METHOD OF INSTALLATION FOR OVERHEAD TRANSMISSION LINE

CONDUCTORS & OPGW

CONTENTS: The Contents of this Methodology describe the main activities Involved and comprise:

1. OBJECTIVES
2. GENERAL
3. SAFETY
3.1 Suitability of Plant and Tools
3.2 Safety equipment
3.3 Safety of Third parties

4. PLANT AND EQUIPMENT

4.1 Tensioner
4.2 Puller
4.3 Travelers (Aerial Rollers)
4.4 Pilot wires and ropes
4.5 Installation tools
4.6 Joint protectors

5. SITE PREPARATORY WORK

5.1 Stringing Plan

5.2 Conductor drums
5.3 Crossings
5.4 Equipment anchors
5.5 Back stays for towers
5.6 Temporary stays for conductors
6. ERECTION WORKS
6.1 Insulators and travelers
6.2 Equipment grounding
6.3 Pulling conductors
6.3.1 Installation of pulling lines
6.3.2 Installation of conductors

7. SAGGING

7.1 Design Criteria

7.2 Sagging Operation
7.3 Clamping-in / Clipping

8. JOINTING
8.1 General
8.2 Mid-span compression joints
8.3 Dead-end joints
8.4 damper and Spacer damper installation
8.5 Tension tower jumpers
8.6 Aircraft warning
9. STRINGING OF OPGW
9.1 Length of Each drum
9.2 Splices

9.3 Preparation for installation

9.3.1 Drum
9.3.2 Puller & Tensioner
9.3.3 Pulleys
9.3.4 Auxiliary Components
9.3.5 Pulling Rope
9.4 Installation of OPGW Cables
9.4.1 Basic Controls
9.4.2 Stringing Speed
9.4.3 Pulling Tension
9.4.4 Minimum Bending Radius
9.4.5 Communication during Stringing
9.5 Sagging of Cable
9.6 Installation of fittings & accessories
9.7 Personnel training
9.8 Splices
9.9 Transmission Test during installation process
9.9.1 Measurements after installation
9.9.2 Splices measurements
9.9.3 Final Acceptance Test

10. QUALITY RECORDS

OBJECTIVES:

To define the operations involved during conductor stringing and the procedures for each activity to
ensure compliance with the technical specification and safety to plant, personnel and the public.

1. GENERAL:

The stringing method to be used is the “tension” method in which the conductor is maintained, at all
times, under tension during the stringing process. This has the advantage of maintaining a clearance
between the conductors and the ground. The tension method necessitates the pulling of a suitable pilot
line into the travelers. Conductor joints are to be made at the tensioner and then pulled through to their
final position with each joint equipped with joint protectors.

Major equipment required for stringing using the tension method are reel stands, tensioner, puller, reel
winder, pilot line winder, pilot ropes and wires, splicing cart, pulling vehicle and communication
equipment.

2. SAFETY:
Stringing of conductors can be a hazardous task and, unless due care and attention is paid, may result
in injury, loss of life or materials. Conductors comprise almost 30% of the cost of a transmission line
and can be easily damaged. All accidents will cause delays to the project and are to be avoided.

All Installation work will be carried out employing the safety guidelines set out within this document.

3.1 Suitability of Plant and Tools

All plant and ancillary equipment will only be operated by authorized and competent personnel. The
Foreman of each gang will be responsible for the inspection of all equipment daily before use to ensure
it is fit for purpose without any defects. Any deficiencies will be immediately reported to the Supervising
Engineer.
All tools and plant will be regularly serviced and maintained in a safe working order. All sheaves and
blocks will be cleaned and greased after each use and packed in an appropriate manner prior to
transportation to the site or next stringing section. All synthetic or natural fibre and steel wire ropes will
be inspected for damage. Any equipment found to be damaged will be repaired or disposed of as
appropriate.

3.2 Safety Equipment

All workers working on the towers will be provided with undamaged safety belts and safety ropes and
these will be employed at all times. Safety helmets will be available and used by all personnel when
working on and within the vicinity of the structures and work sites.

Electrical charges may appear on the conductors due to any one of the following reasons:-
• Electrical charge induced from a neighboring energized line
• Accidental contact with a neighboring energized line
• Induced static charge due to prevailing atmospheric conditions
• An error in which the line is accidentally energized
• A lightning strike to the line or towers
 Equipment and conductors will be grounded at all times to provide personnel protection. For further
details see Section 6.2.

3.3 Safety of Third parties

During the stringing process it will be necessary for the pulling lines, conductors to cross over areas to
which the general public has access. Prior to commencement of stringing activities all areas or
locations along the line route that is being strung to which the public have access will be identified and
suitable measures taken to ensure the safety of the public. This may require special safety structures
to be erected or personnel positioned to ensure public access is limited to safe times. Special safety
requirements are further addressed within this methodology.

4. PLANT AND EQUIPMENT

All plant and equipment used during the stringing operations will be of the correct type and size. Only
the correct type and size of equipment or tools will be employed. All Tools and stringing equipment will
be inspected by Company Supervisors and prior to erection and stringing activities. The following
particular equipment items have particular requirements and will be sized as follows:-

4.1 Tensioner:

The tensioner employed will be suitable for use with the conductor to be erected. To minimize the risk
of any loosening of the outer layer of strands when passing through the bull wheels the conductor will
enter (non-tension / drum side) on the left side wheel (in case of right hand lay conductor & vice versa)
and exit in the direction of pull (line side) on the right side wheel (looking towards tensioner with
conductor drums behind)

The pulling and breaking system of the tensioner will have the following characteristics:
• Have a safe working capacity (3.5kN for line conductor & OPGW)
• Operate smoothly without any jerking movements.
• The operation of pulling and or tensioning will be easily controllable and be able to maintain a
constant tension.
• Be provided with a calibrated tension measuring device.
• Have a positive breaking system to allow the tension to be maintained when pulling or
tensioning activities are stopped
• Have a failsafe breaking system

4.2 Puller:

The puller will be provided with a suitable number of drums / wheels of the correct size to suit the
range of rope and wire sizes it is expected to cope with. The operating characteristics will be as
follows:-
• Have a safe working capacity (3.5kN for line conductor & OPGW)
• Operate smoothly without any jerking movements.
 • The operation of pulling and or tensioning will be easily controllable and be able to maintain a
constant tension.
• Have a failsafe breaking system

4.3 Travelers (Aerial Rollers):

All travelers (aerial rollers) will be sized to suit the intended use. All rollers will be in good condition
throughout their use. Damaged or worn out rollers will be removed from the site.

4.4 Pilot Wires and Ropes:-

All pilot wires and ropes will be sized to suit the intended application. Pilot wires will be in good
condition throughout their length. Repairs to ropes will be subject to approval from Company’s
supervising engineer.

4.5 Installation tools

All tools will be sized correctly for the work. All spanners and torque wrenches will be of the correct
type and size and, where measurements are to be made will be calibrated.

4.6 Joint Protectors

Jointing Machine with correct dies shall be used & Joint Protectors of suitable sizes shall be used
after midspan compression joint to protect the joint while passing through aerial rollers.

5. SITE PREPARATORY WORKS:

5.1 Stringing Plan

Prior to the commencement of mobilization of stringing equipment to site the following information will
be available:
• An approved stringing plan for the stringing section;
• Approved initial and final stringing sags and tension tables for the stringing section;
• A structure list showing the weight spans on each tower (particular attention will be paid to the
possibility of uplift arising from either or both adjacent spans during stringing);
• Identify all nominated crossing spans;
• Identify all areas subject to risk of access by the public;
• Identify all spans where clearance between the ground and the conductors under stinging
tensions may be a problem.

The stringing plan will identify the following:-

• Drum site (tensioner)
• Puller site
• required location of mid span joints
• String section end towers
• Sagging section(s)
• Sag check span(s)
 The stringing plan will consider the following matters:-

Access: The selection of the sites for the drums, puller and tensioner will take due regard of the access
requirements for each. Will a site be unavoidably selected where access is difficult, the access will be
upgraded to suit prior to mobilization of the conductor drums and stringing equipment. Due
consideration will be given to the possible degradation of the access due to use and or climatic
conditions

Stringing sections will consider the maximum drum lengths of conductor available; puller and tensioner
capacity; availability of space for positioning of equipment and equipment anchors.

Design limits: The location of puller and tensioner sites will be selected so that the snub structure
(Anchors) is not overloaded. A maximum horizontal angle of 34º will be obtained between the tensioner
and puller sites to the first and last towers of the stringing section. Due consideration will be given to
the height of attachment at the tower.

Midspan Joint locations: The midspan joints will be provided meeting as per the conditions of the
contract.

The sagging spans will be selected on following basis:

a) For a pull up to six spans, there will be one sag check point. If the pulling section is more
than six spans, there will be at least 2 check points are required.
b) If there is only one check point, the span will be located near the center of the pull and also
its span length will be close to that of the equivalent span to keep errors to a minimum. It is
desirable that the transit and the targets are at approximately the same heights.
c) Before sag spans are selected, a scale profile of the entire sag section will be reviewed to
provide a complete, clear picture of the relationship between the terrain and the conductor.

The reel winder to recover the pulling line is located at the pulling site. The pilot line winder is located
at the tension site.

5.2 Conductor drums

All drums will be in a good condition. There will be no damage to the main sides that may result in a
collapse when rotating during stringing. Drums will be kept clear of the ground at all times. Drums will
always be lifted carefully by the correct lifting points.

5.3 Crossings

If the stringing section contains any crossings of power lines, telecommunication circuits, public
roads, railways or waterways advance notice will be given by the Contractor to the appropriate
authorities, clearly indicating the date(s), time(s) and duration(s) of execution. No work will
commence until the necessary permissions have been granted, preferably in writing, by the
responsible Authorities
 For railway crossings the Railway Authority requires the stringing and sagging work to be carried out
at times that consider their operational timetable and that all measures are taken to ensure the
protection of their employees or property or of the public.

Safety structures will be employed at all crossings of main roads, highways, railroads and energized
lines. The safety structure will comprise a wooden/pipes/scaffolding structure which will be of
adequate strength to resist the forces imparted by a sudden release of tension and subsequent drop
of the pulling wires, conductors. In case of High voltage power line crossings suitable discharge rods
shall be used in the crossing spans.

5.4 Equipment Anchors

Anchors are required for holding equipment in place and or anchoring the conductors tensions when
other works are being undertaken, i.e. dead ending or mid span jointing.

All anchors and their corresponding stay wires will be designed to resist the tension imposed
together with a minimum factor of safety of 1.5. The type of anchor is dependent upon the soil
conditions, sagging and stringing tensions. Some equipment, notably the tensioner and pullers, are
supplied with their own anchors. Additional equipment anchors will be provided, if needed, by means
of stay wires embedded to the ground.

For all equipment the stay wires will be a minimum of 10 mm. Conductor anchor stays will be a
minimum of 10 mm.

5.5 Back-stays for towers

Terminal towers do not require backstays for stringing. All other tension towers that will be employed
to terminate the conductors on one side of the tower only, pending stringing of the adjacent section,
will require back stays.

Tower back-stays will comprise two stays at each conductor level. The stays will be attached to the
main leg at the intersection of the cross-arm main compression member. The stays will be a
minimum of 16 mm with a breaking load of 15 tons. Care will be taken to ensure the tower steel work
is sufficiently protected to avoid damage to the galvanizing. This will normally require a large wooden
blocks (sized to be at least the same size as the member flange) together with suitable materials to
protect the galvanizing.

The stay ground anchors will generally comprise concrete blocks or a hardwood log of suitable size
with respect to maximum loading of the conductors.. The ground anchor will be positioned so the
horizontal angle between the stay and ground will not be more than 34º. The anchor foundation will
be excavated so the bearing face is undisturbed, i.e. a vertical excavation face facing towards the
tower. The stay wire will be located in a slotted excavation suitable for the angle of the stay. The stay
wire will be wrapped on the wooden log. After installation the anchor and stay excavation will be
backfilled and well compacted.
5.6 Temporary stays for conductors

When required, conductors will be stayed to anchors similar to the tower back stay anchors. Only
one conductor will be anchored to each ground anchor. The stays will be a minimum of 12 mm with a
breaking load of 9 tons. The conductor will be protected from localized damage by rubber tubing or
similar.

6. ERECTION WORKS

Only the erection holes provided are to be used for attaching pulling and lifting equipment. If other
attachment positions are found to be required then approval will be required from the Company
supervising engineer who will consider the most suitable point of attachment, load to be applied and
measures required to protect the steel and its galvanize coating.

Stringing of Line Conductor

6.1 Insulators and Traveler (Aerial Roller)

All insulator units and fittings will be carefully handled during transportation, assembly and installation
on the tower to avoid chipping or damage to the insulating material. All insulator units identified as
being damaged will be suitably marked and removed from the site.

At no time will insulator units or the fittings be allowed to come into contact with the ground.
Protective ground sheets or timber will be used and the insulator units themselves will be covered.

At suspension towers the suspension insulator sets will be employed to support the travelers. Initially
the suspension insulator sets will be assembled without the suspension clamps and arcing horns.

For single suspension sets the traveler will be securely attached to the Yoke plate central hole. For
double suspension sets the two holes for the suspension clamps will be used to for attachment of
travelers.

After assembly the insulator set complete with traveler together with the finger line (located in the
central sheave) will be hoisted to the cross-arm by a block and tackle arrangement. Care will be
taken to ensure the finger line does not come loose.

The finger line will be of a length that will permit attachment of the pilot wire and leave sufficient to
draw the pilot wire through the traveler.

Precautions will be taken to ensure that insulator units and fittings are not damaged during hoisting of
the insulator sets. The hoisting point on the insulator set will be the shackle attached to the clevis
tongue. On no account will the hoisting rope be wrapped around the insulator units themselves. The
insulator sets will be attached to the nominated permanent insulator attachment hole at the tower
cross-arm end.

At tension towers the travelers will be directly connected to one of the stringing holes located on the
cleat on the underside of the cross-arm point. If the stringing section requires the conductors to be

pulled through angles the normal traveler may be used up to angles of deviation of 15º. For angles
greater than 15º or when the weight span is greater than 600 m a special traveler arrangement

consisting of two travelers in tandem will be used to reduce the bending radius of the conductor or
the load on each traveler. Pulling of conductors through angles greater than 15º is not permitted.
At the time the travelers are hung, finger lines, when used, will be installed and tied off at the base of
the structures.
6.2 Equipment Grounding

Due to the risk of electrical induction all equipment connected to the conductors will be grounded and
confirmed grounded prior to the commencement of pulling activities.

Electrical earths are required at the following locations:

• Tensioner (ground rod)
• Puller (ground rod)
• Conductors at the exit of the tensioner (running earths)
• At both sides of a crossing over an energized line (running earths)

For the ground rods copper clad steel and or steel rod connected to the equipment by means of a
copper stranded cable of 15 mm diameter will be employed. If feasible the ground rod may be used
as a common earth for more than one item of equipment (i.e. the tensioner earth may be employed
for the conductor running earths.

When making dead ends or during clipping the conductors will be grounded to the tower by portable
earth leads with clamps suitable for the conductor.

For the running earths either side of an energized crossing the tower itself may be employed as the
earth.

Portable earths will be available to ensure the safety of personnel when required.

At the mid-span jointing stations the connections to earth will be established with 3 m of each end of
the conductors to be spliced.

6.3 Pulling Conductors

6.3.1 Installation of Pulling Lines

After the travelers and finger lines have been installed the initial pilot line is pulled employing a
vehicle such as pickup / tractor or pulled manually by workers depending on site condition, to each
tower in turn and, by connection to the finger lines, threaded through the traveler, and so on to the
next tower. Care will be taken when the line crosses populated / residential areas.

For conductor stringing:

• Conductor shall be pulled using Pilot wire of suitable size
• To avoid damage to the sheave lining and subsequently to the conductors themselves at no time
will steel wires be permitted to be pulled through sheaves designed for use with conductors.
• The responsible stringing engineer/Supervisor will, at all times when conductor is being pulled,
be located at the tensioner.
 • Prior to commencement of pulling a communication check will be performed to ensure the
communication equipment is working; at the same time each station will report that their
equipment is in good working order and that all personnel are in position ready to commence
pulling operations.
• Generally, Walkie –Talkie will be provided to the linesman for the purpose of effective
communication and control of pulling operations.

6.3.2 Installation of Conductors

After the pulling wire has been installed the pulling wire is to be connected to the running board. The
ends of the phase conductors and are attached to the running board arrangement employing swivel
links and woven wire grips. The conductors being pulled will be continuously inspected for damage.
Should any damage be observed pulling will cease and the matter will be referred to the Engineer for
decision. Scratches on the aluminum surface are considered “damage”. When the total length of the
conductor to be pulled is longer than the conductor length in one reel, the conductor must be spliced
together at the tensioner site. All midspan joints will be equipped with joint protectors before
continuing with the pulling.
The speed of pull is an important factor in achieving a smooth stringing operation. A maximum speed
of about 1 or 2 km/hour will be maintained. The maximum tension imposed on a conductor during
stringing operations will not exceed that necessary to clear obstructions on the ground and after
pulling is complete the tensions will be increased to 60% of the sagging tension. During pulling
operations special care will be taken when the running board or joint protectors comes near a
traveler. At these times the speed of pull will be reduced until the item has successfully passed the
traveler. To ensure this a personnel will be located throughout the stringing section and will, at all
times, equipped with means of communicating with the stringing supervisor.

Immediately after the joint protector(s) has passed through the final traveler into its designated span
the protector will be removed and the joint inspected for damage or bending.

Once the conductor has been pulled into place, dead end clamps shall be compressed to the
conductor ends and attached to the insulator string on the cross arm. Then excess conductor shall be
pulled back on the tensioner till the conductor reaches its near sag position. Automatic grip come-a-
long clamps shall be attached to the conductor and with the help of sagging winch the conductor shall
be pulled to desired sagging tension.

At no time will the conductors be allowed to come into contact with the ground. The use of repair
sleeves will require the approval of the Engineer. Repair sleeves will only be made if the damage is
limited to localised and minor damage to isolated strands. Any damage at all to the inner strands will
be cut and removed.

7. Sagging

7.1 Design Criteria

The sagging of the Conductor will be done as per the approved stringing tables. The stringing table
includes the initial and final sags for conductor and the corresponding tensions for the actual spans in
the sagging section under conditions of different temperatures. The equivalent span for a particular
section is indicated in the stringing tables along with the corresponding sags for each span.
 The sag check spans will be identified in the stringing plan. Sags will be measured and checked
using the Transit – Target method.

If the sag span is not a level span, it is best if the transit is located at the lower structure since
conductor control is increased.

7.2 Sagging Operation

Equipment required for sagging includes transits / theodolite, portable radios, conductor
thermometers, targets, hand-levels, stadia rods, measuring tapes, pulley blocks, winches and
miscellaneous marking device.

After the conductors are in place and ready for sagging to the design sag the conductor temperature
will be taken. The conductor temperature will be measured by two reliable thermometers calibrated in
1º C intervals (one at each end of the sagging section). A sample of the conductor will be specially
prepared with the central wires withdrawn from one end sufficiently to permit a thermometer to be
inserted. The withdrawn strands will not be removed from the sample. The sample will at all times be
shaded from direct sunlight, be protected from rain and be suspended horizontally on the tower at
the bottom cross-arm level for a minimum of two hours before sagging commences.

Immediately prior to sagging activities, after all preparations have been made and all personnel
associated with the sagging operation are in position, the conductor temperature will be read and
communicated to all sag measuring stations. The person who controls the sag will relay all last
minute details to the conductor puller.

For sag measurement due consideration will be taken of the different lengths of insulator set and
height of the conductors when in the travelers.

The allowed sagging tolerances after clamping are:-

• The measured sag of any one conductor will not differ from the required sag by more than 150
mm.
• In any one span, the maximum permissible difference in sag between conductors of different
phases will not exceed 150 mm.
• The sag of the component conductors of any one phase will not differ by more than 40 mm.

The conductor sag will be measured using zoom sag scopes using the target method/or any other
method in practice. This requires the sag scope and the target to be located on the tower at a
position that is equivalent to the required sag. This dimension together with the required sag for the
nominated temperature will dictate the position necessary for the sag scope and target on the
towers. All these values will be recorded and the positions on the towers will be verified.

Adequate sag scopes and operators will be available to cover all the nominated check spans
simultaneously.

The sag will be adjusted by use of a sagging winch. Winch instructions will be given by the stringing
foreman who will relay the required adjustments received from the sag measuring operator(s).
7.3 Clamping-in / clipping

After the sagging operations are completed the conductors will be transferred from the travelers to
the suspension clamps. In order to dissipate the initial tension of conductor, they shall be left on the
sheaves for at least 48 hours after sagging. All clamping-in will be completed thereafter for achieving
the correct sag. When the Insulator string is vertical a mark (a piece of sticky tape or felt tip pen - on
no sharp instrument be used) will be put on the conductor to indicate the center line of the
suspension string. This center line will coincide with the center line of the suspension clamps before
bolting the clamp. This entails removing the conductors from the travelers and placing them in their
permanent suspension clamps attached to the insulator assemblies. If armour rods are required
same shall be provided. While clipping, a ladder will be used. The insulator units will not be
employed for climbing.
After the conductors are clamped in for the whole string section:-
• The suspensions sets will be vertical.
• The insulator units will be cleaned with a soft cloth.

8. Jointing

8.1 General

The equipment required for splicing operations consists of a splicing cart equipped with a hydraulic
compressor, compression joints, strand restraining clamps, hold down blocks, wire rope conductor
grips, hoists, ground rods, personal grounds, bonding cables. Jointing will only be conducted under
clean conditions. The jointing position will comprise as a minimum a flat platform higher than the
surrounding ground and of a size necessary to accommodate the compressor, press head, the joint
and the work crew comfortably. A copy of the relevant jointing instructions will be available at all
times. Prior to joining adequate supplies of jointing grease will be available to complete the joint in
hand. The dies used to compress the compression joint must be of the correct size and all presses
must be made in the proper sequence specified by the manufacturer of the joint. The electrical
resistance of all joints, whether mid-span, dead- ends or non tension compression or bolted type will
be measured employing a micro-ohm-meter and recorded.

8.2 Mid span Compression Joint

Mid-span joints are to be made at the jointing station located at the tensioner. During jointing
activities the joint station will be kept clean and preferably protected against rain. The joints on
conductors will be located not closer than 10 meter from a tower. The midspan joints will not be
located in major crossings.

8.3 Dead End Joints

Dead-end joints are required at all tension towers. These joints will be made by as per the Jointing
Instruction.

8.4 Dampers and spacer damper installation

Vibration dampers and flexible spacer will be fixed on the conductors immediately following clipping
and dead ending to prevent any possible wind vibration damage to the conductors. The required
 number of spacers, the spacer cycle, tools and tackle will be brought to the site prior to clipping in
and dead ending. The installation of the fittings will be in strict accordance with the manufacturer’s
recommendations. The correct fitting tool and tightening torque will be used.

8.5 Tension Tower Jumpers

Once the sagging and clipping work is completed, the jumpering is to be done at all tension towers.
The length of the jumper shall be measured actually for each phase on every tension tower. A
measuring tape or polypropylene rope can be used for this purpose. Once the length is derived
conductor of that length shall be cut and cone jumpers shall be compress at both end. The jumper
then shall be installed from one side dead end clamp to other side dead clamp and all nut bolts shall
be tightened properly. Jumpers for all phases and sub conductors shall be installed similarly.

8.6 Aircraft Warning

To fix Warning spheres, special cycle shall be used (to travel on single OPGW / Earth Wire).
Distance to fix the warning sphere shall be measured on ground and cycle shall be stopped at that
point. Technician traveling on cycle shall fix armour rod initially and over it warning sphere shall be
fitted.

9. Stringing of OPGW

In general, the system and the equipment used for installation of the OPGW Cable with optical fibre
are similar to those used for installation of the standard ground wire cable.
Nevertheless, since there is an optical fibre core, special care should be taken to avoid any damage to
the fibres by observing the minimum bending radius at all times. Therefore, specific components and
machinery are used for the OPGW cable: pullers, tensioners, anti- twisting counterweights, swivels,
pulling grips, pulley-blocks, self -gripping clamps, pulling ropes, pulling cables, etc.

Procedure

Survey of the line

Prior planning for installation of the OPGW cable is performed by monitoring the line, taking into
account the following parameters:

9.1 Length of each drum

The OPGW drum lengths are determined based on the following considerations: position of the tension
towers, tower access, distance between supports and crossing with other lines, roads, railways, routes,
services and other obstacles.

9.2 Splices

The position of the splices depends on the maximum available length of OPGW, on the position of the
towers and the tower access.

9.3 Preparation for the Installation

9.3.1 Drum

The drum is placed at the selected site (with the space required for its location) so that the cable outlet
is on the upper part and aligned with the planned laying direction.
The drum must be located at a distance of 2 or 3 metres from the tensioner. The lifting components
usually used are hydraulic jacks and a bar with the suitable dimensions inserted in the central opening
of the drum. The drum must be located at a height of 10 to 15 cm from the ground.
9.3.2 Puller and tensioner.

Both the puller and the tensioner must be placed at a minimum distance from the tower equal or
greater than 1.5 times the height of the tower.
The tensioner as well as the puller should be placed aligned with the conductors. The maximum
acceptable deviation angle is 34º.

If it is not possible to achieve this angle, the puller and/or the tensioner are placed close to the
following tower, using an additional pulling cable of the required length. 90º or less retracking of the
optic cable is not allowed. The tensioner as well as the puller should be positioned at a minimum
distance equivalent to twice the height of the support to which the cable is fastened.
In an installation with retracking, the smallest angle must be more than 90º and the final pulley should
be placed at a distance equal to 2 times the height of the tower. In the tensioner, the first groove the
cable will pass through must be perpendicular to the axis of the drum. A double armour OPGW in the
tensioner it will enter from the left and leave from the right for right-hand lay sense (and from the right
and leave from the left for left-hand lay sense).
The tensioner reels must be protected with material that does not damage the outer layer of the
OPGW cable.

The pulling cable should be joined to the OPGW cable by a swivel and a pulling grip. The minimum
diameter of the reels (where the OPGW is to be coiled) used during the installation should be at least
80 times the diameter of the OPGW cable, with no need of exceeding 1500mm. For example, the
tensioner reels for a 15mm cable should have a diameter of approximately 1.2 metres.

9.3.3 Pulleys

The pulleys have to be under good use conditions. The pulley groove should be protected with
neoprene or other similar material.
In case of sharp angles, the pulley must be placed so that the cable always passes through the center
of the groove.
If the angles are greater than 45 º, a dual pulley system must be used in order to increase the bending
radius during the installation. The diameter of each pulley should be at least 0.6 m.

9.3.4 Auxiliary components

The swivels are specifically designed for OPGW cables. They are of the suitable size for the cable to
be installed and in optimum condition for use.
The pulling grip for OPGW cable stringing must be at least 1.5 metres long and specifically designed
for stringing OPGW cables. Moreover, it should be of the suitable dimensions and in optimum
condition for use.
The clamps used during stringing and sagging operations have to be specifically designed for OPGW
cables and must be suitable for the OPGW cable diameter.
If preformed fittings are used, these should be specifically designed for the OPGW cable to be
installed. The diameter as well as the length and material of these components must be suitable for the
OPGW cable.
9.3.5 Pulling rope

The metallic pulling rope has to be specifically designed for cable stringing. The pulling cable must be
joined to the optical cable by a swivel and a pulling grip. The swivel is necessary to prevent any
twisting of the cable when stringing is performed.

9.4. Installation of OPGW cables

9.4.1 Basic controls

Strict controls must be established during installation to ensure that it is performed correctly, without
excess tension, twist of the OPGW, unsuitable compression, regulating a correct sagging. Neither the
fibres nor the aluminium tube will be damaged.
The tensioner and the puller should be placed at a distance from the first tower pulley which is
equivalent to at least 1-1.5times the height of the pulley.
Intermediate control points should be established, with the necessary precautions that are required at
critical points during installation (beginning/end of drum, angles, etc.).
During installation, the OPGW cable should not strike nor graze any objects other than the pulleys.
No obstacles must prevent the pulleys from rotating in the correct way.
The minimum bending radius must be controlled during all installation operations.
Ensure that the metal part of the pulleys do not make contact with the cable to prevent it from being
damaged.

9.4.2 Stringing speed

Generally it is recommended an installation speed about 60 m/min, depending always on the

environmental conditions and the topology of the overhead line. The supervisors (or the technical
responsible) for the installation will take care that all supplier recommendations are fully applied during
the installation process.

9.4.3 Pulling tension

The recommended pulling tension shall be lower than 1.5 times the weight (kg) of 1 km OPGW cable
length.

9.4.4 Minimum bending radius

The minimum bending radius is as follows:

- On tensioner reels 40 times the cable diameter
- During installation 400 mm
- After installation 20 times the cable diameter

9.4.5 Communications during stringing

The personnel located at the puller, the tensioner, the pulley crossings and the cable ends are in
communication at all times by communication system.
9.5 Sagging of the cable

Generally, the methods used to obtain the correct sag values of the OPGW cables are the same used
for conventional ground wire cables. The specific recommendations are as follows:
Pulling is performed by a preformed fitting or tension clamp (in intermediate spans) or with the pull
jacket at the end. Special attention must be taken on using appropriate clamps adapted to the OPGW
cable diameter.
Sagging of the cable and fittings installation are always performed after stringing. At this time, the
attachment fittings are also installed to prevent damage to the OPGW cable. The installer is
responsible for any damage to the OPGW cable that may occur due to failure cause by incorrect
application of the previous points.

9.6 Installation of fittings and accessories

The fittings: tension clamps, suspensions, earthing clamps, dampers, etc. should be installed in
accordance with the manufacturer’s instructions and using the appropriate tools. Special attention
must be taken on using appropriate clamps adapted to the OPGW cable diameter. Finally the cable
must be conducted till the joint box place.

9.7 Personnel training

All personnel who participate in the installation of the OPGW cable should be informed of handling
problems and installation procedures for the OPGW cable. It is responsibility of the installer to assure
the correct instruction to the whole personnel involved in the installation works.

9.8 Splices

After stringing and the optical measurements taken to verifiy it meets the customer’s requirements, the
OPGW cable will be spliced Joint boxes used should have a device for fixing properly to the tower.

9.9 Transmission test during the installation phases

9.9.1 Measurements after installation

After the cable has been installed, and prior to the splices, each of the cable fibers is verified once
again using OTDR. The attenuation values recorded are registered.

9.9.2 Splices measurement

After splicing, each joint is optically verified using OTDR in order to ensure that the attenuation values
are within the required values.

9.9.3 Final acceptance test

After installation, a final measurement of the transmission characteristics is and the values are duly
recorded. A copy of this is submitted to the customer.

10. QUALITY RECORDS

All processes and actions undertaken during stringing are subject to quality control checks.