Date of issued 13 / 04 / 2010

Revision No. 002

Power Cable System Team

INSTALLATION MANUAL FOR OPGW

2010. 4. 13

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 Date of issued 13 / 04 / 2010
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Power Cable System Team

CONTENTS

1. General
1.1 General
1.2 Attention in general

2. Route Surveying for Installation

2.1 To consider before route survey
2.2 To determine stringing sectors
2.3 Result of route survey

3. Installation Plan
3.1 Installation plan
3.2 Management materials and fitting
3.3 Preparation of installation

4. Stringing Plan
4.1 Stringing Plan
4.2 Location of drum site
4.3 Location of engine site
4.3 Stringing tension
4.4 Block attachment
4.5 Sagging tension

5. Equipment and tool for stringing

5.1 Equipment for stringing works of OPGW
5.2 Equipment for splicing works of OPGW

6. Stringing
6.1 Arrangement of stringing equipment
6.2 Stringing method and procedure

7. Sagging
7.1 Method of sag measurement
7.2 Clipping
7.3 arrangement of accessories and fitting

8. Jointing
8.1 General
8.2 Flow of jointing procedure
8.3 Jointing works

9. Pulling of Approach cable

9.1 General
9.2 Materials and tools
9.3 Procedure of installation

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START

Route Survey

Moving equipment

OPGW Test Inspection

No
Yes

Prepare Pulling

Stringing

sagging

No
OPGW Test Inspection

Yes

splicing

Final Test

Finish

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1. General
1.1 General

OPGW(Optical ground wire) is generally composed of optical fibers in the center and AW
wire for outer layer. Accordingly, it is necessary to take care of OPGW during stringing to
avoid splicing not only it’s mechanical and electrical properties, but also it’s optical properties.
Installation procedure for OPGW is basically similar to that for conventional overhead ground
wires in overhead transmission line construction, however particular attention must be paid
on the protection of optical components and jointing of optical fibers.
This paper describes the stringing procedure and equipment of OPGW briefly.

1.2 Attention in general

1) Water proof

Each ends of OPGW are usually treated as waterproof at the factory before shipment.
Keen attention must be paid to maintain these waterproof treatment without spoiling and
the sealing should be opened at the time of optical fiber jointing after completion of
stringing

2) Bending

For the protection of optical components included, it is very important to avoid the bending
at sharp angle or the kind of OPGW during handling. For instance the minimum diameter
for coiling up of OPGW at site is recommended approx. 1 meter and also the diameter of
the stringing block is recommended to be more than 20 times of OPGW out-diameter.

3) Uniform tensioning during stringing works.

In order to avoid unbalanced tension or over tension to OPGW, it is not recommended to

pay off OPGW together with phase conductors or other wires tied in parallel. The tension
during stringing works should be well managed uniformly.
And for the smooth operation of stringing works, the OPGW should be paid off one by one
in length from the reel to each stretched section.

4) Jointing

Jointing of OPGW is recommended to be made with a joint box, which will be installed on
the tower. The necessary quantity of join box is related to continuous packing length of
OPGW on one reel and arrangement of towers. Also, the total necessary quantity of
OPGW should be calculated from the route length of the transmission line and an adequate
surplus length of OPGW leading down to the joint box.

5) Inspection on breakage of optical fibers.

If necessary, inspection on breakage of optical fibers can be made before paying off the
OPGW at site.

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6) The others

All the bolts of accessories and fitting, especially for strain clamp, must be correctly
tightened up to specified torque by means of qualified torque wrench respectively.
The short of fastening torque causes less gripping force and excess fastening causes
deflection of aluminum tube.

2. Route surveying for installation

Surveying a distance of span, to minimize measurement error and protect natural environment,
by optical measurement instrument. Excepting the former be using that it is usual measurement
instrument.

2.1 To consider before route survey

 The method of center line measurement.

 A route directions, An interference kinds and positions.
 Location of engine site and tensioner site.
 Steel towers types and heights.
 Joint tower position.
 Route of a non-metal optical cable in substation.

2.2 To determine stringing sectors.

Stringing sectors should be determine that before stringing to make an investigation into the
following.

 Location of engine site and tensioner site , OPGW length.

 Pulling tension of engine and strength of messenger wire.
 Damage of OPGW by unbalance of stringing tension.
 Topography adjacent to the line.
 The number of workers, instruments and tools.

2.4 Result of route survey

The result of route survey should include articles as below.

 Steel tower No, type, height, horizontal angle.

 Span, Dip, OPGW length.
 Drop down length.
 A difference of height and low.
 Installation site, installation type, number of aircraft warning spheres.
 Transmission line under the crossing obstacle.
(rail road, highway, High voltage transmission line and low voltage distribute line.
Telephone and signal lines.)

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3. Installation Plan
3.1 Installation plan

1) Following plans are to be made for the completion of the installation in time.

 Plans for process

 Preparation of installation machine and tools.
 Plan for personal mobilization
 Plan for safety
 Plan for quality
 Plan for transportation
 Environmental counter measure

3.2 Management materials and fittings

1) Inspection of material

Tender shall inspect all materials for proper documentation and physical damage.
Any material which is not properly documented or is damaged shall not be used.

Material Inspection of items

 Packing condition
Outer
 Packing list (Object, Type, Length, Weight, Drum No. etc)
OPGW surface
 Each ends waterproof treatment
Attenuation  Measure of attenuation by OTDR
Outer  Bolts, Nuts Pitch
Fittings
surface  Type & Quantity

2) Transportation and storage

 All material other than OPGW reels shall be stored off the ground or on wooden pallets.
 All OPGW reels shall be identified and stored in group of similar lengths and shall be
braced against accidental rolling.
 To storage complement packing condition.
 To storage each other use and type.
 Extreme care shall be exercised during the loading, transporting unloading and using of
materials.
A reel shall be lifted using a spreader bar protruded through the arbor hole it, or fork lift
truck will be used.

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3.3 Preparation of installation

1) Establishment of communication network.

There must be furnished with cable telephone and wireless telephone so as to be able to
make rapid and affirmative liaison always within the stringing sectors.

2) Scaffold should be installed by following.

Scaffold for protection must be installed as follows in order to prevent accident against
other structure and third person for damage of power line and to secure the safety of works.

 High voltage overhead transmission line and low voltage distribute line.
 Rail road, Highway and buildings.
 Telephone and signal lines.
 Fruit trees, ornamental plants and agricultural produce being worried of damages.
 The other sites to be regarded as necessary.

3) Counter measure for protection of inductance.

In case power lines under construction approaches or being crossed with other existing
power line, a high voltage might occur on the wire by static inductance, electronic
inductance reaction, so that adequate counter measure of inductance prevention must be
taken according to the conditions.

4. Stringing Plan
4.1 Stringing plan

The stringing plan should be decided by taking into account the topography over which the
transmission line shall pass through, suitable work area, stringing distance and situation of
crossed objects.

 Condition of location of drum site and engine site.

 Stringing tension and the twist of block passing.
 Horizontal angle of steel tower and catenary angle of OPGW.
 The number of persons to an object.
 The quantity of tools and mobility.
 Construction periods.
 The method for significant facilities crossing.

4.2 Location of drum site.

Drum site should not deviate from the transmission line, and it should be decided by
following.

 Transportation of drum and stringing equipment.

 Area for work.

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 Block installation of tensioner, drum and drum site.

 The difficulty of OPGW pulling work due to the facilities near the drum site.
 Pulling angle of OPGW.
 Damages for agricultural produces.
 Traffic barrier.
 Disaster counter measure.

4.3 Location of engine puller site.

Engine puller site should be decided near the transmission line by considering following.

 Transportation of engine and messenger wire

 Area for work.
 Damages for agricultural produces and traffic barrier.
 Excessive load applied to steel tower.

4.4 Stringing tension

The strength of stringing tension must be below 15% in U.T.S of OPGW.

4.5 Block attachment

The tensile strength to be added to block attachment wire for stringing must satisfy following
condition.
Out-diameter of block is more than 20 times of OPGW out-diameter(ex.450mm). In case of
end towers such as puller-area, tensioner-area, The block of 25 times of OPGW out-diameter
shall be recommended(ex.600mm block). And If line-angle is more than an angle of 300,
double block shall be recommended.

4.6 Sagging Tension

At sagging works, the sagging tension must be checked in the case of following

 In case the difference of height, in the sagging sector is large.

 In case there is extra ordinary span of height difference in supporting point, in the sagging
sector.
 In case span length is extra ordinary different.

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5. Equipment for OPGW

5.1 Equipment for stringing works of OPGW.

Description Type Unit Qt’y Remark

Engine Puller 3 ton Ea 1

Tensioner 3 ton Ea 1

Block Φ450 Ea 20

Block Φ600 Ea 6

Running Board 20 Kg Ea 4

Come Along Clamp Φ14.8 Ea 8

Drum Stand Set 2

Swivel 3 ton Ea 10

Snatch Block 1way 2ton Ea 8

Snatch Block 2way 2ton Ea 4

B.V Winch 2 ton Ea 2

Chain Block 3 ton Ea 4

Reel Winder Ea 6

Shackle Ea 30

Wire Connector Ea 20

Braid Clamp Φ14.8 Ea 6

Wire Clamp Ea 20

Wire Rope Nylons 12mm M 600

Pilot Wire 14mm M 1000

Pilot Wire 16mm M 7000

Torque Wrench Max. 1ton Ea 2

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5.2 Equipment for splicing works of OPGW.

Description Qt’y Remark

Stabilized light source 1 Measure loss

Optical power meter 1 Measure loss

Dummy fiber 1 Measure loss

Fusion splicer 1 Splicing fiber

Fiber cutter 2 Cutting fiber

Jacket stripper 2 Remove fiber jacket

Washing agent 2 Cleaning fiber

Ethyl alcohol 2 Cleaning fiber

Gauze 1set Cleaning fiber

Dust remove 1 Cleaning splicer

Cable cutter 1 Cutting OPGW

Hacksaw 1 Cutting aw wire

Pipe cutter 1 Cutting al tube

Knife 1

Screw driver set(+,-) 1

Pliers 2

Light stand 1 Lighting

Hexagon wrench 1

Portable telephone set 2

Engine generator 1 Power supply

OTDR 1

Electric reel 1

Optical telephone set 2

Electric cord 1

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6. Stringing of OPGW
6.1 Arrangement of stringing equipments

1) Establishment of tensioner

 The stringing tensioner should be arranged in consideration of the distance from the first
tower to tensioner. Also, the tensioner should be arranged in the straight position to the
stringing block at the first tower. The distance “L” between tensioner and the first block is
required to be longer than the necessary OPGW length of leading down along with the
tower, which will make the handling works of OPGW easy.

60。
60。
above
above

Engine Puller
Tensioner L : Min. distance
L’ L from 1st tower L
L = tan Θx h
= tan 60。 x h
=2xh

Fig. ( 1 ) Arrangement of Engine puller and Tensioner

 The distance(L’) between drum and tensioner shall be about 5m.

 It is recommended to use the tensioner of the double capstan type or shoe chain wheel
type, which is free from surging of tension throughout the string works and also prevent
OPGW from twisting during paying off. The minimum diameter of the capstan or wheel is
recommended as 1.2 meter.

2) Establishment of engine puller

 Establishment must be firmly made so as to sufficiently endure impacts during stringing

and of it’s stringing tension.
 The axis direction of capstan shall be rectangular against messenger wire.

 Pull up tension should not be reached to capstan and if necessary, direction switching

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block shall be established.

 Starting, stop and speed controlling must be done in close contact with respective
working site.

 Stringing speed shall be below 30M/minute.

The winded numbers of messenger-wire on capstan shall be more than 5 times.
 When the tentative connecting portion of OPGW is passing through the block, the
stringing speed shall be reduced so as not to give any impact to wire and steel tower.
 A keen attention must always be paid for tension variation of messenger wire, if there is
any irregularity, immediately let it be stopped.
 The standard of stringing tension of the OPGW shall be regarded to be less than 15% of
OPGW UTS.
 When operating, the reverse rotation on preventing device must be operated without fail.

3) Attachment of block

 Minimum diameter of stringing block is recommended as not less than 20 times of the
OPGW diameter and also shall be more than 450mm in diameter, and also the surface of
groove should be with aluminum or urethane for protection of OPGW surface.
 In case of end towers such as puller-area, tensioner-area, The block of 25 times of
OPGW out-diameter shall be recommended(ex.600mm block).
 If line-angle is more than an angle of 300, double block shall be recommended.
 In case of high level difference such as an angle of 30o at some tower on stringing,
double block shall be recommended.

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6.2 Stringing method and procedure.

1) The outline of OPGW stringing method is illustrated briefly in fig. (2)

Running board
2 counter weight

Polite Wire

OPGW
Engine
Stringing Block Reel
Puller
winder

Tension Tower Engine Site

Suspension Tower

Suspension Tower
Tension Tower
Drum

Tensioner
Drum Site

Fig. ( 2 ) Out line of OPGW stringing

2) Decision for the stringing should be made by following

 Tensile strength of messenger wire.

 Maximum stringing tension and engine pulling force
 Shape of ground and total length for stringing
 Crossing facilities and scope of lookout

3) Stringing tension is recommended to be about half tension.

Unless other wide specified on the technical specification. Following equation are for
further detailed stringing tension calculation.
Actual stringing tension shall be monitored by pulling tension gages equipped on bull wheel
tensioner.

Tmax = T1, T1 = WL2 / 8D

W Weight per unit length of OPGW

L Span length in the meter
D Sag during stringing
T1 Tension to support wire in span
N Number of support
Tmax tension to pull OPGW

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4) Comnnecting OPGW and Braid clamp

Treat the OPGW end part in order to prevent Fiber damage caused by string
Tension or gripping force as below.

- Bind steel wire 2~3 times on OPGW.

- Removal AS Wire and cutting the Al Tube(OP Unit) around 1.2m position.

- To prevent inside water using the Vinyl Cap or PVC Tape

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- Repositioning the AS Wire and making gap between Al-Tube and Al-Road
2~3cm

5) Running board Counter weight

Attach the running board with two counter weight tails tandem between the wire rope and
OPGW in order to prevent OPGW from twisting during stringing works.

Swivel
OPGW
Pilot Wire Braid Clamp
Weight

Pulling Tension [kgf] 800 1,000 1,500 2,000

Weight [kg] 30 40 50 60

Running Board and counter weight Fig.(3)

6) Treatment of OPGW ends

 The temporary clamp at leading end of OPGW should provide enough gripping force
against pulling throughout stringing works, and the clamps such as braid clamp,
preformed armor grip and compression type clamp are recommended in proper size.
Attention must be paid to the diameter of OPGW, because it is sometimes different from
that of corresponding conventional overhead ground wires.

 Come-along clamp of wedge type can be used to OPGW, but the wedge must be
suitable to it in size and diameter in order to prevent the aluminum tube from excess
deflection.

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7) Down lead to joint box

Surplus length of OPGW is necessary to lead down from the strain clamp on the top of
tower to the joint box along with the arm and tower structures. The position of joint box is
subject to specific requirement by the customers or the height of tower. For the ease of
stringing works, it is recommended to mark the length approximately in advance at the
drum site.

7. Sagging

7.1 Methods of sag measurement

For the measurement of sagging, the easy and low tolerance method is applicable among
the following methods.
Methods and procedures for sagging of OPGW are the same as those of normal overhead
ground wire except fittings such as suspension clamp and tension clamp and tool to pull the
OPGW for tensioning.
For determination of sags, the amount of OPGW can be also regarded as equivalent to that
of conventional ground wires.

 Method of slope measurement

 Method of horizontal sagging measurement
 Method of catenary angle

1) The selection of measurable span

The sag measured span in the sagging area shall be basically decided to the following
table

-Between tension tower and tension tower

-Between suspension tower and suspension tower

Number of span for Number of measuring
Selection of measurable span
sagging selection span

Not more than 3 spans Not less than 1 span The longest span

Not more than 6 spans Not less than 2 spans The longest span & the last span

Longer span of center area & the

Not more than 7 spans Not less than 3 span
span of both end

2) After stringing the OPGW shall be sagged using information furnished on the sag and
tension chart. Unless otherwise specified on technical specification.

3) Sagging thermometers shall be used at each sag station to determine accurate

temperature and OPGW sag of each sag section. Sagging thermometer shall be used
sufficiently prior to the actual sagging operation and should be inserted in a container or
OPGW section to represent the temperature internal to the OPGW.

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4) The sag shall be controlled with transits or scopes using calculated target, horizontal line of
sight or calculated angle of sight method.

5) OPGW shall have tolerance as following unless otherwise specified on technical

specification.

 At the time of sagging OPGW, the sag of any given phase should be within 6 inches of
the theoretical value for existing temperature condition. The sag of all phase of a circuit
shall have similar tolerances

6) OPGW tension between each sag section shall be equalized and this shall be determined
by the vertical position of the suspension clamps on the last clipped structure of the
preceding sag section.

7) The tension clamp and suspension clamp must be designed taking into account the
slipping strength and the shape which prevents any damage of surface and deformation of
aluminum pipe and optical fibers.

8) For pulling the OPGW with tension, the device of come-along is to be recommended by
experience. Guy-grip is also available instead of come-along, but it is troublesome in
handling to use it as a tool.

9) After completion of sagging and clipping, the surplus OPGW is to be lain temporary in the
tower body in coil (Diameter of coil is approximately 1.0 - 1.5 m) and fixed on the tower. It
is important that precautions must be taken to prevent any damage of OPGW.

10) Vibration dampers must be fitted at OPGW suspension and tension points. Normal type of
dampers shall be attached to the OPGW over the suitable preformed armor rods which
will protect OPGW and its aluminum pipe from any damage.

7.2 Clipping

1) This is one big difference between OPGW and normal overhead ground wire in stringing.
Two lines of OPGW can not be jointed by a mid span joint in a span. Therefor, the jointing
operating shall be made on the tension tower and for this joint it is necessary to add the
surplus of approximately 20m length of OPGW at the either end in one reel.
The length of surplus is accurately to be get in accordance with tower construction and
location of joint box and also with selection of type of jumper device, that is splicing type or
non-splicing type.

2) When only one OPGW reel length is to be strung at once time, the line can be pulled into
place and one end is normally attached to the tower counting on the surplus length.

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7.3 Arrangement of accessories and fitting

1) Typical arrangements of accessories at the tension tower and the suspension tower are
shown from fig.(4) to fig.(6). In order to lead down OPGW to the joint box, the
arrangement of tension assemblies is different from that for conventional overhead ground
wires, while the suspension assembly is almost similar to that for conventional ones.

Typical Dad end clamp accessories fig.(4)

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Suspension clamp accessories fig.(6)

Typical Suspension clamp assembly fig.(5)

2) All bolts of accessories and fittings must be correctly tightened up to specified torque by
means of well qualified torque wrench respectively.

3) The bending radius of OPGW is recommended to be more than 500mm at the corner
position leading from the strain clamp to the arm of tower.

4) Surplus length of OPGW leading down from the strain clamp to the joint box shall be fixed
to the tower along with arm and structures by fixing clamps and racks, as shown in Fig.
(6). Such fittings should be arranged to the tower at intervals of specified of distance
respectively.

5) The balanced length of OPGW should be coiled in a diameter more than 1 meter after
completion of jointing, and then be firmly fixed to the tower as shown in Fig.(6).

6) Installation is shown in Fig. (6). Joint box should be firmly attached to one of the main
tower structures.

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7) The outline of a typical joint box is shown in the drawing for reference and the example of
its installation is shown in Fig. (6). Joint box should be firmly attached to one of the main
tower structures.

Fig.(6)

8) During the works leading down OPGW to the joint box, keen attention must be paid not to
bend or twist OPGW locally, which causes the deterioration of optical properties or
loosening the outer wires for reinforcement.

8. Jointing

8.1 General

1) Jointing works of OPGW must be done usually at the high position on the tower, while
the splicing of optical fibers must be made with high accuracy not to spoil the optical
transmitting properties at the spliced part. For ease of jointing works with such high
accuracy, it is recommended to provide some temporary floor space on the tower in
advance for jointer and equipment. Also, such floor space should be protected against
the heavy wind, strong sunshine, high temperature, rain and dusty atmosphere.

2) Keen attention must be paid not to damage OPGW including its optical components
during the works such as handling, cutting, unstranding of component wires and
jointing.The jointing works of optical fiber itself must be done by well trained and qualified
person.

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3) Before joint work, please check the OPGW fiber, it is recommended to wait around a
week until repositioning Fiber.

4) It is recommended to measure the optical transmitting properties such as attenuation of

the spliced part respectively just after splicing of optical fibers at site.

5) Spliced part of optical fiber with reinforcement should be accommodated to the qualified
joint box and be free from tension after completion.

6) Joint box should be waterproof after completion.

8.2 Flow of jointing procedure.

Process flow chart of OPGW jointing works is summarized briefly, which is typical instance
as a model case for reference.

Start

Cutting and treatment of OPGW ends.

Preparation of materials, tools and equipments.

Removing of AL tube over optical fiber units.

Taking out of optical units.

Splicing of optical fibers.

Reinforcing of spliced parts.

Treatment of surplus lengths of optical fibers.

Measurement of splicing loss.

Sealing of a joint box.

Installation of a joint box.

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8.3 Jointing works.

1) Preparation of materials, tools and equipments.

Confirm that all of the materials, tools and equipments listed in tables 1 and 2 are
prepared.
In addition to above, it is also important to ensure enough wide working space on a
tower in order to work easily and safely.

2) Cutting and treatment of OPGW ends.

 Stretch the OPGW coiled beforehand near the joint box, and cut off unnecessary
lengths of the OPGW with a cable cutter.
 Put cutting marks on OPGW at positions where the OPGW is to be fixed to glands of
the joint box. Grip each OPGW at a position about 100mm below the cutting mark by
two or three turns binding of copper wire to prevent the AW wires from coming loose
after cutting off the unnecessary parts.

100mm
Binding ≒ 4m

AL-Tube

AW

 Notch the AW wires of the OPGW with a hacksaw to the 1/3 to 1/2 depth of the AW
wire diameter. In this case, take care not to be damage the inside AL tube of the
OPGW.
 Loose AW wire from the OPGW ends one by one and snap them off at the notched
position.
 AL Tube cutting.

50mm

AL Tube
Optical unit
AW

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 The end is treated waterproof of OPGW.

AL-Spacer
150mm 30mm

OPGW
AL Tube Optical unit
Heat Shrink Tube

3) Taking out of optical units

 Remove the PBT tube of optical units with leaving remain of each suitable length from
the edge of the AL tube.
 Make every optical units into loops of about 5 to 10 cm diameter, and stick the optical
units loops to the suitable position of the joint box with adhesive plastic tape in order
not to be damaged during following splicing work.

4) Splicing of optical fibers.

 Cleave length
Bear fiber length is 16mm ±5 after cleaving.

 Remove the fiber coating, clean the fiber and then cleave the bare fiber to the
predetermined length. Set the prepared fiber in the v grooves as shown in the figure
below.

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 Clamp the prepared fiber exactly by pushing the clamp lever. After clamping the right
and left fibers, close the hood. Make sure that the prepared fiber is not trapped by the
hood, and not caught by any other part of the machine.

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 Evaluation of the splice.

The evaluation of the splice should be done by estimated splice loss and the external
appearance at the splice point.

(1) The following splices should be rejected, even if the

Be sure to remove this type of splice, because
Bubble the splice loss can be extremely high.

Caused by
1. Dust on fiber end
2. Condensing
3. Bad cleaving
4. Prefusion time is too short.
5. Arc power is too strong.

Thick black line

In this case, make refusion by ARC Switch,

and check it again.(*)
Black shadow

(*) In the case where fluorine doped fiber is splicer, a black line will always appear at the splicing point, but does not
cause any damage to the characteristics of the optical transmission.

(2) The following splices are acceptable, even if the external appearance at the splice
point does not look good.

It is all right if the estimated splice loss is within

White line
the specified value.
This is due to optical causes upon observation,
and there is no effect on the splice
characteristics.

Blurred thin line

Same as above

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Because of core alignment, this is possible for

fiber with large core eccentricity.

This appearance is due to differences in fiber

diameter.

Dust or scratches
No bad effect to spliced fiber but more care is
necessary in cleaning and cleaving fibers.

When the spliced portion is required to be observed in detail, “FIELD CHANGE” and “FOCUS UP” and
“FOCUS DOWN” SW on top mounted console panel are useful

5) Reainforcing of spliced parts.

1) Open the heater cover, the left fiber clamp and right fiber clamp

Fig. 8-5A

2) Open the hood, take out the spliced portion, close the hood, and press the “RESET”
SW.

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Fig. 8-5B

3) Slide fiber protection sleeve FPS-1 over the spliced portion.

Fig. 8-5C

Note
 Make sure fiber coating is clean.
 Put the sleeve over the splice as shown in Fig. 4-6C
 Don’t twist the fiber.
 FPS-1 should be straight.

4) Apply a slight tension and place the splice in the heater, close the right hand heater
clamp by pressing down with the right hand fiber.

5) Next, close the left hand heater clamp while pulling the fiber slightly, and close the
heater cover.

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Fig. 8-5D

Note
 Fiber should be straight.
 Make sure that there is no dust, or jelly in the protection sleeve.

6) Press the “HEATER SET” SW, and the “working” indicator lights up.

Fig. 8-5E

7) After the tensile proof test(a few seconds), it takes a few minutes until the fiber
protection sleeve is shrunk. A buzzer will indicate the finishing of shrinking the sleeve.
If the fiber breaks, or the fiber is loosely clamped or slips during the tensile proof test,
the buzzer will beep intermittently. Correct the condition before proceeding.

Note 1
 Both the splicer and heater can be operated simultaneously.

Note 2
 The tensile proof strength can be set from 50 to 500 grams. This value is set
to 200 grams normally.

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8) Open the heater cover and clamps.

Take out the protected splice carefully while pulling the fiber slightly.
Cool the protection sleeve for a few minutes, as it is very hot just after reinforcement.

9) Check the appearance of the reinforced portion.

Bad protection examples

 Short coverage of coated fiber.

Bubble on bare fiber.

 Bending bare fiber

bending

Good protection examples

 Unshrink sleeve end

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 Bubble on coated fiber

6) Treatment of surpuls lengths of optical fibers.

 Arrangement of loose tube

The optic unit be arranged in storage of joint box that it is protected against impact,
corrosion and bend.
The loop diameter of optic unit is more than 50mm.

Typical Joint Box fig.

 Arrangement of optical fiber

The splicing portion of optical fiber put in regular order the fusion splice protector, and
then put the extra length of optical fiber on the splice tray.
The loop diameter of optical fiber is more than 50mm.

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7) Mesurement of splicing loss.

Refer to manual of OTDR.

8) Sealing of joint box.

 Apply sealing compound to the edge parts of the AL tube of the OPGW.
 Fix the cover to the joint box after having conformed not to be anything left in the joint
box such as tools and dusts.

9) Installation of a joint box.

Check Point
 Joint box using the same type OPGW.(Check gland type)
 To carry into effect fusion splice in joint box.
 Check the status of water proof.
 Compounding in gland for holding in check moisture.
 Fusion splice working is protection it against dirt, grit and moisture.
 Fixed tension member and glass yarn to the joint box.

9. Pulling of dielectric optical fiber cable

9.1 General
This article details the procedure for dielectric optical fiber cable inside a continuous duct
running out from a terminal building.
The general precautions to be considered are as follows.

1) A safety values more than the allowable ones for tension and bending applied to
dielectric optical fiber cable during installation shall be considered as standard.

2) Dielectric optical fiber Cables should be normally paid out by hand.

When using a winch, tension should be monitored by a tension meter, and the works
should be performed accordingly.

3) Moving of drum
(1) When moving the dielectric optical fiber cable to the pay out location (called a cable
pay out site) during the installation, the drum should be rotated in a direction which
is indicated by an arrow mark ( ) on the side boards of the drum.

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Fig 1

(2) During moving, or when leaving the drum, the drum should not be stacked flat, and
stoppers should be placed properly.

(3) Paying out of dielectric optical fiber cables requires an appropriate area of space for
drum moving, and the selection of the site has to be made carefully.

(4) Unloading of dielectric optical fiber cable drum

When unloading a drum carried by a vehicle or other means, on the ground, the
drum should not be dropped on the ground directly, which may cause impact to the
cable. The drum should be unloaded quietly and carefully if it is necessary to
prove gangplanks between the deck of the vehicle and the ground.

4) Allowable Pulling Tension, Bending Radius and Pulling Speed

Dielectric optical fiber cables should be laid under a specified pulling tension, pulling
speed and bending radius.
During dielectric optical fiber cable installation it should be avoided to pull the cable with
shock or to stop pulling suddenly, and the cable should be kept under uniform tension.
When using a winch the pulling tension should be monitored by a tension meter.

(1) Pulling tension

The allowable pulling tension of dielectric optical fiber cable is shown in Table 1, in
case the cable is pulled at the pulling end with a grip or pulling eye fixed to the cable
end.
(2) Cable bending radius
Dielectric optical fiber cables should be laid with the bending radius shown in table 1.
(3) Pulling Speed
The pulling speed is shown in Table 1.

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Table 1
Steel Tension member cable or
Item
equipment
Pulling Tension Max. 270kg
During
Bending Radius Min. 20D
Installation
Pulling Speed Max. 15m/min
(D : Cable outer diameter)
(4) The value of pulling tension and bending radius depends on the specification.

9.2 Materials and Tools

The essential materials and tools are shown in Table 2 & 3 respectively.

Table 2. Materials
No. Item Description
1 Dielectric Optical Fiber Cable CFOA – SM – DD – G – 24
2 Protective Spiral Sleeve or the like For protection
3 PE(Poly Ethylene) pipe and fitting 28 ~ 36 Φ
4 Steel Pipe and fitting 28 ~ 36 Φ
5 Flexible Tube and fitting 28 ~ 36 Φ
6 Cable tie
7 Binding Rope For binding

Table 3 Tools
No. Item Description
1 Drum Stand
2 Drum Trailer
3 Shovel and Pickax
4 Cable Grip For laying
5 Flexible Cable Guiding Tube 〃
6 Pulling Rope 〃
7 Swivel 〃
8 Cable Cutter For cutting cable
Transmitter and Receiver or Portable
9 Telephone Set
For communication
10 Safety Facilities For safety work

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9.3 Procedure of installation

The major steps for dielectric optical fiber cable pulling in duct are shown below. Before
starting each job or new step, be sure to check how far along the work of the preceding
step has been completed, and how well preparations for the subsequent work have been
made.

1) Preparing materials, Equipment and tool

Before starting work, confirm the presence of all necessary materials, equipment, and tools
required for use in the work.
Be careful not to make a mistake in distributing dielectric optical fiber cable drums to
designated sections of the work in accordance with the results of survey.

2) Installation of PE pipe at duct

(1) Determine to pulling route of dielectric optical fiber cable, then measure the length of
pulling route.
(2) Fixed a PE pipe to bracket every 1.5m in duct by cable tie.
(3) When PE pipes to connecting use connector of PE pipe.
(4) Fixed a line nameplate to PE pipe every 10m.

CAUTION
Dielectric Optical Fiber Cable SM / 24C

Section ~
Date

3) Set - up procedures for sending and pulling sides

For sending out the cable from the drum, use a flexible feed pipe to prevent the cable from
being damaged by the corner of the duct inlet.
On the pulling side, dielectric optical fiber cable can be pulled manually.

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4) Pulling of dielectric optical fiber cable.

First, prepare the pulling end of dielectric optical fiber cable.
Before beginning to lay dielectric optical fiber cable, make prior arrangements for
communications between the sending side and the pulling side. Usually, transceivers are
used between the two sides for this purpose. For cable laying on a straight-line route, it is
possible to use a pre-arranged system of signaling with red and white flags, or the like.
When pulling dielectric optical fiber cable, keep the pulling speed within the range specified.
Maintain a constant cable speed without sudden stopping or starting.

When pulling through at turning points and bend area shall be protected by the protective
spiral sleeve.

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