to prevent the escape of filling
compounds and dust & moisture ingress during shipment and
handling. Spare cable caps shall be provided with each drum
as required.

The spare cable shall supplied on sturdy, corrosion resistant, steel drums suitable for
long periods of storage and re-transport & handling.

There shall be no factory splices allowed within a continuous length of cable. Only
one continuous cable length shall be provided on each drum. The lengths of cable to
be supplied on each drum shall be determined by a “schedule” prepared by the
Contractor; however, the length of cable generally be 4km.

6.8 Installation Hardware

The scope of supply of the optical cable includes the assessment, supply and
installation of all required fittings and hardware. The Bidder shall provide
documentation justifying the adequacy and suitability of the hardware used. To
ensure their satisfactory performance, the Contractor shall determine the exact
requirements of all accessories used to install and secure the OPGW.

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 The OPGW hardware fittings and accessories shall follow the general requirements
regarding design, materials, dimensions & tolerances, protection against corrosion
and markings as specified in § 4.0 of EN 61284 1997 (IEC 61284). The shear
strength of all holts shall be at least 1.5 times the maximum installation torque. The
OPGW hardware & accessories drawing & GTP shall consist of all component
reference numbers, dimensions and tolerances, bolt tightening torques & shear
strength and ratings such as UTS, slip strength etc. shall be marked on the drawings.

The fittings and accessories described herein are indicative of installation hardware
typically used of OPGW installations and will be used for payment purposes and any
extra fittings if required are to be supplied & erected without any extra cost. The
bidder should carry out an actual field survey and to assess such extra attachments so
that their cost can be included in the supply rates of the specified items while quoting.

a) Suspension Assemblies :
Performed armour grip suspension clamps and aluminium alloy armour
rods/reinforcing rods shall be used. The suspension clamps shall be designed to carry
a vertical load of not less than 25KN. The suspension clamps slippage shall occur
between 12KN and 17KN as measured in accordance with type test procedures.
The Contractor shall supply all the components of the suspension assembly including
shackles, bolts, nuts, washers, split pins, etc. the total drop of the suspension
assembly shall not exceed 150mm (measured from the centre point of attachment to
the centre point of the OPGW). The design of the assembly shall be such that the
direction of run of the OPGW shall be the same as that of the conductor. The
designed length of the assembly should be such as not to violate the electrical
clearance between OPGW & Live conductor.

b) Dead End Clamp Assemblies :

All dead end clamp assemblies shall be of the performed armoured grip type and
shall include all necessary hardware for attaching the assembly to the tower strain
plates. Dead end clamps shall allow the OPGW to pass through continuously without
cable cutting. The slip strength shall be rated not less than 95% of the rated tensile
strength of the OPGW.

c) Clamp Assembly Earthing Wire :

Earthing wire consisting of a 1500 mm length of aluminium or aluminium alloy
conductor equivalent in size to the OPGW shall be used to earth suspension and dead
end clamp assemblies to the tower structure. The earthing wire shall be permanently
fitted with lugs at each end. The lugs shall be attached to the clamp assembly at one
end and the tower structure at the other.

d) Structure Attachment Clamp Assemblies (for attachment with (a) Suspension

Towers & (b) Tension Towers) :
Clamp assemblies used to attach the OPGW to the structures shall have two parallel
grooves for the OPGW, one on either side of the connecting bolt. The clamps shall be
such the clamping characteristics do not alter adversely when only one OPGW is
installed. The tower attachment plates shall locate the OPGW on the inside of the
tower and shall be attached directly to the tower legs/cross-members without drilling
or any other structural modifications. Clamp assemblies earth wire should be

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 provided for attachment to each suspension/tension tower. Clamp assemblies shall
be designed suitably for attachment to the suspension towers/tension towers.
e) Vibration Dampers :
Vibration dampers type 4R Stockbridge or equivalent, having four (4) different
frequencies spread within the Aeolian frequency bandwidth, shall be used for
suspension and tension points in each span. The Contractor shall determine the exact
numbers and placement(s) of vibration dampers through a detailed vibration analysis,
if required. Vibration damper clamps shall be made of aluminium or aluminium
alloy, shall support the dampers during installation and shall maintain the dampers in
position without damage to the OPGW and without causing fatigue. Armour or patch
rods made of aluminium or aluminium alloy shall be provided as required to reduce
clamping stress on the OPGW. The vibration damper body shall be hot-dip
galvanized mild steel/cast iron or shall be permanent mould cast zinc alloy. Damper
placement charts along with calculations need be submitted by the successful bidder.

7.0 Fibre Optic Approach Cables

For purposes of this specification, a fibre optic approach/lead cable is defined as the
cable installed between the final in line splice enclosure on the gantry forming the
termination of the fibre cable on the power line (OPGW) and the Fibre Optic
Distribution Panel (FODP) installed within the terminal building. The Contractor
shall supply and install the optical fibre approach cable as required based on detailed
site survey to be carried out by the Contractor during the project execution.
Approach Cable shall be a UV resistant fire retardant rodent proof, armoured cable
with steel tape, corrugated tube or galvanized wire type armour construction cable.
The cable shall be suitable for direct burial, laying in trenches & PVC/Hume ducts,
laying under false flooring and on indoor or outdoor cable raceways and shall have
minimum 2.0 mm HDPE outer jacket thickness.
Approach cable shall contain fibres with identical optical/physical characteristics as
those in the aerial cables. The cable core shall comprise of tensile strength
member(s), fibre support/bedding structure, core wrap/bedding, and an overall
impervious jacket.
It will be the responsibility of the Contractor to arrange for splicing of the Approach
Cable with the OPGW cable inside a splice box located at the base of the terminal
towers at both ends.
The termination of the other end of the approach cable inside the building will be
done by the Contractor.

8.0 Optical Fibre Termination and Splicing

Optical fibre terminations shall be installed in Fibre Optic Distribution Panels
(FODP) designed to provide protection for fibre splicing of preconnectorized pigtails
and to accommodate connectorized termination and coupling of the fibre cables. The
Contractor shall provide appropriate sized Fiber Optic Distribution Panels (FODPs)
and shall terminate the fibre optic cabling upto the FODPs. The Contractor shall be
responsible for connectivity between the FODP and the terminal equipment. The
location of FODP rack shall be fixed in suitable place preferably adjacent to the
Optical equipment.

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 9.0 Fibre Optic Distribution Panels
At each location requiring the termination of at least one fibre within a cable, all
fibres within a cable, all fibres within that cable shall be connectorized and
terminated in Fibre Optic Distribution Panels in a manner consistent with the
following :
a) All fibre optic terminations shall be housed using FODPs provisioned with splice
organizers and spile trays. All fibres within a cable shall be fusion spliced to
preconnectorized pigtails and fitted to the “Back-side” of the provided fibre optic
couplings.
b) FODPs shall be suitable for use with each of the cable types provided as part of this
contract. FODPs shall accommodate pass-through splicing and fibre terminations.
c) All FODPs shall be of corrosion resistant, robust construction and shall allow both
top of bottom entry for access to the splice trays. Specific selection of the entry
points shall be made at the time of installation. Ground lugs shall be provided on all
FODPs and the Contractor shall ensure that all FODPs are properly grounded. The
FODP for indoor installation shall meet or exceed ingress protection class IP55
specifications.
d) FODP will be of minimum 96 fibre.

Table 2.2(c)
Technical details of FODP
Sl. Description Tchnical Particulars
No.
1 Dimension (H*W*D) mm 1400*600*400
2 Construction Materials Sheet Steel/ CRCA minimum 2mm thick
3 Installation clearance:
Front Access (cm) 60
Rear Access(cm): 60
Top*Bottom*Sides(cm) 60

4 Colour & Finish Light Grey, RAL 7035

5 Coating thickness 75 µm
FODP 96Fibres Sub-rack
1 Construction Materials Cold-Rolled Steel minimum 2mm thick
2 Cable Glanding & Fixing Six Cable glanding & fixing
3 Locking Arrangement Two slots for door snap-on/ Two slots
with Nylatch
4 Total no. Of optical couplings 96 FC/PC connectors
5 Provision for pass through yes
splicing
6 No. of cables that can be 6 (each of 48Fibre)
accommodated
7 Diameter of cable that can be 8-30mm
accommodated
8 Cable entry Suitable for all 24 & 48 Fibre approach
cable
9 Method of mounting 19” rack mounting in cabinet
Splice Trays
1 Material Acrylonitrile Butadiene Styrene(ABS)

WBSETCL / TECH SPEC / Rev.-1 Page 13 of22 OPGW&FODP

 2 Method of mounting Sub-rack containing all splice trays or
individual splice trays to be of sliding and
detachable type.
3 No. of splice Trays 8
4 Maximum no. of splices per tray 12

10.0 Optical Fibre Connectors

Optical fibres shall be connectorised with FC-PC type connectors. Fibre optic
coupling supplied with FODPs shall appropriate for the fibre connectors to be
supported. There shall be no adapters allowed.

11.0 IN-LINE FIBRE OPTIC SPLICE ENCLOSURES

All in-line splices shall be enchased in In-Line Fibre Optic Splice enclosures.
Suitable splice enclosures shall be provided to encase the optical cable splices in a
protective enclosure and dust free environment. The splice enclosures shall be
designed for the storage and protection of a minimum of 144 optical fibre splices and
shall provide access through lockable doors. They shall be fitted with suitable
encapsulant that is easily removable, should re-entry be required into the enclosures.

In-line splice enclosures shall be suitable for outdoor use specifications and shall be
suitable for tower mounting. with the OPGW cable provided under this contract.
The OPTIC SPLICE ENCLOSURES for outdoor installation shall meet or exceed
ingress protection class IP66

Splice enclosures shall be appropriate for mounting on EHV Transmission towers

above anti-climb guard levels at about 10 meters from ground level and shall
accommodate pass-through splicing.

12.0 OPTICAL FIBRE SPLICES

Splicing of the optical fibre cabling shall be minimised through careful contractor
planning. There shall be no mid-span splices allowed. All required splices shall be
planned to occur within facilities or on tower structures. All optical fibre splicing
shall comply with the following :

a) All fibre splices shall be accomplished through fusion splicing.

b) Each fibre splice shall be fitted with a splice protection sheath fitted over the final
splice.
c) All splices and bare fibres shall be neatly installed in covered splice trays. No more
than six (6) fibres shall be installed in each splice tray.
d) Attenuation of single mode fusion splices shall not average 0.05 dB and no single
splice attenuation shall exceed 0.1 dB when measured at 1310 / 1550 nanometers.
e) For in-line splicing, fibre optic cable service loops of adequate length shall be
provided so that all splices occurring at tower structures can be performed at ground
level.

13.0 Methodology for installation and Termination

All optical fibre cable termination, installation, stringing and handling plans, guides
and procedures, and engineering analysis (e.g. tension, sag, vibration etc.) shall be
submitted to the Employer for review and approval in the engineering/design phase
of the project, prior to establishing the final cable lengths for manufacture.

WBSETCL / TECH SPEC / Rev.-1 Page 14 of22 OPGW&FODP

 Installation procedures including details of personnel and time required shall be
documented in detail and submitted to Employer for approval. All installation
practices shall be field proven and ISO accredited.

All cable segments shall include service loops. The maximum allowable stringing
tension, maximum allowable torsional shear stress, crush strength and other physical
parameters of the cable shall not be exceeded. The preventative measures to be taken
shall be documented in detail and submitted to Employer in advance of installation.

Optical fibre attenuation shall be measured after installation and before splicing. Any
increase in attenuation or step discontinuity in attenuation shall not be acceptable and
shall constitute a cable segment failure. In the event of cable damage, the complete
span shall be replaced as mid-span joints are not acceptable.

Any or all additional steel work of modifications required to attach the fibre cabling
to the overhead transmission/distribution line towers shall also be carried out by the
Contractor. The Contractor shall supply all tools and accessories required for
installation. It shall be the Contractors responsibility to provide adequate
communications among all crew members and support staff to ensure safe and
successful installations.

14.0 Service Loops

For purpose of this specification, cable and fibre service loops are defined as slack
(extra) cable and fibre provided for facilitating the installation, maintenance and
repair of the optical fibre cable plant.

a) Outdoor Cable Service Loops :

FODPs and in-line splice enclosures installed outdoors and mounted on the utility
towers, shall be installed with sufficient fibre optic cable service loops such that the
recommended minimum bend radius is maintained while allowing for installation or
maintenance of the cable to be performed in a controlled environment at ground
level.

b) Indoor Cable Service Loops :

FODPs shall provide at least three (3) metres of cable service loop. Service loops
shall be neatly secured and stored, coiled such that the minimum recommended bend
radius are maintained.

c) Fibre Units Service Loops :

For all fibre optic cable splicing, the cable shall be stripped back a sufficient length
such that the fan-out or fibre units shall provide for at least one (1) metre of fibre unit
service loop between the stripped cable and the bare fibre fan-out.

d) Pigtail Service Loops :

Connectorized pigtails spliced to bare fibres shall provide a least 0.5 metre of service
loop installed in the FODP fibre organizer and at least 1(one) metre of service loop to
the couplings neatly stored behind the FODP coupling panels.

e) Fibre Service Loops :

WBSETCL / TECH SPEC / Rev.-1 Page 15 of22 OPGW&FODP

 At least 0.5 metre of bare fibre service loop shall be provided on each side of all fibre
splices. The bare fibre service loops shall be neatly and safely installed inside
covered splice trays.

The Contractor shall supply and install this fibre optic cable, including design, supply
& installation of all required installation hardware fittings & accessories and
including any custom designed hardware fittings & accessories as required. The
installed unit shall be used mainly as the pilot wire suitable for the numerical pilot
wire current differential protection system to be operated between concerned line
terminals. The Contractor shall supply and install the optical fibre cable and
approach cable & other accessories as required based on the actual requirement. The
specified items will be paid as per the unit rates quoted. Un-specified items shall be
included in the supply rates after actual site visit. Termination of fibres to FODPs
through appropriate connectors shall be done by the Contractor at no extra cost. Cost
of supply of connectors & other termination materials as along with termination
work, shall be included in rate for “laying & termination” of fibre optic cables.

15.0 Installation of Approach Cable :

A network of cable trenches and / of ducts may exist at some sites but shall require
expansion and / or new construction at stations. It shall be a responsibility of the
Contractor to co-operate fully with the Employer and all other on-going project
Contractors in the planning and efficient use of existing and new-construction
infrastructure supporting on-station communications cabling. The existing cable
trenches / cable raceways proposed to be used shall be identified in the survey report.
The contractor shall make its best effort to route the cable through the existing
available cable trenches. Where suitable existing cable trenches are not available,
suitable alternatives shall be proposed for Employer’s approval. The contractor shall
provide any additional outdoor cable raceways and / or cable trenches required for
such approved alternative.
It may be noted that in order to utilise the existing trenches, the approach cable may
be required to be co-located with HV and LV cables. Accordingly, the approach
cable shall be installed in corrosion resistant flexible conduit. Suitable provisions
shall be made by the Contractor to ensure adequate safety earthing and insulated
protection for the approach cable.
Approach cables existing from the ground or passing through floors shall be
protected against mechanical damage.
Approach Cables will be laid within HDPE cable duct throughout from Gantry-
joint box to FODP. Approach cables shall penetrate buildings through cable ducts.
The cabling shall route within buildings in cable raceways or under raised floors. The
Contractor may utilise existing ducts, building penetration, cable trays, racks, etc.
where appropriate and approved by the Employer. The cables shall be affixed to
cable supports using approved ties, clips or cleats at regular intervals.
On short approach cable runs for which cable supports are not required, the Contractor
shall fix the cable to the structure of the building using approved fixing and cable
cleats.
The Contractor shall be responsible for new building penetrations required for
approach cabling. Caution shall be taken to ensure that existing equipment and site
personnel are protected from dust and debris incident to the cable penetration work.

WBSETCL / TECH SPEC / Rev.-1 Page 16 of22 OPGW&FODP

 Penetrations shall be neatly formed and sealed for protection from moisture, dust,
wind and vermin intrusion.
All required fittings, supports accessories, ducts, inner ducts, conduits, risers and any
item not specially mentioned but required for lay and installation of approach cables
shall be supplied and installed by the Contractor.
16.0 Cable Raceways:
The Contractor is required to provide and install any additional indoor cable raceways
which may be required for proper implementation of the fibre optic cabling system the
cable raceways shall conform with the following :
a) All cable raceways shall be sized to support full loading requirements plus at least a
200% safety loading factor.
b) Indoor cable raceways shall be fabricated from construction grade aluminium,
galvanized iron or anodized sheet metal or any other suitable material approved by the
Employer. Suitable anti-corrosion measures shall be provided steel fabricated
raceways shall be finished inside and out, treated to resist rust and to form a metal-to-
paint bond.
c) Mechanical construction drawings of the cable raceways shall be submitted for
Employer’s information and review.
17.0 INSPECTION AND TESTS
17.1 TYPE TESTS:
Type Test for Indigenous or fully Imported Materials:
The offered equipment must have fully type tested as per relevant ISs and / or any
other specified international standards, during the last five years period reckoned from
the date of opening of the tender. Photocopy of such type test reports/certificates must
be submitted along with the tender bid. The type test certificates of prototype
manufactured and tested by foreign collaborators of the tenderers at their works shall
not be acceptable for indigenously manufactured equipment.
17.2 Inspection
The material for final inspection shall be offered by the Contractor only under packed
condition. The employer shall select samples at random from the packed lot for
carrying our acceptance test.
Certificate of manufacturing tests shall be maintained by the Contractor and be
produced for verification as and when desired by the Employer.
Materials shall not be transported/shipped from its point of manufacture before it has
been satisfactorily inspected and tested.
The acceptance of any quality of materials shall in no way relieve the contractor of his
responsibility for meeting all the requirements of the specification and shall not
prevent subsequent rejection, if such materials are later found to be defective.
The Contractor shall give the Employer thirty (30) days written notice of any material
being ready for testing.

17.3 General Condition for Tests

a) The entire cost of testing for acceptance and routine test and test during
manufacture specified herein shall be treated as included in the quoted unit price
of materials.
WBSETCL / TECH SPEC / Rev.-1 Page 17 of22 OPGW&FODP
 b) The Contractor shall submit for the Employer’s approval a Test Procedure
Specification at least three(3) months before each individual test will be performed.
Fully approved test procedures shall be submitted to Employer at least 4 weeks prior
to the commencement of testing. The test procedure specification shall specify the
details test in accordance with the requirement of this specification.
c) The Employer reserves the right to require the Contractor to perform any other
reasonable test(s) at the Contractors premises, on site or elsewhere in addition to the
aforementioned Acceptance, Routine or manufacturing tests to assure Employer of
specification compliance.

17.4 Test Plans

Test Plans and procedures for both factory and field tests shall be provided by the
Contractor. Test plans and procedures shall ensure that each factory and field test is
comprehensive and verify all the features of the equipment to be tested. Test plans and
procedures shall be modular to allow individual test segments to be repeated upon
request.
There shall be two factory and field tests shall be submitted for Employer’s approval
at least three months before the start of testing.

17.5 Factory Acceptance Tests

Factory tests shall be conducted on selected sample of equipment to be supplied.
Equipment shall not be shipped until required Factory tests are completed
satisfactorily, all variances are resolved, full test documentation has been delivered to
the Employer and the Employer has approved for shipment/transportation. Successful
completion of the Factory tests and the Employer’s approval to ship/transport shall in
no way constitute final acceptance of the system or any portion thereof.
Factory tests shall not proceed without the prior delivery to and approval of all test
documentation by the Employer. In addition, upon the approval of the test documents
by the Employer, the Contractor-supplied maintenance and operators manuals will be
used during the tests as guide and as a check that each manual is correct and complete.

1. Acceptance Test of OPGW

10% of all offered items of each LOT shall be selected for witnessing acceptance
tests.

A) Tests on finished Cable

1) Cable dia
2) Attenuation of Fibers at 1310nm & 1550nm
3) Attenuation coefficient at water peak
4) Chromatic Dispersion
5) Cable Cut-off wavelength
6) Rated/Ultimate Tensile Strength for 1 Sample from selected OPGW drums/Lot
7) Cable lay length & lay ratio
8) Rewinding Test
9) Cable bend Test
10) Weight of Cable
11) Strain Margin Test

WBSETCL / TECH SPEC / Rev.-1 Page 18 of22 OPGW&FODP

 B) Tests on Aluminium Alloy wires and Aluminium Cladded Steel wires
1) Dia of wire
2) Tensile sterength
3) Elongation at break
4) Resistivity at 20°C
5) Winding/wrapping test for Al. Alloy wires and Torsion test for Al. Cladded Steel
wires
6) Thickness of Aluminium coating for Al. Cladded Steel wires
7) No. of ACS Strands

C) General Tests on Optical Unit

1) Total no. of Fibers, No. of fibers per buffer tube & color coding of optical fibers
in each tube
2) No. of buffer tubes, colour of buffer tubes, material of buffer tube
3) Aluminium tube (Outer and inner dia)
4) Binding Yarn /Tape (Thermal barrier)
5) Filling Material
6) Strengthening Member (FRP)

D) Chemical compositions of Al. Alloy wire, Al. Cladded Steel wire and Aluminium
tube

2. Acceptance Test of OPGW Hardwares:

A) Suspension Clamp Assembly

i) Visual & dimensional verification
ii) Mechanical Strength (UTS) of the Assembly
iii) Clamp Slip Strength Test
iv) Mechanical Strength Test of each component
v) Electrical Conductivity Test and UTS Test on Outer Rods and Structural
reinforcing rods
vi) Galvanising Test
vii) Chemical Test to know material composition

B) Tension Clamp Assembly

i) Visual & dimensional verification
ii) Mechanical Strength (UTS) of Tension Assembly
iii) Clamp Slip Strength Test
iv) Mechanical Strength Test of each component of tension clamp assembly
v) Electrical Conductivity Test and UTS Test on Dead end Rods and Structural
reinforcing rods
vi) Galvanising Test
vii) Chemical Test to know material composition
C) Vibration Damper
i) Visual & dimensional verification
ii) Calmp slip Test
iii) Attachment of Weights of Messenger Cable
iv) Attachment of Clamp to Messenger Cable Test
v) Clamp Bolt Tightening Test & Clamp Bolt Torque Test

WBSETCL / TECH SPEC / Rev.-1 Page 19 of22 OPGW&FODP

 vi) Vibration Damper Response (Resonant Frequencies) Test and dynamic
Characteristics Test
vii) Strength of Massenger wire Test
viii) Galvanising Test
D) Down Lead Clamp & Earth Lead Assembly
i) Clamp Fit Test
ii) Clamp Strength Test
iii) Visual Material Verification and Dimensional Check
iv) Galvanising Test

E) In Line Splice Enclosures (Joint Box) Visual Material Verification and Dimensional
Check

3. Acceptance Test of Approach Cable

i) Physical Check of the cable

ii) Optical fiber continuity
iii) fiber attenuation with OTDR (≤ 0.20DB/km @ 1550nm & ≤ 0.35dB @ 1310 nm.
iv) Max. Tensile Strength As per IEC60794-1-E1
v) Cable Bend Test As per IEC60794-1-E11
vi) Repeated Bending Test As per EIA-455-104
vii) Crush Strength As per IEC60794-1-E3
viii) Impact Test As per IEC60794-1-E4
ix) Torsion resistance As per IEC60794-1-E7
x) Kink Test As per IEC60794-1-E10
xi) Drip Test on cable As per TEC procedure
xii) Sheath/Inner Jacket i) Material, ii) Thickness
xiii) Outer Jacket i) Material, ii) Thickness
xiv) Armouringi) Material, ii) Thickness
xv) Rewinding Test
xvi) Starin Margin Test

17.6 Site Acceptance Tests

During the course of installation the Employer shall have full access for inspection of
the progress of the work and for checking workmanship and accuracy as may be
required. On completion of the work prior to commissioning, all equipment shall be
tested to the satisfaction of the Employer to demonstrate that it is entirely suitable for
commercial operation.
The tests shall be carried out in the presence of and to the satisfaction of the Employer
by the qualified technical representatives of the Contractor.
Prior to installation every spooled fibre optic cable segment shall be tested for
compliance with the Pre-shipment data previously received from the manufacturer.
This requirement will preclude the installation of out of specification cable segments
that may have been damaged during shipment.
During the installation, spliced cable segments shall be tested and documented. Upon
completion of a continuous cable path all fibres within the cable path shall be
WBSETCL / TECH SPEC / Rev.-1 Page 20 of22 OPGW&FODP
 demonstrated for acceptance of the cable path. Fibre Optic cable field testing
minimum requirements are provided in the following tables.

Fibre Optic Cable Pre-Installation Testing

Item Description
1 Physical Inspection of the cable assembly for damage
2 Optical fibre continuity end-to-end
3 Per fibre OTDR

Fibre Optic Cable Splice Testing

Item Description
1 Per Splice Attenuation
2 Per splice OTDR
3 Physical inspection of splice box/enclosure for proper fibre routing
techniques.
4 Physical inspection of sealing techniques, weatherproofing, etc.

18.0 MISCELLANEOUS SUPPLIES

The Contractor shall provide all required consumable and non-consumable supplies
necessary to support all installation and test activities through final operational
acceptance.

19.0 MAINTENANCE SUPPORT FACILITIES IN INDIA

The Bidder shall describe his own maintenance support capabilities and facilities in
India in his technical bid.

20.0 Other Services

The following services shall be included in the proposal.

a) An experienced, English speaking instructor shall hold training sessions on
installation, commissioning, operation and maintenance of OPGW.
- One week training for installation, commissioning, jointing, splicing,
maintenance etc. for about 5 to 6 persons shall be held at site.
b) WBSETCL shall bear all necessary charges for boarding and lodging at the place of
training for the above engineers/working personnel of WBSETCL or authorised
representatives for attending the above mentioned training programme at onwers’
premises. The training programmes shall be of class room training as well as on job
training as mentioned in Clause (a), above. Bidder also to submit training programme
and schedule including context of training well in advance (minimum one month) for
deputing engineer/working personnel).
c) Factory inspection/acceptance test : The vendor shall bear all necessary charges for
inspecting personnel (2 persons)including to and fro journey by air from purchasers
headquarters to manufacturers works. This also includes boarding, lodging, medical
insurance (in case of inspection to be carried out outside India)etc. at the
manufacturers’ place and transit, if any for the purpose of inspection and testing.
d) If inspection call raised by the bidder more than one time, they shall have to be borne
necessary inspection charges in each inspection.

WBSETCL / TECH SPEC / Rev.-1 Page 21 of22 OPGW&FODP

 21.0 Optional Testing Instruments

Price of testing instruments shall have to be quoted by the bidder as per price schedule.
Price of testing instruments shall be considered for the purpose of evaluation to
consider the most competent bidder.

WBSETCL / TECH SPEC / Rev.-1 Page 22 of22 OPGW&FODP