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171

Development of Thermo-resistant Wrap-on type OPGW

Hirofumi Ito* ABSTRACT: As the demand for telecommunication capacity at power utilities grows,
Toshiharu Takahashi** attention has been focused on the development of wrap-on type fiber-optic overhead
ground wire with multiple fibers (more than 24). Wrap-on type wire can be used not
Yoshikazu Namekawa***
only for existing conventional ground wire, but also for existing regular type fiber-optic
Hiromitsu Takagi** overhead ground wire, to increase the existing telecommunication capacity without
having to shut down existing telecommunication lines. New thermo-resistant wrap-on
type wire with 24 and 48 fibers has been developed together with a wrapping machine
and necessary accessories and fittings. The diameter of wrap-on type optical fiber cable
has been made as small as 4.5 mm for 24-fiber cable and 6.1 mm for 48-fiber cable to
minimize the increment of wind loading.

〔1〕INTRODUCTION 〔2〕OPTICAL FIBER CABLE DESIGN AND

Composite fiber-optic overhead ground wire (OPGW) has
been widely used since the early 1980's. Three types of OPGW
have been developed “regular” OPGW with optical fibers
housed inside, “wrap-on type” OPGW with optical fibers
helically wrapped on existing ground wire, and “all dielectric
self supporting (ADSS) cable”. As a leading manufacturer of
OPGW, Hitachi Cable has been supplying mainly the regular
type OPGW to major utilities both domestically and abroad.
Regular type OPGW, which was installed in the
introductory stages of OPGW, usually has six fibers but may
have more. However, the rapid growth in demand for
telecommunication capacity has driven the development of
wrap-on type OPGW with as many as 24 and 48 fibers. This
wrap-on type OPGW with multiple fibers can be used for
existing conventional overhead ground wires to provide large
new telecommunication systems.
It is particularly noted that the current carrying capacity of
most existing OPGWs in Japan has been designed at the
temperature of 150˚C for continuous operation and 300˚C for
short circuit. To match the performance of the existing ground
wires, optical fiber cable for wrap-on type OPGW needs to be
thermo-resistant. In addition, in order to minimize the
increment of wind loading to existing towers, the diameter of
wrap-on OPGW optical fiber cable should be 4.5 mm for 24-
PERFORMANCE
Various factors including mechanical and electrical
properties, thermo-resistance, and minimization of cable
diameter have been considered in the design of optical fiber
cable for wrapping. The basic construction of the cable is such
that six fibers are grouped together as a sub-unit and four or
eight of these sub-units are stranded on the FRP tension
member for 24-fiber or 48-fiber cable respectively, as shown in
Fig. 1.
To ensure the reliable lifetime design of optical fiber, all
factors for the elongation of fibers such as strain caused by
wrapping-on, temperature and tension variation and creep of
Optical fiber cable
Ground wire
(a) Wrap-on type OPGW
Optical fiber
Approx. 6.1 mm

(thermo-resistant type)
Approx. 4.5 mm

fiber cable and 6.1 mm for 48-fiber cable.

Hitachi cable has successfully applied 24-fiber wrap-on Filler
type OPGW with the above specifications to practical use, and
has developed 48-fiber wrap-on type OPGW in cooperation Tension member
with Chubu Electric Power co., Inc.
Fluorinated resin
(b) Cross section of optical fiber cable

Fig. 1−Cable construction of wrap-on type OPGW

* Chubu Electric Power Co., Inc. (a) Optical fiber cable helically wrapped on ground wire
** Toyoura Works, Hitachi Cable, Ltd. (b) Six-fiber sub-units are stranded on the FRP tension member,
*** Hitaka Works, Hitachi Cable, Ltd. then covered with fluorinated resin

HITACHI CABLE REVIEW No.18 (October 1999) 13

 TABLE 1 PROPERTIES OF OPTICAL FIBER CABLE FOR WRAP-ON TYPE OPGW
Properties of optical fiber and optical fiber cable

Item Properties
Optical fiber Type Single mode (SM) Dispersion-shifted fiber (DSF)
Wavelength 1.3 µm 1.55 µm
Optical attenuation 0.45 dB/km 0.26 dB/km
Screening level 1.1%
Type (Number of optical fibers) 24 fibers 48 fibers
Cable diameter 4.5 mm 6.1 mm
Weight 25 kg/km 46 kg/km
Breaking load (N) 1,470 1,860
Optical fiber cable

Fluctuation of attenuation during

0.3 dB/km
wrapping
Allowable temperature −20˚C to 150˚C
Max. temperature of ground wire
300˚C×0.3 sec.
for short circuit
Dry
Commercial voltage test Min. 395 kV / 10 m (virtual value)
Wet
Arc resistance test Min. 200 Coulomb charge

Optical fiber cable

Fig. 2−Appearance of wrap-on type OPGM after arc

test
Appearance of wrap-on type OPGW after arc test (200
Coulomb charge). 48-fiber optical fiber cable, and AC
Ground wire (AC260 mm2) 260 mm2.

ground wire etc, are duly evaluated. The amount of proof load
on the optical fibers is chosen in due course. The primary fiber AC70 mm2, P＝300 mm AC260 mm2, P＝300 mm
AC70 mm2, P＝400 mm AC260 mm2, P＝400 mm
coating is made of silicone, which results in a maximum
AC70 mm2, P＝500 mm AC260 mm2, P＝500 mm
allowable temperature of 150˚C for continuous operation and
P: wrapping pitch length
300˚C for short circuit. This maximum allowable temperature
makes the fiber compatible with conventional regular type 20
Increasing rate of drag coefficient (%)

OPGW and other ground wires. The wrap-on type OPGW can
be supplied with a UV-cured primary coating when required. 15
Although this coating provides a slightly lower temperature
resistance, it reduces the diameter of the completed optical 10
fiber cable.
Table 1 shows the typical properties and test results of the 5
wrap-on type cable. Tests showed that the cable has sufficient
mechanical and electrical properties, including sufficient 0
bending, torsion, compression, and vibration strength. Figure 2
shows a wrap-on type OPGW after an arc test. The cable was −5
4 5 6 7
not damaged, where as the surface of a ground wire AC 260
Diameter of optical fiber cable (mm)
sqmm (aluminum-clad steel wire of 19/4.2 mm) showed severe
damage. Fig. 3−IIncrement of drag coefficient versus diameter of optical
Since the wrap-on type OPGW is usually applied to cable (diameter of ground wire; AC70 mm2 10.5 mm, AC260
existing overhead ground wires, where of course, the towers mm2 21.0 mm)
are also existing with an occasional requirement for additional When the diameter of the optical fiber cable is larger, the drag
coefficient increases. When the diameter of the ground wire is
reinforcement, it is quite important to minimize the increment larger, increasing rate of drag coefficient is smaller for the same
of wind loading as well as cable weight. Figure 3 shows the optical fiber cable.

14 HITACHI CABLE REVIEW No.18 (October 1999)

measured increment of drag coefficient by wind loading in
conjunction with the increase of cable diameter and wrapping
pitch length. In consideration of the screening level for optical
fiber, the area highlighted is the practical applicable range, and
it is possible to suppress the increment of drag coefficient at a
level of approx. 10% or less.
〔3〕DEVELOPMENT OF WRAPPING MACHINE
The wrapping machine must be light weight to ensure less
sag during wrapping work on site, while the capacity of the
optical cable bobbin must be as high as possible. In
consideration of these contradictory requirements, development
of the wrapping machine was necessary to find optimum
performance at site. As shown in Fig. 4, the wrapping machine
consists of a main frame, the optical cable bobbin, a self-
adjustable balance weight, and a counter-weight for stability.
The machine is designed to be pulled forward with a light rope
from the front tower eliminating the need for a self-driving
device and thus reducing its weight. In this system, called a
cradle block system, a constant driving force is applied to the
pulling rope which the machine converts to self-rotation power

Ground wire

Balance weight

Pulling rope

Wrapped cable

Optical fiber cable bobbin

Counterweight

Fig. 4−Appearance of wrapping machine

Wrapping proceeds from right to left. The cable on the right is already wrapped.

TABLE 2 PERFORMANCE OF WRAPPING MACHINE for wrapping the optical fiber cable around the ground wire at a
Can be used on slopes with a catenary angle of as much as 35˚, and regular pitch under well conditioned tension.
can easily pass over the mid-span joint. Table 2 shows the major performance of a wrapping
Item Performance machine with a self-weight of 85 kg, maximum cable length
24 fibers 2,000 m/bobbin
per bobbin without joint (2000m for 24 fiber and 1400m for 48
Max. length
of cable fibers), and the running speed of 10 - 20 m/min. The machine
48 fibers 1,400 m/bobbin
can be used with ground wire having a diameter ranging from
Running speed 10 to 20 m/min
9.6 mm to 21.0 mm (outer most diameters). It is designed in
Catenary angle of 35˚
Applicable slope
(Climbing and descanding)
such a way that it can pass over the mid-span joint, and can
function properly even when climbing or descending slopes
Wrapping pitch length 400 to 500 mm
with a catenary angle of as much as 35 degrees without
AC55 mm to AC260 mm2 slipping.
Applicable size of ground wire
(cable diameter: 9.6 mm to 21.0 mm)
Mid-span joint Possible to run through
Weight of machine 85 kg

HITACHI CABLE REVIEW No.18 (October 1999) 15


〔4〕DESIGN FOR ACCESSORIES AND FITTINGS
For proper installation of wrap-on type OPGW, several
special accessories and fittings are required to ensure reliable
telecommunication lines. The typical arrangement of these
accessories and fittings at the tower is shown in Fig. 5. For
example, a protection tube is used to protect the optical cable in
the span close to the tower, while a reinforced protection tube
is used for the arrangement of optical fiber cable along and
within the tower.
In addition to an ordinary joint box for splicing the wrap-on
cable on the tower, a housing box for expansion length was
developed which stores up to approximately 10m of additional
wrap-on cable without cutting, and keeps it ready for system
expansion or maintenance in the future.
cradle blocks at intervals small enough to prevent excess
sagging. The rope is used to pull the wrapping machine and
bobbin loaded with optical fiber cable at a constant and stable
speed and tension towards the adjacent tower. The rope is
driven by a winch located on the ground near the base of the
adjacent tower. Since the rotation of the wrapping machine is
quite stable throughout the operation, it is possible to conduct
installation work by shutting down only one of the circuit's
two-circuit towers.
Figure 7 shows the actual installation of a wrap-on type
OPGW at the top of a tower. In this photograph, workers are
transferring the wrapping machine from one already completed
span to the next. These procedures are standardized and the
workers are highly-trained. Hitachi Cable not only supplies
wrap-on type OPGW, but also provides installation as a
contractor.

〔5〕INSTALLATION PROCEDURES AT SITE

〔6〕CONCLUSION
As mentioned above, the wrapping machine is designed
with a cradle block system as shown in Fig. 6. At the Thermo-resistant wrap-on type OPGW with 24 and 48
commencement of installation work at the site, a very light and fibers was successfully developed. Mechanical and electrical
strong fiber-rope is laid out along the span, held by many small tests showed the performance of the cables to be superior to

Ground wire

Tower top

Protection tube
with reinforcement

Wrap-on cable

Housing box
for expansion
length

Fig. 5−Typical arrangement of housing box for expansion length

Typical arrangement of special housing box for expansion length is provided at the tower.

16 HITACHI CABLE REVIEW No.18 (October 1999)

 Wrapping direction

Cradle block
Optical fiber cable Pulling rope
Wrapping machine
Ground wire

Phase conductors

Tower A Tower B Tower C

Winch

Fig. 6−Installation of wrap-on type OPGW

First, the pulling rope is laid out along the span. Then the wrapping machine is pulled towards the adjacent tower using a winch.

Wrapping direction
Removal crane

Wrapping machine

Ground wire

Phase conductor

Fig. 7−Wrap-on type OPGW installation work at the tower top

Wrapping machine is transferred from one span to the next.

other cables. In order to apply wrap-on OPGW to existing
overhead ground wires without excessive increase of wind
loading, the actual increment of wind loading is examined. In
consideration of the screening level for optical fiber, the
diameter of the cable was reduced to as little as 4.5 mm for 24-
fiber cable and 6.1 mm for 48-fiber cable. This reduction made
it possible to use the wrap-on type OPGW for most ground
wires without requiring reinforcement of the existing towers
when the cable is used to replace existing transmission lines.
A wrapping machine was developed to be compatible with
the optical fiber cable and the maximum length of the cable
that can be wrapped without joints is found to be 2,000m.
Special accessories and fittings such as protective tubes and
reinforcement tubes at the tower arrangement for the optical
fiber cable were also used. Since early 1999, several projects
have been carried out in which 24-fiber wrap-on type OPGW
has been successfully installed by Hitachi Cable to 77-kV
overhead transmission lines for the Chubu Electric Power Co.,
Inc.

HITACHI CABLE REVIEW No.18 (October 1999) 17

〔7〕ACKNOWLEDGEMENTS
The authors would like to express their appreciation to the
Chubu Electric Power Co., Inc. for their cooperation with the
development work and for permission to publish.
REFERENCES
(1) S. Tanaka et al., Development of High Fiber Count Optical
Wrap Cable around Overhead Ground Wire; Proceedings
of the Electronics, Information, and Systems Conference;
Electronics, Information and Systems Society, I.E.E. of
Japan (September 1998)
18 HITACHI CABLE REVIEW No.18 (October 1999)
Hirofumi Itou
Control & Telecommunications Engineering Dept.,
Chube Electric Power Co., Inc.
Development of telecommunication line equipment
for power utilities
Graduated from Komagane Technical High School,
1988
Toshiharu Takahashi
Aluminum Wire & Cable Dept., Toyoura Works
Design and development of conductors for overhead
transmission lines
Received a M.E. degree in Mechanical Engineering
from Utsunomiya University, 1997
Yoshikazu Namekawa
Telecommunication Design dept., Hitaka Works
Design and development of optical fiber cables and
telecommunication cables
Graduated from Takahagi Technical High School,
1992
Hiromitsu Takagi
Overhead Transmission Dept., Toyoura Works
Design and management of overhead transmission
line construction
Graduated with a degree in Electrical Engineering
from Tomakomai Technical College, 1976