Inst_OAC_steel_tube-GB, Rev.

05 10/01/2011, Gi

GUIDELINES FOR INSTALLATION OF SELF-SUPPORTING OPTICAL AERIAL CABLES (OPGW, OPPC, MASS) WITH STEEL TUBE(S)

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1.

Scope and purpose

This guide provides general recommendations for the selection of methods, equipment and tools for the stringing of optical aerial cables with:

stranded steel tube(s) central steel tube central steel-aluminium tube

made by AFL Telecommunications GmbH. The installation methods for such cables are essentially the same as those used for usual conductor ropes. However special care must be taken in order to not exceed the maximum pulling tension and the minimum bending radius. It is also essential to avoid damages to the strands caused by touching the ground or the tower structure. Special care must be taken to avoid any damage to the optical unit by applying inadmissible pressure, torsion or bending. For further information refer to the references where stringing equipment and methods are described in detail. Tension and suspension hardware and also the required clamps and fittings must be adapted to the specific cable type and approved by the manufacturer. A more detailed description of the fundamental precautions and procedures can be found in the references. This guideline focuses mainly on those points which are different from usual installations or which need special care. However it is expected that the installation company has already experience in stringing of at least usual conductors on high voltage lines.

2.

References
IEC/TR 61328: IEEE Std 524: Live working Guidelines for the installation of transmission line conductors and earthwires - Stringing equipment and accessory items IEEE guide to the installation of overhead transmission line conductors

3.

Safety

All safety practices of the government, the power utility and the installation contractor must be followed. These safety procedures will take precedence over any information contained in this document. For the safety requirements towards inductive and capacitive influence it is necessary that the cable is properly grounded during installation. For detailed information refer to above mentioned standards.

4.

Transport and storage of the cable reels

Reels must be transported and stored in an upright position and safely secured against movements during transportation. Loading and unloading must be done using suitable cranes or forklifts. The reels must not be tipped out or thrown. When using wooden reels it must be checked if the bolt nuts have to be retightened after transportation .

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5.

Stringing Method

To prevent damages, the cable must be installed using the tension method. That means the cable is tensioned during stringing to keep it clear of the ground and obstacles. Cable lengths must be installed separately, that means it is not allowed to connect several delivery lengths to be strung in one step.

6.

Bending radius

The minimum permissible bending radius under load is 15 times the cable diameter. The unloaded cable is permitted to be bent with a minimum radius of 10 times the cable diameter. See technical data sheet for specific values.

7.

Sheaves

The sheaves must be in good condition. Diameter of sheaves (bottom of groove): Initial and terminal points of the line (deflection angle 120) At tension towers At suspension towers

800 mm

600 mm 450 mm

In any case the minimum bending radius of the cable must not be exceeded. Generally it is recommended that the sheave diameters should be as big as possible to limit the load for the cable. For cables with ACS wires in the outer layer it is absolutely necessary to have metallic sheaves with neoprene coated grooves or sheaves with grooves made of plastic (e.g. PA) at initial and terminal points and at angle points of the line. In case of only AA or Al wires in the outer layer the sheaves can be coated or blank. (Note the earthing requirements). In any case it must be ensured that the sheave grooves do not damage the cable's armour. Grooves have to be adapted to cable diameter and must not be smaller than 0.55 times the cable diameter. Groove profile and radius should be wide enough to allow passage of swivels and wire mesh grips. If an old conductor is used as pulling rope the size of rope joints must also be taken into consideration. For that reason the sides of the grooves should open in an angle between 15 and 20. The sheaves must be in good working order and properly lubricated. Sheaves should preferably be provided with high quality roller or ball bearings to minimise the rolling and frictional resistance.

Figure 1: Groove dimensions

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8.

Cable Pay-Off

Cable pay-off can be a reel stand or a movable reel carrier. In any case it must be equipped with a suitable brake to prevent the reel from carry on turning when the stringing stops. This would cause the cable layers slackening on the drum. The pay-off should be positioned not less than 5m behind the tensioner. It is strictly prohibited to do tension stringing directly from the reel without using a tensioner!

Figure 2: Reel Carrier

9.

Tensioner (brake)

The bullwheel sheave diameter has to be more than 70 times the cable diameter or 1200 mm whatever is smaller. The wheels must be in such condition that they do not have any burrs or cavities which may damage the cable. The running-grooves must be adapted in size to the cable diameter. At best they are coated with neoprene or similar material. The tensioner must be able to assure constant tension and allow a steady slow down at different stringing speed without the effect of cable run after. Tensioning should be readily controllable and capable of maintaining constant and even operation. There should be a minimum of 6 turns to anchor the cable. To prevent from birdcaging the correct orientation for entry and exit of the cable must be respected. For right hand lay (Z), the cable must enter the brake on the left and exit on the right (see figure 4). For left hand lay (S), the cable must enter on the right and exit on the left.

Figure 3: Bullwheel Tensioner

Figure 4:

Bullwheel Reeving for Right-Hand Lay Conductor (Z)

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10. Puller
The puller should preferably a bullwheel puller with integrated or separate reel winder. The speed must be infinitely variable and allow a smoothly pull of the cable without jerking or bouncing. The puller must be equipped with a tension control system and an adjustable tension dependant switch off. The stringing tension has to be recorded during the whole installation. Before stringing, the puller has to be checked according to accuracy of tension measurement.

Figure 5: Puller with Integrated Reel Winder

11. Stringing tension

During cable stringing the maximum installation tension, which is given in the data sheet must not be exceeded. This value should be understood as an absolute maximum for unforeseen disturbances during the stringing process or for installations with very difficult conditions (e.g. mountains, valley crossing etc.). The regular installation force should not exceed 20% of the cable's rated tensile strength. The stringing tension must be controlled by a puller with automatic switch off at the limit tension.

12. Cable stringing

The cable is supplied with band clamps at both ends. These clamps must not be removed before the stringing process is finished. The pulling rope should have a low twist effect. In case of replacement, the old conductor can be used as pulling rope, if it is suitable regarding size and condition. Figure 6: Connection with Wire Mesh Grips and Swivel

The pulling rope should be attached to the cable by a swivel link with the help of a of wire mesh grip (see figure 6). The installation equipment i.e. the puller and tensioner should be placed in line with the two first towers (within app. 10). The sheaves at the running-in point and at the exit point of the line should be arranged in such a way that bird-caging of the cable is prevented. If there are signs of bird-caging the stringing has to be interrupted and the stringing arrangement must be corrected. At the start of stringing the puller should be slowly speeded up with about 5m/min and in case of properly run the speed can be increased to maximum speed of 60m/min. The actual installation speed is of course dependent upon the line configuration. During stringing special attention must be paid to the swivel and wire mesh grip running through the sheaves and lattice towers. Special attention must be paid during insertion of the cable into the lattice tower for joint box installation, to prevent damage or bird-caging.

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For cable jointing a certain excess length of tubes and fibres is necessary which will be placed in the joint box. For this purpose a cable surplus of approximately 5 m is required. Sagging procedure is the same as for ordinary conductor ropes.

Important notes:
Anti-torque devices: As cables with only one armouring layer tend to rotate, the use of suitable anti-torque devices (pendulum weights) is mandatory. They should be directly placed onto the cable. In case of a central steel tube cable it can be installed without anti-torque device if the line configuration allows for a limitation of the stringing tension to a maximum of 10% of the rated tensile strength. This does not apply for cables with steel-aluminium tube! Come Along Clamps: If for sagging or installation of the accessories come along clamps shall be used, please note that common self-gripping clamps are strictly prohibited for any cable listed in chapter 1. Self gripping clamps which are properly adapted to the cable diameter or suitable preformed fittings shall be used as come along clamps for stranded steel tube and central steel-aluminium tube designs. Only suitable preformed fittings are allowed as come along clamps for central steel tube cables.

13. Cable Handling and Preparation

Whenever the cable has to be cut for any purpose as measurement, splicing or preparation for stringing, special care must be taken to prevent an opening of the armouring layers. This should be done by proper binding of the cable near to the place of cut. To prevent injury the personnel working with the cable should wear safety goggles and gloves .

14. Accessory installation

The issued instructions from the accessory supplier have to be followed. In case of using vibration dampers they always have to be placed on cable guards with an appropriate length. The locations of the dampers have to be taken from the damper location sketch. Earth connecting fittings and cable fastening clamps must be adapted to the cable diameter and installed with the rated torque. In any case, only approved accessories must be used. Consult with AFL Telecommunications GmbH or your accessory supplier to select the appropriate accessories.

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15. Conductor Cars

For installation of special devices like warning spheres or for maintenance reasons it may be necessary to use a conductor car on the cable. To ensure safety of personnel and to prevent damages to the cable the following rules must be followed: All cables of AFL Telecommunications GmbH with two or more armouring layers and an ACS or galvanised steel content of at least 25 mm can be considered as passable. The conductor car must be equipped with at least two wheels with a minimum diameter of 25 cm which are permanently carrying the car. If the diameter of the wires in the outer layer is smaller than 3.0 mm, the wheels must be lined with an elastomer to protect the surface wires from damage. In case of bigger wires the wheels can also be made of aluminium or plastic (e. g. PA). The groove must be rounded at the bottom with a radius bigger than the radius of the OPGW. To prevent pinching of the cable there must be adequate clearance at the sides of the groove. By means of sag calculation with appropriate software it must be ensured that under no condition the Permissible Maximum Working Tension of the cable is exceeded. If there are stricter safety regulations given by the government, the power utility or the installation contractor, these safety procedures will take precedence over the limit given above. In case of an existing (older) installation it must be ensured that the cable is not damaged to a degree which influences the safety. The weight of the conductor car is very important for tension and maximum sag limits. For that reason in any case it should be lowest possible. The maximum weight for steel tube cable is limited to 250kg.

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