OPGW BROCHURE - Sterlite

Sterlite’s end-to-end solutions for smart grids

Sterlite AERIAL-LITE OPGW Cable Series - Aluminum Clad Central Steel Tube Design 

Sterlite AERIAL-LITE OPGW Cable Series - Central Core Aluminum Sheathed Tube 

Sterlite AERIAL-LITE OPGW Cable Series - Central Steel Tube Design Design 

Sterlite AERIAL-LITE OPGW Cable Series - High Fault-Current Design 

Sterlite AERIAL-LITE OPGW Cable Series - High Strength Design 

Standard Product Features 

Sterlite OPGW Accessories 

09 

10 

11 

12 

13 

14 

15

OPGW – the smart energy 

management solution 

The development of smart energy management systems is the 

need of the hour and is aimed at alleviating the burgeoning 

demands from today's power infrastructures. 

Optical Fiber Composite Ground Wire (OPGW) is a revolutionary 

solution that enables synergies between efficient power 

distribution grids and high speed optical fiber-based SCADA 

networks, giving power utility companies the unique 

capabilities of a telecom carrier or service provider. 

OPGW replaces a conventional ground wire (or earth wire) to 

protect the transmission system from lightning strikes and 

serves as a conductive medium for carrying fault currents to 

ground. It also acts as a medium for real-time monitoring and 

security of the transmission system over which it is installed - 

doubling up for SCADA controls and network. 

The OPGW cable is run between the tops of high-voltage 

electricity pylons. The conductive part of the cable serves to 

bond adjacent towers to earth ground, and shields the highvoltage 

conductors from lightning strikes. The optical fibers 

within the cable can be used for high-speed transmission of 

data, either for the electrical utility's own purposes of protection 

and control of the transmission line, for the utility's own voice 

and data communication, or may be leased or sold to third 

parties to serve as a high-speed fiber interconnection between 

cities 

Installation 

Supply 

Sterlite’s end-to-end project management capabilities 

Analysis 

OPGW as a communication medium has unique advantages 

over buried optical fiber cable wherein installation cost per 

kilometre is lower than a buried cable. Effectively, the optical 

circuits are protected from accidental contact by the high voltage 

cables below (and by the elevation of the OPGW from ground). 

A communications circuit carried by an overhead OPGW cable 

benefits from the lower likelihood of accidental damage due to 

excavation work, for example road expansion or by any kind of 

repairing work of underground drainage system or water supply 

system. 

Since the past two decades, Sterlite has developed technical 

expertise in fiber optic cables and proven its capabilities in 

manufacture of energy efficient bare overhead power 

conductors. Sterlite has integrated these core strengths in its 

comprehensive OPGW solution that includes Optical Fiber 

Composite Ground Wire and related hardware. 

Sterlite has successfully offered its OPGW technology to several 

prestigious projects involving companies like Adani Power, 

ENICL,Eskom, GETCO, NHPC, PGCIL, Saurashtra Cement, 

TNEBTANTransco, Ultratech, UPPTCL, Areva and Vedanta 

Aluminium, among others. 

Designing 

Manufacturing

Sterlite’s suite of 

solutions 

With over two decades of experience in global markets, Sterlite 

offers an end-to-end suite of solutions that includes: 

• OPGW cables 

• Suspension sets 

• Tension Set Assemblies 

• Vibration Dampers 

• Joint Boxes 

• Bonding Clamps 

Sterlite’s OPGW cable is produced strictly according to 

IEEE1138, IEC60794 and relevant international standards 

pertaining to its constituents. 

Sterlite’s value 

proposition 

Global experience 

Sterlite has a significant experience in implementation of 

projects for Government incumbents, utilities and enterprises. 

End-to-end project implementation 

Sterlite ensures complete control over the value chain and 

delivers end-to-end project management services. Sterlite’s 

project management suite includes network planning & 

design,network build, network operation & management, 

system auditing and consultancy services. 

Qualified and experience talent pool 

Sterlite has a qualified talent pool, experienced in network 

design, project management, network implementation and 

network maintenance. 

Credible partners 

Sterlite has partnered with reputed project management 

companies and Original Equipment Manufacturers (OEMs), to 

ensure that the delivery of the project is streamlined. 

Solution development for newer applications 

Sterlite continues to enhance its portfolio taking into account 

the bandwidth needs evolving from client applications. 

Local support 

With offices in 11 countries, Sterlite always has a relationship 

manager who is a mere phone call away, to understand your 

growth aspirations and to explore areas where it add value to 

your business. 

Installation of Sterlite Central Steel Tube at Ultratech, Gujrat (India) 

Fiber splicing during the installation of Sterlite Central Steel Tube at 

Vedanta Aluminium Ltd., Jharsuguda (India)

Approvals and 

certifications 

Quality and 

reliability 

Test Items Test Condition 

1 Creep Test IEEE 1138 : 2009 

Section 6.4.1.1 

2 Stress strain Test IEEE 1138 : 2009 


(EIA/TIA 455-82B) 

3 Strain Margin Test IEEE 1138 : 2009 


4 Ultimate Tensile 

Strength test 

IEEE 1138 : 2009 


5 DC Resistance test IEEE 1138 : 2009 


6 Sheave Test IEEE 1138 : 2009 


7 Crush Test IEEE 1138 : 2009 


8 Bend test IEEE 1138 : 2009 


9 Twist test IEC 60794-1-2 

Method E7 

10 Aeolian Vibration 

Test 

IEEE 1138 : 2009 


11 Galloping test IEEE 1138 : 2009 


12 Short Circuit Test IEEE 1138 : 2009 


13 Lighting arc test IEEE 1138 : 2009 


14 Water Ingress Test IEEE 1138 : 2009 


15 Seepage of filling 

compound 

16 Temperature Cycle 

test 

17 Salt Spray Corresion 

test 

18 Cable Cut off 

wavelength test 

IEEE 1138 : 2009 


IEEE 1138 : 2009 


IEEE 1138 : 2009 


IEEE 1138 : 1994 


19 Impact Test IEC 60794-1-2 

Method E4 

Sterlite’s solutions have been tested and approved by 

DRDO,CPRI and ERDA in India and SABS in South Africa.

Ordering guide 

Example : 24B1-108[65;120] 

xxx xxx xxx [xxx; xxx] 

Fiber count Type of fiber 

B1-G652A 

B2-G652D 

B3-G655 

Cross section of 

OPGW (mm2) 

Break strength of 

OPGW (kg) 

Fault current rating 

(kA².sec)

Sterlite AERIAL-LITE OPGW Cable Series 

Aluminum Clad Central Steel Tube Design 

PRODUCT DESCRIPTION 

ACS Wires 

Aluminum Cladded Steel Tube 

Fibers In Filling Jelly 

Sterlite AERIAL-LITE OPGW cable with aluminum clad central steel tube is available in fiber counts up to 24. It is the perfect solution for overloaded 

towers due to its small diameter and light weight construction. The fibers are protected from environmental conditions to ensure reliability and long life. 

PRODUCT FEATURES 

Very small, low weight cable resulting in low added load to the poles/towers. 

Central tube provides mechanical and thermal protection to optical fibers. 

High fault current rating with good crush resistance. 

Obtaining the best balance of electrical and mechanical properties by adjusting AA/AS combination. 

The stranded wires can be customized to individual customer requirements. Single or dual layered designs available as per strength and 

fault current requirements. 

PRODUCT APPLICATION 

Ideal for installation in highly corrosive environments. 

PRODUCT OPTIONS 

Optical fiber options: 

ITU G 652 D < 0.35/0.21 dB/km @ 1310/1550 nm 

ITU G 655 < 0.23/0.25 dB/km @ 1550/1625 nm 

Identification options: 

EIA/TIA 598 

Black ring marking for >12 fibers in a tube. 

Bundle binders for each 12 fiber. 

Operating temperature range: -40° C to +85° C 

Installation temperature range: -20° C to +70° C 

TYPICAL PRODUCT SPECIFICATION 

Fiber Count 

24 

24 

24 

Product Code 

24B1-59 [78;39] 

24B1-65 [88;47] 

24B1-81 [69;41] 

Fault Current 

(kA². sec) 

39 

47 

47 

Effective Area 

(mm²) 

59 

65 

81 

Overall Diameter 

(mm) 

12.5 

13.4 

11.8 

Weight 

(kg/km) 

530 

545 

437 

UTS(KN) 

78 

88 

69 

DC Residence @ 

@ 20degC(ohm/km) 

0.9 

0.6 

0.6 

Issued: April 2012 

Supercedes: April 

2011


Central Core Aluminum Sheathed Tube Design 



Auminium Tube 

Thermal Barrier 

FRP 

PBT Tube With Fibers 

ACS Wires 

Sterlite AERIAL-LITE OPGW cable with central core aluminum sheathed tube is made of polymer loose tubes and the outer layer can be a suitable combination 

of ACS and AAwires for the right ratings as required by the end-user. 

Ideal for very high fiber count requirements -Fiber count up to 144 fibers. 

Optical unit sheathed with aluminum which provides high mechanical protection for the fiber and excellent moisture proofing. 

The extruded aluminum tube also adds to the fault current receptivity of the cable. 

The stranded wires can be customized to the individual customer requirements of electrical and mechanical properties by adjusting AA/AS combination. 


This design is suitable for high fiber counts under high heat dissipation requirements. The cable is ideal for lower span lengths and distribution 

transmission lines. 



ITU G 652 D < 0.35/0.21 dB/km @ 1310/1550 nm 

ITU G 655 < 0.23/0.25 dB/km @ 1550/1625 nm 


EIA/TIA 598 





TYPICAL PRODUCT SPECIFICATIONS 

Fiber 

Count 

Product Code 

Fault Current 

(kA².sec) 


(mm)² 


(mm) 

Weight 

(kg/km) 

UTS (KN) 

DC Resistance 


24 24B1-90 [102;41] 41 90 13.2 581 102 0.7605 

48 24B1-90 [102;41] 41 90 13.2 581 102 0.7605 



2011


Central Steel Tube Design 



ACS Wire 

Steel Loose Tube 

Jelly Filled Fiber 

Optical Fiber 

 

Sterlite AERIAL-LITE OPGW cable with central steel tube is simple and offers a robust design with scope for up to 48 fiber counts, resulting in good 

protection to the fiber. 

Optical fibers are housed in a hermetically sealed, stainless steel tube filled with jelly. 

High RTS of the cable. 

Designed to have a larger stress-strain window, thereby ensuring longevity of performance over the years. 

The stranded wires can be customized in diameter, number of wires and conductivities or a combination of AA/AS wires is worked 

out to meet the individual customer requirements of electrical and mechanical properties. 


A perfect solution for easy installation, short hauls and basic layouts which need minimum design complications. 



ITU G 652 D < 0.35/0.21 dB/km @ 1310/1550 nm 

ITU G 655 < 0.23/0.25 dB/km @ 1550/1625 nm 


EIA/TIA 598 


Or 




TYPICAL PRODUCT SPECIFICATIONS 

Fiber 

Count 

12 

Product Code 

12B1-81 [64;40] 

Fault Current 

2 

(kA .sec) 

40 


(mm ) 

2 

81 


(mm) 

12.3 

Weight 

(kg/km) 

490 

UTS (KN) 

64 

DC Resistance 


24 24B1-81 [64;40] 40 81 12.3 490 64 0.72 

48 48B1-81 [64;40] 40 81 12.3 490 64 0.72 

0.72 



2011


High Fault-Current Design 


Sterlite AERIAL-LITE high fault-current OPGW cable is available up to 96 fibers making it suitable for application is high fiber count and super-high 

voltage power lines. Steel tubes are stranded with high strain steel wires to create a dual-layer design suitable for a range of high fault applications. 





ITU G 652 D < 0.35/0.21 dB/km @ 1310/1550 nm 

ITU G 655 < 0.23/0.25 dB/km @ 1550/1625 nm 


EIA/TIA 598 






Fiber Count 

24 

48 

96 

Product Code 

24B1-180[103;464] 

48B1-180[103;464] 

96B1-120 [76;146] 

Aluminium Alloy Wires 

Steel Tube With Fibers 

ACS Wires 

High fiber counts and flexible as per customers requirements. 

Typically have higher cable diameter. 

Laser welded stainless steel provides mechanical and thermal protection for optical fibers. 

High load and long span capabilities. 

Each stainless steel tube is uniquely identified for organization at splice locations. 

The stranded wires can be customized to the individual customer requirements of electrical and mechanical properties by adjusting 

AA/AS combination. 

Ideal design for transmission lines with very high fault current requirements. 

Fault Current 

(kA². sec) 

464 

464 

146 


(mm²) 

180 

180 

120 


(mm) 

17.90 

17.90 

14.5 

Weight 

(kg/km) 

756 

756 

504 

UTS(KN) 

103 

103 

76 



0.2344 

0.2344 

0.3434 



2011


High Strength Design 


Al Alloy Wires 

Steel Tube With Fibers 

ACS Wires 

Sterlite AERIAL-LITE high strength OPGW cable is available up to 96 fibers making it suitable for applications that require high fiber count and superhigh-voltage 

power lines. Steel tubes are stranded with high strain steel wires to create a dual-layer design suitable for a range of high strength 

applications. The layer of aluminum gives this product a high fault rating current values. 



Ideal design for transmission lines above 400 kV. 



ITU G 652 D < 0.35/0.21 dB/km @ 1310/1550 nm 

ITU G 655 < 0.23/0.25 dB/km @ 1550/1625 nm 


EIA/TIA 598 




Installation temperature range: -20 C° to +70° C 


Fiber Count 

24 

48 

96 

Product Code 

24B1-82 [81;41] 

48B1-86 [83;43] 

96B1-100[96;82] 

Fault Current 

(kA². sec) 

41 

43 

82 

ACS Wires 

High fiber counts and can be customized as per customer requirements. 

Optimum stranding makes secondary fiber excess length available. 

Laser welded stainless steel provides mechanical and thermal protection for optical fibers. 

Have maximum allowable tension due to high cable strain as a result of its unique design 

High load and long span capabilities. 

Each stainless steel tube is uniquely identified for individual organizations at splice locations. 

The stranded wires can be customized to individual customer requirements, electrical and mechanical properties met by adjusting AA/AS 

combination. 


(mm²) 

82 

86 

100 


(mm) 

12 

12.5 

13.7 

Weight 

(kg/km) 

420 

520 

548 

UTS(KN) 

81 

83 

96 



0.61 

0.73 

0.55 



2011

SUPPLY LENGTHS 

Maximum length per reel is 4 km. Length per reel is available as per customers request. 

MANUFACTURING PROCESS 

To ensure the accuracy and precision of the manufacturing process, Sterlite has a state of the art plant with top of the line machines enabling control of critical 

process and quality parameters,. All Sterlite production lines are backed with strong-quality-assurance systems, thereby ensuring that all process and test 

equipment are periodically calibrated with defined benchmarks. 

INTERNATIONAL STANDARDS 

These cables comply with IEEE1138:2009 and IEC60794-4 specification standard. 

SERVICE USPs 

World-wide sales support 

Web-based order tracking & customer support 

Specialized technical support 

TECHNICAL SPECIFICATIONS 

The above designs are only a sample of the options available from Sterlite. Contact our sales team for a cable designed to your exact specifications. 

DISCLAIMER 

Sterlite's policy of continuous improvement may result in a change in specifications without prior notice. Any warranty of any nature relating to any Sterlite product 

in only contained in the written agreement between Sterlite Technologies Limited and the direct purchaser of such product(s). 

sterlitetechnologies.com 

Aurangabad I Beijing I Campobello I Haridwar I Johannesburg I London I Moscow I Mumbai I Noida I Pune I Shanghai I Silvassa 

Sterlite 

communications@sterlite.com 

RECYCLABLE 


Supercedes: April 2011

Sterlite® OPGW Accessories 

Vibration Dampers 


The Vibration Damper is made of the messenger wire, to whose ends 

the damper weights are attached. The damper is fixed to the conductor 

by the conductor clamp. 


Vibration Dampers effectively reduce the level of Aeolian vibrations on 

Optical Ground Wire (OPGW) cables. They respond to wind induced line 

vibrations that is characterized by high frequency, low amplitude 

motion. 

PRODUCT BENEFITS 

The product is custom made for each cable produced by Sterlite. The 

design of the Vibration Dampers set is paid utmost attention for hassle 

free installation and utmost compatibility with the cable being offered 

by Sterlite. 

Splice Enclosure 


Splice Enclosure (FDC) consists of outer cases, gaskets, trays and inner 

kits. it has three main entry ports on one end. The outer case consists of 

body, cable inlet part and constructed of robust metal body. 


Splice Enclosure can be used for the storage of splicing of fiber 

andstoring the same on the transmission tower and hence this Splice 

enclosure is specifically made of metal from the outside to protect the 

enclosure from electrical field. 



design of the Splice Enclosure set is paid utmost attention for hassle free 

installation and utmost compatibility with the cable being offered by 

Sterlite. 

Down Lead Clamps 


The Down Lead Clamps consists of a parallel grove metal clamp to hold 

the OPGW cable in place. These clamps can be attached to the above for 

fixing in poles and steel towers without having to make a hole on the 

structure. 


Fixing Clamps are used to guide OPGW cables from the top of the 

structure to the splice box or for grounding the cable. They provide 

proper spacing and holding strength without damaging the cable. 



design of the Down Lead Clamps set is paid utmost attention for hassle 

free installation and utmost compatibility with the cable being offered 

by Sterlite. 

Suspension Assemblies 

Fiber Cable 

Optional Ground Point Bolt 




EPDIM Insert 

Armor Rods 

Reinforcing Rods 

The Suspension Assembly consists of Elastomer inserts, Metallic clamp 

and reinforcing rods provide protection against bending stress. The 

cable is progressively stiffened up to the suspension point by the double 

rod sets and protected by the Elastomer inserts. 

Suspension Assemblies are designed for use with OPGW cable at 

Suspension tower positions. Suspension Assemblies reduce static 

compressive stresses at the support point and cushion the OPGW cable 

against the dynamic stress of Aeolian vibration. 

These products are custom made for each cable produced by Sterlite. 

The design of the Suspension Assembly set is paid utmost attention for 

hassle free installation and utmost compatibility with the cable being 

offered by Sterlite. 



2011

Tension Assemblies 

Anchor Shackle 

Clevis Thimble 

OPGW Cable 


The Tension Assembly consists of a reinforcing rod set, a helical wire dead-end and a clevis thimble, connecting the OPGW cable and the tower. The 

OPGW is protected by the reinforcing rods and the mechanical load is taken by the dead-end and transferred to the tower. 


Tension Assemblies are designed for use with OPGW cable at termination, section, angle and joint tower positions. They will hold up to 95% of the 

OPGW RTS and maintain optical integrity over the operating load range. 

MANUFACTURING PROCESS 

® 

Sterlite controls every stage of the manufacturing process so that quality is built into every component of product, rather than selected out at the end 

through testing. To ensure the accuracy and precision of the manufacturing process, Sterlite routinely calibrates and recertifies process equipment 

and measurement benchemarks. 

INTERNATIONAL STANDARDS 

IEC 61284:2007 – requirements and tests for fittings. 

SERVICE USPs 

Complete range of OPGW accessories 

World-wide sales support 

Web-based order tracking & customer support 

Specialized technical support 

TECHNICAL SPECIFICATIONS 

The above designs are only a sample of the options available from Sterlite. Contact our sales team for a cable designed to your exact specifications. 

DISCLAIMER 

Extension Link 


Ground Clamp 

Dead End Reinforcing Rods 

These products are custom made for each cable produced by Sterlite. The design of the Tension Assembly set is paid utmost attention for hassle free 

installation and offers utmost compatibility with the cable offered by Sterlite. 

The below mentioned points are applicable for Vibration Dampers, Down Lead Clamps, Splice Enclosure Suspension Assemblies and Tension Assemblies. 

Sterlite's policy of continuous improvement may result in a change in specifications without prior notice. Any warranty of any nature relating to any 

Sterlite product is only contained in the written agreement between Sterlite Technologies Limited and the direct purchaser of such product(s). 

sterlitetechnologies.com 

Aurangabad I Beijing I Campobello I Haridwar I Johannesburg I London I Moscow I Mumbai I Noida I Pune I Shanghai I Silvassa 

Sterlite 

communications@sterlite.com 

RECYCLABLE 


Supercedes: April 2011

Email: communications@sterlite.com 

April 2012

About Sterlite Technologies Limited 

Sterlite Technologies Limited (“Sterlite”) [BSE: 532374, NSE: STRTECH], is a leading global provider of connectivity solutions for the power 

and telecom industries. Equipped with a product portfolio that includes power conductors, optical fibers, telecommunication cables and a 

comprehensive telecom systems / solutions portfolio, Sterlite's vision is to 'Connect every home on the planet'. 

Sterlite is also executing multimillion dollar power transmission system projects, pan-India. 

For more details, please visit www.sterlitetechnologies.com

OPGW BROCHURE - Sterlite

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