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Technical Specification of OPGW cable and associated hardware & fittings

This section describes the functional & technical specifications of OPGW cabling and associated
hardware & fittings.

1.1 Fibre Optic Cabling

This section defines the requirements for G.652D & G655 Dual-window Single mode (DWSM)
telecommunication grade fibre optic. Bidders shall furnish with their bids, detailed descriptions
of the fibres & cable (s) proposed.

All optical fibre cabling including fibre itself and all associated installation hardware shall have a
minimum guaranteed design life span of 25 years. Documentary evidence in support of
guaranteed life span of cable & fibre shall be submitted by the Contractor during detailed
engineering.

1.1.1 Required Optical Fibre Characteristics

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

1.1.1.1 Physical Characteristics

Dual-Window Single mode (DWSM), G.652D optical fibres shall be provided in the fibre optic
cables. DWSM optical fibres shall meet the requirements defined in Table 2-1 (a).

1.1.1.2 Attenuation

The 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. The attenuation coefficient between
1285 nm and 1330 nm shall not exceed the attenuation coefficient at 1310 nm by more than 0.05
dB. 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 (a) shall be “guaranteed” fibre attenuation of any & every fibre reel.

The overall optical fibre path attenuation shall not be more than calculated below:

Maximum attenuation @ 1550nm: 0.21 dB/km x total km + 0.05dB/splice x no. of splices + 0.5
dB/connector x no. of connectors.

Maximum attenuation @ 1310nm: 0.35 dB/km x total km + 0.05 dB/splice x no. of splices + 0.5
dB/connector x no. of connectors.
Table 1-1 (a)
DWSM OPTICAL Fibre Characteristics

Fibre Description: Dual-Window Single-Mode

Mode Field Diameter: 8.6 to 9.5 µm (± 0.6 µm)
Cladding Diameter: 125.0 µm ± 1 µm
Model field concentricity error < 0.6 µm
Cladding non-circularity < 1%
Cable Cut-off Wavelength λcc < 1260 nm
1550 nm loss performance As per G.652 D
Proof Test Level > 0.69 Gpa
Attenuation Coefficient: @ 1310 nm < 0.35 dB/km
@ 1550 nm < 0.21 dB/km
Chromatic Dispersion; Maximum: 18ps/(nm x km) @ 1550 nm
3.5 ps/(nm x km) 1288-1339 nm
5.3 ps/(nm x km) 1271-1360 nm

1300 to 1324 nm
Zero Dispersion Wavelength: 0.092 ps/(nm²xkm) maximum
Zero Dispersion Slope:

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Polarization mode dispersion coefficient < 0.2 ps/km^½

Temperature Dependence: Induced attenuation < 0.05 dB (-60ºC -
+85ºC)
Bend Performance: @ 1310 nm (75±2 mm dia Mandrel), 100
turns:
Attenuation Rise < 0.05 dB
@1550 nm (30±1 mm radius Mandrel),
100 turns;
Attenuation Rise < 0.05 dB
@ 1550 nm 32±0.5 mm dia Mandrel, 1
turn;
Attenuation Rise < 0.50 dB

1.1.2 Fibre Optic Cable Construction

Overhead Fibre Optic Cables shall be OPGW (Optical Ground Wire). The OPGW cable is
proposed to be installed on transmission lines. The design of cable shall account for the varying
operating and environmental conditions that the cable shall experience while in service.

1.1.2.1 Transmission Line Details

Typical details of transmission lines are indicated in the Appendices. Any other details, as
required for cable design etc, shall be collected by the Contractor during survey.

1.1.2.2 Optical Fibre Cable Link Lengths

The Contractor shall supply & install the optical fibre cable as required based on detailed site
survey to be carried out by the Contractor during the project execution. The Contract price shall
be adjusted accordingly.

For the purpose of payment, the optical fibre link lengths are defined as transmission line route
lengths from Gantry at one terminating station to the Gantry in the other terminating station. The
actual cable lengths to be delivered shall take into account various factors such as sag, service
loops, splicing, working lengths & wastage etc, and no additional payment shall be payable in
this regard. The unit rate for FO cable quoted in the Bid price Schedules shall take into account
all such factors.

1.1.2.3 Optical Fibre Identification

Individual optical fibres within a fibre unit and fibre units shall be identificable in accordance
with EIA/TIA 598 OR IEC 60304 or Bellcore GR-20 colour-coding scheme.

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 manufacturer’s fibre
number and parameters of the fibre. If more than the specified number 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.

1.1.2.4 Buffer Tube

Loose tube construction shall 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 identificable utilizing colour coding. Buffer
tubes shall be filled with a water-blocking gel.

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1.1.2.5 Optical Fibre Strain & Sag-tension chart

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.

For the purpose of this specification, the following definitions shall apply;

 Maximum Working Tension (MWT) is defined as the maximum cable tension at which
there is no fibre strain.
 The no fibre strain condition is defined as fibre strain of less than or equal to 0.05%, as
determined by direct measurements through IEC/ETSI(FOTP) specified optical
reflectometry techniques.
 The Cable strain margin is defined as the maximum cable strain at which there is no fibre
strain.
 The cable Maximum Allowable Tension (MAT) is defined as the maximum tension
experienced by the Cable under the worst case loading condition.
 The cable max strain is defined as the maximum strain experienced by the Cable under
the worst case loading condition
 The cable Every Day Tension (EDT) is defined as the maximum cable tension on any
span under normal conditions.
 The Ultimate / Rated Tensile Strength (UTS/RTS/breaking strength) is defined as the
maximum tensile load applied and held constant for one minute at which the specimen
shall not break.

While preparing the Sag-tension charts for the OPGW cable the following conditions shall be
met:

 The Max Allowable Tension (MAT) / max strain shall be less than or equal to the
MWT/Strain margin of the cable
 The Sag shall not exceed the earth wire sag in all conditions.
 The Max Allowable Tension shall also be less than or equal to 0.4 times the UTS.
 The 25 years creep at 25% of UTS (creep test as per IEEE 1138) shall be such that the 25
years creep plus the cable strain at Max Allowable Tension (MAT) is less than or equal to
the cable strain margin.
 The everyday tension (EDT) shall not exceed 20% of the UTS for the OPGW cable.

The Sag-tension chart of OPGW cable indicating the maximum tension, cable strain and sag
shall be calculated and submitted along with the bid under various conditions mentioned below:

1. 53ºC, no wind and no ice

2. 32ºC, no wind and no ice
3. 0ºC, no wind and no ice
4. 32ºC, full wind and no ice
5. 32ºC, 75% full wind and no ice
6. 0ºC, 2/3rd / 36% of full wind (IS 802:1977/1995)

The above cases shall be considered for the spans from 100 m to 600 m or higher span length in
the range of 50 m spans. Max. vertical sag, max. tension and max sag at 0º C & no wind shall be
considered for in line with the design parameter of transmission line. The typical details are
indicated in the appendices. The full wind load shall be considered as the design wind load for all
the specified transmission lines as per relevant IS 802 version and the sag-tension chart shall be
submitted considering the transmission lines. The contractor shall submit the stringing chart for
review of Employer.

1.1.2.6 Cable Materials

The materials used for optical fibre cable construction, shall meet the following requirements:

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1.1.2.6.1 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-794-1-F-5.

The filling compound used shall be a 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 waterproofing filling materials shall not affect fibre coating, colour coding, or encapsulant
commonly used in splice enclosures, shall be dermatologically safe, non-staining and easily
removable with a non-toxic cleaning solvent.

1.1.2.6.2 Metallic Members

When the fibre optic cable design incorporates metallic elements in its construction, all metallic
elements shall be electrically continuous.

1.1.2.6.3 Marking, Packaging and Shipping

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

(a) Drum Markings: Each side of every reel of cable shall be permanently marked in
white lettering with the vendors’ address, the Purchaser’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 & segment no.,
factory inspection stamp and date.

(b) Cable Drums: All optical fibre cabling shall be supplied on 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 be supplied on sturdy, corrosion resistant, steel drums sutiable
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.

1.1.2.6. OPGW cable Installation requirements

OPGW cables shall be installed in off-line conditions. The tentative bill of quantities for both
live- line as well as off-line OPGW cable system installations have been specified in the
appendices and the actual quantities for both types shall be finalized during project execution
after detailed survey.

Supervision of Installation – The Contractor shall supervise the stringing at site as per the
approved stringing procedure. Site visit for supervision shall be carried out as per instruction of
Employer. However, the contract price shall be adjusted as per the actual requirement. The
Supervision/Inspection work in Contractor’s scope shall mainly include inspection as per
stringing procedure, proper location of drum site, installation of stringing blocks/pulleys, proper
sagging, proper installation of hardware, proper tension as per Sag-Tension chart, provision of
service loops of OPGW in jointing locations etc.

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1.1.2.7 Optical Ground Wire (OPGW)

OPGW cable construction shall comply with IEEE-1138, 1994. 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 this specification. There shall
be no factory splices within the cable structure of a continuous cable length.

The composite fibre optic overhead ground wire shall be made up of buffered optical fibre units
(fibres in the buffer tube) embedded in a water tight aluminimum / 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.

1.1.2.7.1 Central Fibre Optic Unit

The central fibre optic unit shall be designed to house and protect multiple buffered optical fibres
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 an fault current, as well as
environmental effects which may produce hydrogen.

Central fibre optic unit may be of aluminium or stainless steel tube with aluminium protective
coating. In case of aluminium protective coating, the coating must completely cover the tubes
leaving no exposed areas of tubing that can make electrical contact either directly or indirectly
through moisture, contamination, protrusions, etc with the surrounding stranded wires. The tube
may be fabricated as a seamless tube, seam welded, or a tube without a welded seam.

1.1.2.7.2 Breaking Strength

The rated breaking strength of the completed OPGW shall be taken as no more than 90 percent
of the sum of the rated breaking strengths of the individual wires, calculated from their nominal
diameter and the specified minimum tensile strength.

The rated breaking strength shall not include the strength of the optical unit. The fibre optic unit
shall not be considered a load bearing tension member when determining the total rated breaking
strength of the composite conductor.

1.1.2.7.3 Electrical and Mechanical Requirements

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 that of the earthwire being replaced such that there is no or minimal
consequential increase in stresses on towers. 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 this section shall also be satisfied. The Bidder shall submit
sag-tension charts for the above cases with their bids.

Table 1.2(a)
OPGW Electrical and Mechanical Requirements

(1) Everyday Tension < 20% of UTS of OPGW

(2) D.C. Resistance at 20ºC: < 1.0 ohm/Km
(3) Short Circuit Current: > 6.32 kA for 1.0 second (for 220 kV & above lines)
≥ 5.6 kA for 1.0 second (for 132 KV & 66KV lines)
Short Circuit shall be applicable as per the Voltage
level of the lines

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1.1.2.7.4 Operating 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
currents. Therefore, is electrical and mechanical properties shall be same as those required of
conventional ground conductors.

1.1.2.7.5 Installation

OPGW installed under off line condition, 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 fibre optic cable handling. The
stringing procedure shall be submitted by the Contractor prior to stringing for Employer’s
approval.

The OPGW cable sections shall normally be terminated & spliced only on tension towers. In
exceptional circumstances, and on Employer specific approval, cable may be terminated on
Suspension towers, but in this case tower strength shall be examined to ensure that tower loads
are within safe limits and if required, necessary tower strengthening shall be carried out by the
Contractor.

1.1.2.7.6 Installation Hardware

The scope of supply of the optical cable includes the assessment, supply and installation of all
required fittings and hardware such as Tension assembly, Suspension assembly, Vibration
dampers, Reinforcing rods, Earthing clamps, Downlead clamps, splice enclosure etc. The Bidder
shall provide documentation justifying the adequacy and suitability of the hardware supplied.
The Contractor shall determine the exact requirements of all accessories required to install and
secure the OPGW.

The OPGW hardware fittings and accessories shall follow the general requirements regarding
design, materials, dimensions & tolerances, protection against corrosion and markings as
specified in clause 4.0 of EN 61284:1997 (IEC 61284). The shear strength of all bolts shall be at
least 1.5 times the maximum installation torque. The OPGW hardware & accessories drawing &
Data Requirement Sheets (DRS) document shall consist of three parts: (1) A technical particulars
sheet (2) An assembly drawing i.e. level 1 drawing and (3) Component level drawings i.e. level 2
& lower drawings. 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 for OPGW installations and shall not necessarily be limited to the following:

(a) Suspension Assemblies: Preformed armour grid 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 25 KN. 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 150 mm (measured from the center point of
attachment to the center 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.
(b) Dead End Clamp Assemblies: All dead end clamp assemblies shall preferably be
of 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.

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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: 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 that 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.
(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 as specified in technical specifications. 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.

1.1.3 Fibre Optic Splice Enclosures (Joint Box)

All splices shall be encased in Fibre Optic Splice Enclosures. Suitable splice enclosures shall be
provided to encase the optical cable splices in protective, moisture and dust free environment.
Splice enclosures shall comply to ingress protection class IP 66 or better. The splice enclosures
shall be designed for the storage and protection of required number of optical fibre splices and
equipped with sufficient number of splice trays for splice trays for splicing all fibres in the cable.
No more than 6 fibres shall be terminated in a single splice tray. They shall be filled with
suitable encapsulate that is easily removable should re-entry be required into the enclosures.
Splice enclosures shall be suitable for outdoor use with each of the cable types provided under
this contract. Splice enclosures shall be appropriate for mounting on transmission line towers
above anti-climb guard levels at about 10 metres from top of the tower and shall accommodate
pass-through splicing. The actual mounting height and location shall be finalized after Survey.
Contractor shall be responsible for splicing of fibres and installation of splice enclosures.

1.1.3.1 Optical Fibre Splices

Splicing of the optical fibre cabling shall be minimized through careful contractor planning.
There shall be no mid-span splices allowed. All required splices shall be planned to occur 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 fibre shall be neatly installed in covered splice trays. No more
than six (6) fibres shall be installed in each splice tray.
(d) For each link, bi-directional attenuation of single mode fusion splices, shall not
average more than 0.05 dB and no single shall exceed 0.1 dB when measured at
1550 nm.
(e) For 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.

1.1.4 Fibre Optic Approach Cables

For purposes of this specification, a fibre optic approach cable is defined as the Armoured
underground fibre optic cable required to connect Overhead Fibre Optic Cable (OPGW) between
the final in line splice enclosure on the gantry / tower forming the termination of the fibre cable
on the power line and the Fibre Optic Distribution Panel (FODP) installed within the building.
The estimated fibre optic approach cabling length requirements are indicated in the appendices.
However, the Contractor shall supply & install the optical fibre approach cable as required based
on detailed site survey to be carried out by the Contractor during the project execution and the
Contract price shall be adjusted accordingly.

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1.1.4.1 Basic Construction

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.

1.1.4.2 Jacket Construction & Material

The approach cable shall be a UV resistant, rodent proof, armoured cable with metallic type of
armoring. The outer cable jacket for approach cable shall consist of carbon black polyethylene
resin to prevent damage from exposure to ultra-violet light, weathering and high levels of
pollution. The jacket shall confirm to ASTM D1248 for density.

1.1.4.3 Optical, Electrical and Mechanical Requirements

Approach cable shall contain fibres with identical optical/physical characteristics a those in the
OPGW cables. The cable core shall comprise of tensile strength member(s), fibre
support/bedding structure, core wrap/bedding, and an overall impervious jacket.

1.1.5 Installation of Approach cable

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 provided after Employer approval. However, the approach cable shall be laid in the
HDPE pipe in all condition.

Suitable provisions shall be made by the contractor to ensure adequate safety earthing and
insulated protection for the approach cable.

All required fittings, supports, accessories, ducts, inner ducts, conduits, risers and any item not
specially mentioned but required for laying and installtion of approach cables shall be supplied
and installed by the Contractor.

1.1.6 Optical Fibre Termination and Splicing

Optical fibre terminations shall be installed in Fibre Optical 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 rack/wall mounted fibre optic distribution panels (FODPs) sized as indicated in the
appendices and shall terminate the fibre optic cabling up to the FODPs. The location of FODP
rack shall be fixed by the Contractor, with the Employer’s approval.

1.1.6.1 Fibre Optic Distribution Panel

At each location requiring the termination of at least one fibre 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 splice 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) FODPs shall be supplied in suitable cabinets/racks with locking arrangement.

The dimension of FODP cabinet shall be minimum 2200mm x 600mm x 600mm (HxWxD)
and shall meet or exceed ingress protection class IP55 specifications.

d) ALL FODPs shall be of corrosion resistant, robust construction and shall allow both top
or bottom entry for access to the splice trays, Ground lugs shall be provided on all

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FODPs and the Contractor shall ensure that all FODPs are properly grounded. The FODP
shall meet or exceed ingress protection class IP55 specifications.

e) Flexible protection shall be provided to the patch cord bunches going out from FODP to
other equipment.

1.1.6.2 Optical Fibre Connectors

Optical fibres shall be connectorised with FC-PC type connectors preferably. Alternatively
connector with matching patch cord shall also be acceptable. Fibre optic couplings supplied with
FODPs shall be appropriate for the fibre connectors to be supported. There shall be no adapters.

1.1.7 Service Loops

For purposes 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: 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 of 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: Connectorised pigtails spliced to bare fibres shall provide at least 1
metre of service loop installed in the FODP fibre organizer and at least one (1) metre of
service loop to the couplings neatly stored behind the FODP coupling panels.
(e) Fibre Service Loops: 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.

1.1.8 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. 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 as specified in this specification. 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 details 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 or any fibre damage, the complete section (tension
location to tension location) shall be replaced as mid-span joints are not acceptable.

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Any or all additional steel work or modifications require to attach the fibre cabling to the
overhead transmission/distribution line towers shall also be carried out by the contractor. It shall
be the Contractors responsibility to provide adequate communications among all crew members
and support staff to ensure safe and successful installations.

1.1.9 Cable Raceways

To the extent possible, existing cable raceways shall be utilized. The Contractor is required to
provide and install any additional indoor cable raceways which maybe required for proper
implementation of and communication system. This requirement shall be finalized during
survey. The cable raceways shall conform to 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 anticorrosion 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 & review.

2.0 Type Testing

“Type Tests” shall be defined as those tests which are to be carried out to prove the design,
process of manufacture and general conformity of the materials to this specification. Type testing
shall comply with the following:

a) All cable being supplied shall conform to type tests as per technical specification.
b) The test reports submitted shall be of the tests conducted within last seven (7)
years for OPGW cable prior to the date of bid opening. In case the test reports are
older than seven (7) years for OPGW cable on the date of bid opening, the
contractor shall repeat these tests at no extra to the purchaser.
c) The contractor shall submit, within 30 days of contract award, copies of test
reports for all of the type tests that are specified in the specifications and that have
previously (before contract award) been performed. These reports may be
accepted by the employer only if they apply to materials and equipment that are
essentially identical to those due to be delivered under the contract and only if test
procedures and parameter values are identical to those specified in this
specifications carried out at accredited labs and witnessed by third party /
customer’s representatives.

In the event of any discrepancy in the test reports or any type tests not carried out,
same shall be carried out by contractor without any additional cost implication to
the employer.

d) Type tests shall be certified or performed by reputed laboratories using material

and equipment data sheets and test procedures that have been approved by the
employer. The test procedures shall be formatted as defined in the technical
specifications and shall include a complete list of the applicable reference
standards and submitted for employer approval at least four (4) weeks before
commencement of test(s). The contractor shall provide the employer at least 30
days written notice of the planned commencement of each type test.
e) The contractor shall provide a detailed schedule for performing all specified type
tests. These tests shall be performed in the presence of a representative of the
employer, if required.
f) The contractor shall ensure that all type tests can be completed within the time
schedule offered in his technical proposal.

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g) In case of failure during any type test, the supplier is either required to
manufacture a fresh sample lot and repeat all type tests successfully or repeat that
particular type test(s) at least three times successfully on the samples selected
from the already manufactured lot at his own expenses. In case a fresh lot is
manufactured for testing then the lot already manufactured shall be rejected.

2.1 Type Test Samples

The contractor shall supply equipment/material for sample selection only after the quality
assurance plan has been approved by the employer. The sample material shall be manufactured
strictly in accordance with the approved quality assurance plan. The contractor shall submit for
employer approval, the type test sample selection procedure. The selection process for
conducting the type tests shall ensure that samples are selected at random. At least three samples
of each of the proposed equipment / item / cable drum except FO cable installation hardware &
fittings shall be offered for selection. For FO cable installation hardware & fittings at least ten
(10) samples shall be offered for selection.

2.1.2 List of Type Tests

The type testing shall be conducted on the following equipment/items

(a) Optical fibres

(b) OPGW Cable

(c) OPGW Cable fittings

(d) Vibration Damper

(e) Splice Enclosure (Joint Box)

2.3 Type Tests for Optical Fibres

The type tests listed below in table 2.1 shall be conducted on DWSM fibres to be supplied as part
of overhead cables. The tests specific to the cable type are listed in subsequent sections.

Table 2.1

Type Tests for Optical Fibres

S.No. Test Name Acceptance Criteria Test procedure

1 Attenuation As per section-02 of IEC 60793-1-40 Or

TS EIA/TIA 455-78A

2 Attenuation Variation with As per section-02 of IEC 60793-1-40 Or

Wavelength TS EIA/TIA 455-78A

3 Attenuation at Water Peak As per section-02 of IEC 60793-1-40 Or

TS EIA/TIA 455-78A

4 Temp. Cycling (Temp IEC 60793-1-52 Or

dependence of EIA/TIA 455-3A cycles
Attenuation)

5 Attenuation with bending IEC 60793-1-47 Or

(bend performance) EIA/TIA 455-62A

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6 Mode Field dia IEC 60793-1-45 Or

EIA/TIA 455-
164A/167A/174

7 Chromatic Dispersion IEC 60793-1-42 Or

EIA/TIA 455-
168A/169A/175A

8 Cladding Diameter IEC 60793-1-20 Or

EIA/TIA 455-176

9 Point Discontinuities of IEC 60793-1-40 Or

attenuation EIA/TIA 455-59

10 Core-Clad concentricity error IEC 60793-1-20 Or

EIA/TIA 455-176

11 Fibre Tensile proof testing IEC 60793-1-30 Or

EIA/TIA 455-31B

- End of table -

2.4 Type Test for OPGW cables

The type tests to be conducted on the OPGW cable are listed in Table 2.2 Type Tests for OPGW
Cables. Unless specified otherwise in the technical specifications or the referenced standards, the
optical attenuation of the specimen, measured during or after the test as applicable, shall not
increase by more than 0.05 dB/Km.

Table 2.2

Type tests for OPGW Cable

S.No. Test Name Test Description Test Procedure

1 Water Ingress IEEE 1138-2009 IEEE 1138-2009 (IEC 60794-1-2

Test Method F5 or EIA/TIA 455-82B):
Test duration: 24 hours

2 Seepage of IEEE 1138-2009 IEEE 1138-2009 Preconditioning

filling EIA/TIA 455- period: 72
compound 81B hours. Test
duration: 24
hours

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3 Short Circuit IEEE 1138-2009 IEEE 1138-2009 Fibre attenuation shall be

Test continuously monitored and
recorded through a digital
data logging system or
equivalent means. A suitable
temperature sensor such as
thermocouple shall be used to
monitor and record the
temperature inside the
OPGW tube in addition to
monitoring & recording the
temperatures between the
strands and between optical
tube and the strand as
required by IEEE 1138. Test
shall be conducted with the
tension clamps proposed to
be supplied. The cable and
the clamps shall be visually
inspected for mechanical
damage and photographed
after the test.

Or IEC60794-4- Initial temperature during the

10/IEC 60794- test shall be greater than or
1-2 (2003) equal to ambient field
Method H1 temperature.

4 Aeolian IEEE 1138-2009 IEEE 1138-2009 Fibre attenuation shall be

Vibration Test Or IEC 60794- continuously monitored and
4-10/IEC recorded through a digital
60794-1-2, data logging system or
Method E19 equivalent means. The
vibration frequency and
amplitude shall be monitored
and recorded continuously.
All fibres of the test cable
sample shall be spliced
together in serial for
attenuation monitoring. Test
shall be conducted with the
tension/suspension clamps
proposed to be supplied. The
cable and the clamps shall be
visually inspected for
mechanical damage and
photographed after the test.

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5 Galloping test IEEE 1138-2009 IEEE 1138-2009 Test shall be conducted with
the tension/suspension
clamps proposed to be
supplied. The cable and
clamps shall be visually
inspected for mechanical
damage and photographed
after the test. All fibres of the
test cable sample shall be
spliced together in serial for
attenuation monitoring.

6 Cable Bend Test Procedure 2 in The short-term and long term

IEC 60794-1-2 bend tests shall be conducted
Method E11 in accordance with procedure
2 in IEC 60794-1-2 E11 to
determine the minimum
acceptable radius of bending
without any increase in
attenuation or any other
damage to he fibre optic
cable core such as bird
caging, deformation, kinking
and crimping.

7 Sheave Test IEEE 1138-2009 IEEE 1138-2009 Fibre attenuation shall be

OR IEC 60794- continuously monitored and
1-2 (2003) recorded through a digital
Method E1B data logging system or
equivalent means. The
Sheave dia. Shall be based on
the pulling angle and the
minimum pulley dia
employed during installation.
All fibres of the test cable
sample shall be spliced
together in serial for
attenuation monitoring.

8 Crush Test IEEE 1138-2009 IEEE 1138-2009 The crush test shall be carried
(IEC 60794-1-2, out on a sample of
Method approximately one (1) metre
E3/EIA/TIA long in accordance with IEC
455-41B) 60794-1-2 E3. A load equal
to 1.3 times the weight of a
400 – metre length of fibre
optic cable shall be applied
for a period of 10 minutes. A
permanent or temporarily
increase in optical attenuation
value greater than 0.1 dB
change in sample shall
constitute failure. The load
shall be further increased in
small increments until the
measured attenuation of the
optical waveguide fibres
increases and the failure load
recorded along with results.

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9 Impact Test IEEE 1138-2009 IEEE 1138- The impact test shall be
2009, (IEC carried out in accordance
60794-1-2 with IEC 60794-1-2 E4. Five
E4/EIA/TIA separate impacts of 0.1-
455-25B) 0.3kgm shall be applied. The
radius of the intermediate
piece shall be the reel drum
radius ± 10%. A permanent
or temporary increase in
optical attenuation value
greater than 0.1 dB/km
change in sample shall
constitute failure.

10 Creep Test IEEE 1138-2009 IEEE 1138-2009 As per Aluminium

Association Method, the best-
fit straight line shall be fitted
to the recorded creep data and
shall be extrapolated to 25
years. The strain margin of
the cable at the end of 25
years shall be calculated. The
time when the creep shall
achieve the strain margin
limits shall also be calculated.

11 Fibre Strain Test IEEE 1138-2009 IEEE 11-38-

1994

12 Strain Margin IEEE 1138-2009 IEEE 1138-2009

Test

13 Stress strain test IEEE 1138-2009 IEEE 1138-2009

14 Cable Cut-off IEEE 1138-1994 IEEE 1138-1994

wavelength test

15 Temperature IEEE 1138-2009 IEEE 1138-2009 Or IEC 60794-1-2, Method F1

Cycling Test

16 Corrosion (Salt EIA/TIA 455-16A

Spary) test

17 Tensile IEC 60794-1-2 E1/EIA/TIA 455- The test shall be conducted

performance test 33B on a sample of sufficient
length in accordance with
IEC 60794-1-2 EI. The
attenuation variation shall not
exceed 0.05 dB/Km up to
90% of RTS of fibre optic
cable. The load shall be
increased at a steady rate up
to rated tensile strength and
held for one (1) minute. The
fibre optic cable sample shall
not fail during the period. The
applied load shall then be
increased until the failing
load is reached and the value
recorded.

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18 Fault current/ IEC 60794-4-10/IEC 60794-1-2 The OPGW cable

lightning test (2003) construction shall be tested in
accordance with IEC 60794-
1-2, Method H2 for Class 1.

19 DC Resistance On a fibre optic cable sample of minimum 1 metre length, two

Test (IEC contact clamps shall be fixed with a predetermined bolt torque. The
60228) resistance shall be measured by a Kelvin double bridge by placing
the clamps initially zero metre and subsequently one metre apart.
The tests shall be repeated at least five times and the average value
recorded after correcting at 20ºC.

- End of table -

2.5 Type Test on OPGW cable fittings

The type tests to be conducted on the OPGW cable fittings and accessories are listed below:

(i) Mechanical Strength Test for suspension/tension assembly

Applicable Standards: IEC 61284, 1997

Suspension Assembly

The armour rods/reinforcement rods are assembled on to the approved OPGW using the
Installation Instructions to check that the assembly is correctly fitted and is the same that will be
carried out during installations.

Part 1:

The suspension assembly shall be increased at a constant rate up to a load equal to 50% of the
specified minimum failure load increased and held for one minute for the test rig to stabilize. The
load shall then be increased at a steady rate to 67% of the minimum failure load and held for five
minutes. The angle between the cable, the suspension assembly and the horizontal shall not
exceed 16º. This load shall then be removed in a controlled manner and the protection splice
disassembled. Examination of all the components shall be made and any evidence of visual
deformation shall be documented.

Part 2:

The suspension clamp shall then be placed in the testing machine. The tensile load shall
gradually be increased up to 50% of the specified Minimum failure load of the suspension
assembly and held for one minute for the test rig to stabilize and the load shall be further
increased at a steady rate until the specified minimum failure load is reached and held for one
minute. No fracture should occur during this period. The applied load shall then be increased
until the failing load is reached and the value shall be documented.

Tension Assembly

The Tension Assembly is correctly fitted and is the same that will be carried out during
installations.

Part 1:

The tension assembly (excluding tension clamp) shall be increased at a constant rate up to a load
equal to 50% of the specified of the specified minimum failure load increased at a constant rate
and held for one minute for the test rig to stabilize. The load shall then be increased at a steady
rate to 67% of the minimum failure load and held of five minutes. This load shall then remove in
a controlled manner and the tension assembly disassembled. Examination of the tension dead-
end and associated components shall be made and any evidence of visual deformation shall be
documented.

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Part 2:

The Tension Dead-End and associated components shall then be reassembled and bolts tightened
as before. The tensile load shall gradually be increased up shall gradually be increased up to 50%
of the specified minimum failure load of the tension assembly and held for one minute for the
test rig to stabilize and the load shall be further increased at a steady rate until the specified
minimum failure load is reached and held for one minute. No fracture should occur during this
period. The applied load shall then be increased until the failing load is reached and the value
shall be documented.

Acceptance Criteria for Tension/Suspension assembly:

- No evidence of binding of the Nuts or Deformation of components at end of Part 1 of

test.

- No evidence of fracture at the end of one minute at the minimum failure load during Part
2 of the test.

Any result outside these parameters shall constitute a failure.

(ii) Clamp slip strength test for suspension assembly

The suspension assembly shall be vertically suspended by means of a flexible attachment. A

suitable length fibre optical cable shall be fixed in the clamps. Once the suspension clamp has
been assembled, the test rig is tensioned to 1 KN and the position scale on the recorder ‘zeroed’.
The test rig is then tensioned to 2.5 KN and the relative positions of the Reinforcing Rods,
Armour Rods and suspension clamp shall be marked by a suitable means to confirm any slippage
after the test has been completed. The relative positions of the helical Armour Rods and
associated Reinforcing Rods at each end shall be marked and also 2 mm relative position
between clamp body and Armour Rods shall be marked on one side. The load shall be increased
to 12KN at a loading rate of 3 KN/min and held for one minute. At the end of this one minute
period, the relative displacement between clamp body and the armour rods shall be observed. If
the slippage is 2mm or above, the test shall be terminated. Otherwise, at the end of the one
minute the position of the clamp body and 2mm. relative positions between clamp body and
armour rods shall be marked on the other side. After the one minute pause, the load shall be
further increased at a loading rate of 3 KN/min, and recording of load and displacement shall
continue until either the relative position displacement between clamp body and armour rods
reaches more than 2 mm or the load reaches the maximum slip load of 17 KN. On reaching
either of the above values the test is terminated. Visual examination of all paint marks shall be
recorded, and a measurement of any displacement recorded in the table of results.

Acceptance Criteria:

The suspension clamp has passed the slip test if the following conditions are met:

- No slippage* shall occur at or below the specified minimum slip load.

* Definition of no slippage in accordance with IEC 61284, 1997:- Any relative movement
less than 2 mm is accepted. The possible couplings or elongations produced by the cable
as a result of the test itself are not regarded as slippage.

- Slippage shall occur between the specified maximum and minimum slip load of 12-
17KN.

- There shall be no slippage of the Reinforcing Rods over the cable, and no slippage of the
Armour Rods over the Reinforcing Rods.

- The relative movement (i.e. more than 2 mm between Armour Rods & Clamp body)
between minimum 12KN and maximum slip 17KN, shall be considered as slip.

- The Armour Rods shall not be displaced from their original lay or damaged**.

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** Definition of no damage in accordance with convention expressed in IEC 61284: 1997

no damage, other than surface flattening of the strands shall occur.

Any result outside these parameters is a failure.

(iii) Slip strength test of tension clamp

Tension clamps shall be fitted on a 8 m length of fibre optic cable on both ends. The assembly
shall be mounted on a tensile testing machine and anchored in a manner similar to the
arrangement to be used in service. A tensile load shall gradually be applied up to 20% of the
RTS of OPGW. Displacement transducers shall be installed to measure the relative movement
between the OPGW relative to the Reinforcing Rods and Tension Dead – End relative to
Reinforcing Rods. In addition, suitable marking shall be made on the OPGW and Dead – End to
confirm grip. The load shall be gradually increased at a constant rate up to 50% of the UTS and
the position scale of the recorder is zeroed. The load shall then gradually increased up to 95% of
the UTS and maintained for one minute. After one minute pause, the load shall be slowly
released to zero and the marking examined and measured for any relative movement.

Acceptance Criteria:

- No movement* shall occur between the OPGW and the Reinforcing Rods, or between the
Reinforcing Rods and the Dead-End assembly.

- No failure or damage or disturbance to the lay of the Tension Dead – End, Reinforcing
Rods or OPGW.

*Definition of no movement as defined in IEC 61284: Any relative movement less than 2
mm is accepted. The possible couplings or elongations produced by the conductor as a result
of the test itself are not regarded as slippage.

Any result outside these parameters shall constitute a failure.

(iv) Grounding Clamp and Structure Mounting Clamp Fit Test

For structure mounting clamp, one series of test shall be conducted with two fibre optic cables
installed, one series of tests with one fibre optic cable installed in one groove, and one series of
tests with one fibre optic cable in the other groove. Each clamp shall be installed including
clamping compound as required on the fibre optic cable. The nut shall be tightened on to the bolt
by using torque wrench with a torque of 5.5 kgm or supplier’s recommended torque and the
tightened clamps shall be held for 10 minutes. After the test remove the fibre optic cable and
examine all its components for distortion, crushing or breaking. Also the fibre optic cable shall
be checked to ensure free movement within the core using dial callipers to measure the diameter
of the core tube. The material shall be defined as failed if any visible distortion, crushing,
craking or breaking of the core tube is observed or the fibre optic cable within the core tube is
not free to move, or when the diameter of the core tube as measured at any location in the
clamped area is more than 0.5 mm larger or smaller of the core diameter as measured outside the
clamped area.

(v) Structure Mounting Clamp Strength Test

The clamp and mounting assembly shall be assembled on a vertical 200 mm x 200 mm angle and
a short length of fibre optic cable installed. A vertical load of 200 kg shall be applied at the end
of the mounting clamp and held for 5 minutes. Subsequently, the load shall be increased to 400
kg and held for 30 seconds. Any visible distortion, slipping or breaking of any component of the
mounting clamp or assembly shall constitute failure.

2.6 Type Test on Vibration Damper

(a) Dynamic Characteristic Test

The damper shall be mounted with its clamp tightened with torque recommended by the
manufacturer on shaker table capable of simulating sinusoidal vibrations for Critical Aeolian
Vibration frequency band ranging from 0.18/d to 1.4/d – Where d is the OPGW cable diameter in
meters. The damper assembly shall be vibrated vertically with a ± 1 mm amplitude from 5 to 15

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Hz frequency and beyond 15 Hz at 0.5 mm to determine following characteristics with the held
of suitable recording instruments.

(i) Force Vs frequency

(ii) Phase angle Vs frequency

(iii) Power dissipation Vs frequency

The force Vs frequency curve shall not show steep peaks at resonance frequencies and deep
troughs between the resonance frequencies. The resonance frequencies shall be suitably spread
within the Aeolian vibration frequency-band between the lower and upper dangerous frequency
limits determined by the vibration analysis of fibre optic cable without dampers.

Acceptance criteria for vibration damper:

(i) The above dynamic characteristics test on five damper shall be conducted.

(ii) The mean reactance and phase angle Vs frequency curves shall be drawn with the
criteria of best fit method.

(iii) The above mean reactance response curve should lie within following limits:

V.D. for OPGW – 0.060 f to 0.357 f kgf/mm*

Where f is frequency in Hz.

(iv) The above mean phase angle response curve shall be between 25° to 130° within
the frequency range of interest.

(v) If any above curve lies within the envelope, the damper design shall be considered
to have successfully met the requirement.

(vi) Visual resonance frequencies of each mass of damper is to be recorded and to be

compared with the guaranteed values.

(b) Vibration Analysis

The vibration analysis of the fibre optic cable shall be done with and without damper installed on
the span. The vibration analysis shall b done on a digital computer using energy balance
approach. The following parameters shall be taken into account for the purpose of analysis.

(i) The analysis shall be done for single fibre optic cable without armour rods. The
tension shall be taken as 25% of RTS of fibre optic cable for a span ranging from
100 m to 1100 m.

(ii) The self damping factor and flexural stiffness (EI) for fibre optic cable shall be
calculated on the basis of experimental results. The details to experimental
analysis with these data shall be furnished.

(iii) The power dissipation curve obtained from damper characteristics test shall be
used for analysis with damper.

(iv) Examine the Aeolian Vibration level of the fibre optic cable with and without
vibration damper installed at the recommended location or wind velocity ranging
from 0 to 30 Km per hour, predicting amplitude, frequency and vibration energy
input.

(v) From vibration analysis of fibre optic cable without damper, antinode vibration
amplitude and dynamic strain levels at clamped span extremities as well a
antinodes shall be examined and thus lower and upper dangerous frequency limits
between which the Aeolian vibration levels exceed the specified limits shall be
determined.

(vi) From vibration analysis of fibre optic cable with damper(s) installed at the
recommended location, the dynamic strain level at the clamped span extremities,

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damper attachment point and the antinodes on the fibre optic cable shall be
determined. In addition to above damper clamp vibration amplitude and antinodes
vibration amplitudes shall also be examined.

The dynamic strain levels at damper attachment point, clamped span extremities
and antinodes shall not exceed the specified limits. The damper clamp vibration
amplitude shall not be more than that of the specified fatigue limits.

(c) Fatigue Tests

(i) Test Set Up

The fatigue tests shall be conducted on a laboratory set up with a minimum

effective span length of 30m. The fibre optic cable shall be tensioned at 25% of
RTS of fibre optic cable and shall not be equipped with protective armour rods at
any point.

Constant tension shall be maintained within the span by means of level arm
arrangement. After the fibre optic cable has been tensioned, clamps shall be
installed to support the fibre optic cable at both ends and thus influence of
connecting hardware fittings are eliminated from the free span. The clamps shall
not be used for holding the tension on the fibre optic cable. There shall be no
loose parts, such as suspension clamps, U bolts, on the test span supported
between clamps mentioned above. The span shall be equipped with vibration
inducing equipment suitable for producing steady standing vibration. The
inducting equipment shall have facilities for step less speed control as well as step
less amplitude arrangement. Equipment shall be available for measuring the
frequency, cumulative number of cycles and amplitude of vibration at any point
along the span.

(ii) Fatigue Test

The vibration damper shall be installed on the test span with the manufacturer’s specified
tightening torque. It shall be ensured that the damper shall be kept minimum three loops away
from the shaker to eliminate stray signals influencing damper movement.

The damper shall be vibrated at the highest resonant frequency of each damper mass. For
dampers involving torsional resonant frequencies, tests shall be done at torsional modes also in
addition to the highest resonant frequencies at vertical modes. The resonance frequency shall be
identified as the frequency at which each damper mass vibrates with the maximum amplitude on
itself. The amplitude of vibration of the damper clamp shall be maintained not less than ±25/f
mm where f is the frequency in Hz.

The test shall be conducted for minimum ten million cycles at each resonant frequency
mentioned above. During the test, if resonance shift is observed, the test frequency shall be tuned
to the new resonant frequency.

The clamp slip test as mentioned herein shall be repeated after fatigue tests without retorquing or
adjusting the damper clamp, and the clamp shall withstand a minimum load equal to 80% o the
slip strength for a minimum duration of one minute.

After the above tests, the damper shall be removed from fibre optic cable and subjected to
dynamic characteristics test. There shall not be any major deterioration in the characteristics of
the damper. The damper then shall be cut open and inspected. There shall not be any broken,
loose, or damaged part. There shall not be significant deterioration or wear of the damper. The
fibre optic cable under clamp shall also be free from any damage.

For purpose of acceptance, the following criteria shall be applied:

(1) There shall not be any resonant frequency shift before and after the test by more
than ± 20%

(2) The power dissipation of the damper before and after test at the individual
resonant frequencies do not differ by more than ± 20%

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Beside above tests, the type tests listed below in the table shall also be conducted on vibration
damper.

S.No. Test Name Test Procedure

1 Visual examination & Dimensional and material IEC 61897 Clause 7.1 & 7.2
verification

2 Clamp Slip test IEC 61897 Clause 7.5

3 Clamp bolt tightening test IEC 61897 Clause 7.7

4 Attachments of weights to messenger cable IEC 61897 Clause 7.8

5 Attachment of clamps to messenger cable IEC 61897 Clause 7.8

6 Damper effectiveness evaluation IEC 61897 Clause 7.11.3.2

2.7 Type Tests for Splice Enclosures (Joint Box)

Following type tests shall be demonstrated on the splice enclosure(s) (Splice Enclosure/Box).
For certain tests, lengths of the fibre optic cable shall be installed in the splice box, and the fibres
must be spliced and looped in order to simulate conditions of use. The attenuation of the fibres
shall be measured, during certain tests, by relevant fibre optic test procedures (EIA/TIA 455 or
IEC 60794-1 procedures).

(i) Temperature Cycling Test

FO cable is installed in the splice enclosure and optical fibres spliced and looped. The box must
be subjected to 5 cycles of temperature variations of -40ºC to + 65 ºC with a dwell time of at
least 2 hours on each extreme.

Fibre loop attenuation shall be measured in accordance with EIA 455-20/IEC 60794-1-C10. The
variation in attenuation shall be less than ±0.05dB. The final humidity level, inside the box, shall
not exceed the initial level, at the closing of the box.

(ii) Humid Heat test

The sealed splice enclosure, with fibres spliced and looped inside, must be subjected to a
temperature of +55 ºC ±2 ºC with a relative humidity rate of between 90% and 95% for 5 days.
The attenuation variation of the fibres during the duration of the test shall be less than ±0.05dB,
and the internal humidity rate measured, less than 2%.

(iii) Rain Withstand Test/Water Immersion test

The splice enclosure with optical fibres cable installed and fibres spliced fixed, shall be subjected
to 24 hours of simulated rain in accordance with IEC 60060 testing requirements. No water
seepage or moisture shall be detected in the splice enclosure. The attenuation variation of the
fibres after the test shall be less than ±0.05dB.

(iv) Vibration Test

The splice enclosure, with fibres united inside, shall be subjected to vibrations on two axes with
a frequency scanning of 5 to 50 Hz. The amplitude of the vibrations shall be constant at
0.450mm, peak to peak, for 2 hours, for each of the vibrations’ axes. The variation in attenuation,
of the fibres, shall be less than ±0.05dB. The splice enclosure shall be examined for any defects
or deformation. There shall be no loosening or visible damage of the FO cable at the entry point.

(v) Bending and Torsion test

The splice enclosure, with fibres spliced inside, shall be firmly held in place and be subjected to
the following sequence of mechanical stresses on the cable:

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a) 3 torsion cycles of ±180° shall be exercised on the cable. Each cycle shall be less than
one minute.

b) 3 flexure cycles of the cable, of ±180° with one cycle less than one minute.

The variation in the attenuation, of the fibres, shall be less than ±0.05dB. The cables connection
ring shall remain securely fixed to the box with the connection maintained firmly. No
defects/fissures shall be noted on the joint ring or on the splice enclosure.

(vi) Tensile test

The splice enclosure with cable fixed to the boxes shall be subjected to a minimum tension of
448 N for a period of two minutes. No fissure shall be noted in the connections or on the box.

(vii) Drop test

With 2 lengths of 11 metres of cable fixed to the box, it shall be dropped five times from a height
of 10 metres. There shall be no fissure, at all, of the box, and the connections shall remain tight.
The test surface shall be carried out in accordance with IEC 60068-2-32.

2.8 Factory Acceptance Tests

Factory acceptance tests shall be conducted on randomly selected final assemblies of all
equipment to be supplied. Factory acceptance testing shall be carried out on OPGW cable and
associated hardware & fittings, Joint box.

Material shall not be shipped to the employer until required factory tests are completed
satisfactorily, all variances are resolved, full test documentation has been delivered to the
employer, and the employer has issued material inspection & clearance certificate (MICC).
Successful completion of the factory tests and the employer approval to ship shall in no way
constitute final acceptance of the system or any portion thereof. These tests shall be carried out
in the presence of the employer’s authorized representatives unless waiver for witnessing by
employer’s representatives is intimated to the contractor.

Factory acceptance tests shall not proceed without the prior delivery to and approval of all test
documentation by the employer.

The factory acceptance test shall demonstrate the technical characteristics of the equipment in
relation to this specifications and approved drawings and documents. List of factory acceptance
tests for fibre optic transmission system. Termination equipment Sub-system, NMS are given in
specified tables in this section. This list of factory acceptance tests shall be supplemented by the
contractor’s standard FAT testing program The factory acceptance tests for the other items shall
be proposed by the contractor in accordance with technical specifications and contractor’s
(including Sub-Contractor’s/supplier’s) standard FAT testing program. In general the FAT for
other items shall include at least: Physical verification, demonstration of technical
characteristics, various operational modes, functional interfaces, alarms and diagnostics etc.

For Test equipment & clock, FAT shall include supply of proper calibration certificates,
demonstration of satisfactory performance, evidence of correct equipment configuration and
manufacturer’s final inspection certificate/report.

2.9 Sampling for FAT

From each batch of equipment presented by the contractor for factory acceptance testing, the
employer shall select random sample(s) to be tested for acceptance. Unless otherwise agreed, all
required FAT tests in the approved FAT procedures, shall be performed on all samples. The
sampling rate for the factory acceptance tests shall be minimum 10% of the batch size (minimum
1) for all items. The physical verification shall be carried out on 100% of the offered quantities
as per the approved FAT procedure. In case any of the selected samples fail, the failed sample is
rejected and additional 20% samples shall be selected randomly and tested. In case any sample
from the additional 20% also fails the entire batch may be rejected. In case a number of
equipments are required for demonstration of the performance of any equipment during FAT, the
sample size shall be taken as that number of equipments which are necessary to demonstrate the
performance, irrespective of the percentage.

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For the OPGW cable hardware fittings & accessories, the minimum sampling rate, and batch
acceptance criteria shall be as defined in IS 2486.

The sampling rate for the factory acceptance tests shall be 10% of the batch size (minimum2)
for FO cable drums, FODPs Joint box and other similar items.

Since FAT testing provides a measure of assurance that the quality control objectives are being
met during all phases of production, the employer reserves the right to require the contractor to
investigate and report on the cause of FAT failures and to suspend further testing/approvals until
such a report is made and remedial actions taken, as applicable.

Production testing shall mean those test which are to be carried out during the process of
production by the contractor to ensure the desired quality of end product to be supplied by him.
The production tests to be carried out at each stage of production shall be based on the
contractor’s standard quality assurance procedures. The production tests to be carried out shall be
listed in the Manufacturing Quality Plan (MQP), along with information such as sampling
frequency, applicable standards, acceptance criteria etc.

The production tests would normally not be witnessed by the employer. However, the employer
reserves the right to do so or inspect the production testing records in accordance with inspection
rights specified for this contract.

3.0 Factory Acceptance Tests on Optical fibre to be supplied with OPGW

The factory acceptance tests listed in table below are applicable for the Optic fibres to be
supplied. The listed tests follow testing requirements set forth in IEEE standard 1138, 1994
section 4.2.2.1 and section 5.2.2.1. The referenced sections specify the detailed test description.
The acceptance norm shall be as specified in the above mentioned IEEE standards unless
specified otherwise in the technical specifications.

Table 3.1 Factory Acceptance Tests for Optical Fibres: Optical Tests

Sl.No. Test Name Acceptance Criteria Test procedure

1 Attenuation Coefficient Table 1-1 EIA/TIA 455-78A

(a)

2 Point Discontinuities of attenuation Section 1.1.1.2 EIA/TIA 455-59

3 Attenuation at Water Peak Table 1-1 (a) EIA/TIA 455-78A

4 Chromatic Dispersion EIA/TIA 455-168A/

169A/175A

5 Core-Clad Concentricity Error EIA/TIA 455-176

6 Cladding diameter EIA/TIA 455-176

7 Fibre Tensile proof testing EIA/TIA 455-31B

- End of table -

The test report for the above tests for the fibers carried out by the fiber manufacturer and used in
the OPGW cables shall be shown to the inspector during OPGW cable FAT and shall be
submitted along with the OPGW cable FAT report.

3.1 Factory Acceptance Test on OPGW cable

The factory acceptance tests for OPGW cable specified below in table follow the requirements
set forth in IEEE standard 1138/IEC 60794. The FAT shall be carried out on 10% of offered
drums in each lot as specified in technical specifications and the optical tests shall be carried out
in all fibres of the selected sample drums. The Rated Tensile strength test shall be carried out on
one sample in each lot.

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Table 3.2

Factory Acceptance Tests on OPGW Applicable standard: IEEE 1138/IEC 60794

Sl.No. Factory Acceptance Test on Manufactured OPGW

1 Attenuation Co-efficient at 1310 nm and 1550 nm

2 Point discontinuities of attenuation

3 Visual Material verification and dimensional checks as per approved

DRS/Drawings

4 Rate Tensile Strength

5 Lay Length Measurements

2.2 Factory Acceptance Test on OPGW Fittings

The factory acceptance tests for OPGW fittings as specified below in Table 3.3. The sampling
plan shall be as per relevant standard:

Table 3.3

Factory Acceptance Tests on OPGW Fittings

Sl.No. Factory Acceptance Test

Suspension Assembly

1 UTS/Mechanical Strength of the assembly

2 Clamp Slip Test

3 Visual Material verification and dimensional checks as per approved

DRS/Drawings

4 Mechanical Strength of each component

5 Galvanising test

Tension Assembly

6 Clamp Slip Strength Test

7 Visual Material verification and dimensional checks as per approved

DRS/Drawings

8 Mechanical Strength of each component

9 Galvanising test

Vibration Damper

10 Galvanising test on damper, masses and messenger wires

11 Damper response (resonant frequencies)

12 Clamp Slip test

13 Strength of messenger wires

14 Attachments of weights to messenger cable

15 Attachments of clamps to messenger cable

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16 Clamp bolt tightening test

17 Clamp bolt torque test

18 Dynamic characteristic test

19 Visual Material verification and dimensional checks as per approved

DRS/Drawings

Structure Mounting Clamp

20 Clamp fit test

21 Clamp Strength Test

22 Visual Material verification and dimensional checks as per approved

DRS/Drawings

- End of Table -

2.3 Factory Acceptance Test on Splice Enclosure (Joint Box)/FODP

The factory acceptance tests for Splice Enclosures/FODP as specified below in Table:

Table 3.4

Factory Acceptance Tests on Splice Enclosures (Joint Box)/FODP

Sl.No. Factory Acceptance Tests

1. Visual check of quantities and specific component number for each component
of splice enclosure/FODP and dimensional checks against the approved
drawings

3.4 Factory Acceptance Tests on test equipment, Pigtail & other items

As per technical specification and approved DRS/Documents.

3.5 Site Acceptance Tests

The contractor shall be responsible for the submission of all equipment & test equipment
supplied in this contract for site tests and inspection as required by the employer. All equipment
shall be tested on site under the conditions in which it will normally operate.

The tests shall be exhaustive and shall demonstrate that the overall performance of the contract
works satisfies every requirement specified. At a minimum Site Acceptance Testing requirement
for FO cable is outlined in following section. This testing shall be supplemented by the
contractor’s standard installation testing program, which shall be in accordance with his quality
plan(s) for FO equipment installation.

During the course of installation, the Employer shall have full access for inspection and
verification of the progress of the work and for checking workmanship and accuracy, as maybe
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.

3.6 Minimum Site Acceptance Testing Requirement for FO Cabling

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.

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3.7 Phase of Site Acceptance Testing

SAT shall be carried out link from FODP to FODP. SAT may be performed in parts in case of
long links.

The tests, checks, adjustments etc conducted by the contractor prior to offering the equipment for
SAT shall be called Pre-SAT activities. The Pre-SAT activities shall be described in the
installation manuals and field quality plan documents.

Sag and tension of OPGW shall generally be as per approved sag-tension chart and during
installation, sag and tension of OPGW shall be documented. Upon completion of a continuous
cable patch, all fibres within the cable patch shall be demonstrated for acceptance of the cable
path. Fibre Optic cable site testing minimum requirements are provided in Table 3.5 through 3.6
below:

Table 3.5

Fibre Optic cable Pre-Installation Testing

Item Description

1 Physical Inspection of the cable assembly for damage

2 Optical fibre continuity and fibre attenuation with OTDR at 1550 nm

3 Fibre optic cable length measurement using OTDR

Table 3.6

Fibre Optic Cable Splicing Testing

Item Description

1 Pre splice bi-directional average attenuation with OTDR

2 Physical inspection of splice box/enclosure for proper fibre/cable routing

techniques

3 Physical inspection of sealing techniques, weatherproofing, etc.

Table 3.7

Fibre Optic Cable Commissioning Testing

Item Description

1 End to End (FODP to FODP) bi-directional average attenuation of each fibre at

1310 nm and 1550 nm by OTDR

2 End to End (FODP to FODP) bi-directional average attenuation of each fibre at

1310 nm and 1550 nm by Power meter.

3 Bi-directional average splice loss by OTDR of each splice as well as for all splices
in the link (including at FODP also)

4 Proper termination and labeling of fibres & fibre optic cables at FODP as per
approved labeling plan.

- End of Table -

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4. TECHNICAL PARAMETERS of OPGW

Sl.No. Description Tech. Particulars

1 Make & Model
2 No. of Fibres in OPGW 24
3 Mode DW-SM
4 Buffer type Loose
5 Buffer tube diameter 2.2 mm
6 Buffer tube material PBT
7 No. of buffer tubes 4
8 No. of fibres per tube 6
9 Identifiaction/numbering of Red, green blue and natural
individual tubes
10 No. of empty tubes( if any) 1
11 Filling material moisture proof & Hydrozen adherent jelly
12 Strength members 1
13 Binding yarn/tape Tapes
14 20.3%Aluminium clad steel 2.55 +/- 0.03 mm & 12 Nos.
wire(Daimeter & number)
15 Aluminium tube diameter 5.4 mm
16 Approximate outside diameter 7.4 +/- 0.03 mm
17 Cable diameter 12.50 mm +/- 0.15 mm
18 Cable cross section area 113 mm ²
19 Min. Breaking load /Ultimate 81.00 k N
Tensile Strength
20 Fibre Strain margin 0.6%
21 Weight 500 kgs / km
22 Crush strength 1000 kg with a 10 cm² piste
23 Modulus of Elasticity 103.4 kN / mm ²
24 Minimum bending radius 300 mm
25 Maximum bending radius Short term 300 mm
long term 400 mm
26 Permissible CTS Tensile 0.669 k N / mm ²
stress
27 Coeffiecint of inner expansion 15.3 X 10¯6 Per ºC
28 Coefficient of expansion 6.3 X 10¯6 Per ºC
Cladding
Core
29 Nominal operating - 10 ºC to 70 ºC
temperature range
30 SC current transient peak 41 KA
temperature
31 Maximum allowable 200
temperature for lightning
strike

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32 Available length of cable per

drum: Min 2500mtrs.
Max . 3500mtrs.
.
33 Splice loss(Max. & Min. 0.05 dB, 0.01dB
allowable)
34 Operating Temperature - 10 ºC to 70 ºC
range -

35 Expected Cable Life 25years

36 Fibre production method
37 Core diameter 9.2 +/- 0.5 µm
38 Core non circularity
39 Cladding diameter 125 +/-0.5 µm
40 Core Clad Concentricity < 1µm
Error
41 Cladding non circularity <2%
42 Protective coating type & Acrylate
material Primary PBT
Secondary
43 Coating concentricity > 70%
44 Colour coding scheme Yes
compliant with
EIA395A/IEC3047
45 Attenuation Coefficient
@1310nm - .36 d B /km
@1550nm - .22 d B /km
46 Attenuation variation
With
Wavelength(+/-5nm 0.05 d B /km
Temperature- 0.05d B /km
47 Mode field non
Circularity - < 2%
48 Chromatic Dispersion

At 1310 nm 2.8 ps/ (nm.km)

At 1550 nm 18 ps/ (nm.km)

Chief Engineer/Telecom

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