Sterlites 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 DesignDesign 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

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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 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.

Analysis

Installation

Designing

Supply

Manufacturing

Sterlites end-to-end project management capabilities

Sterlites 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 Sterlites OPGW cable is produced strictly according to IEEE1138, IEC60794 and relevant international standards pertaining to its constituents.

Sterlites 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. Sterlites 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.
Fiber splicing during the installation of Sterlite Central Steel Tube at Vedanta Aluminium Ltd., Jharsuguda (India)
Installation of Sterlite Central Steel Tube at Ultratech, Gujrat (India)

Approvals and certifications

Quality and reliability

Test Items Test Condition
1 Creep Test IEEE 1138 : 2009 Section 6.4.1.1 IEEE 1138 : 2009 Section 6.4.1.2 (EIA/TIA 455-82B) IEEE 1138 : 2009 Section 6.4.1.3 IEEE 1138 : 2009 Section 6.4.1.4 IEEE 1138 : 2009 Section 6.4.1.5 IEEE 1138 : 2009 Section 6.4.2.1 IEEE 1138 : 2009 Section 6.4.2.2 IEEE 1138 : 2009 Section 6.4.2.3 IEC 60794-1-2 Method E7 IEEE 1138 : 2009 Section 6.4.3.1 IEEE 1138 : 2009 Section 6.4.3.2 IEEE 1138 : 2009 Section 6.4.3.3 IEEE 1138 : 2009 Section 6.4.3.4 IEEE 1138 : 2009 Section 6.4.3.5 IEEE 1138 : 2009 Section 6.4.3.6 IEEE 1138 : 2009 Section 6.4.3.7 IEEE 1138 : 2009 Section 6.4.3.8 IEEE 1138 : 1994 Section 5.1.1.12 IEC 60794-1-2 Method E4

2 Stress strain Test

3 Strain Margin Test 4 Ultimate Tensile Strength test 5 DC Resistance test 6 Sheave Test 7 Crush Test 8 Bend test 9 Twist test

10 Aeolian Vibration Test 11 Galloping test 12 Short Circuit Test 13 Lighting arc test 14 Water Ingress Test 15 Seepage of filling compound 16 Temperature Cycle test 17 Salt Spray Corresion test 18 Cable Cut off wavelength test 19 Impact Test

Sterlites 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
Fiber count

xxx
Type of fiber B1-G652A B2-G652D B3-G655

xxx
Cross section of OPGW (mm2)

[xxx;
Break strength of OPGW (kg)

xxx]
Fault current rating (kA.sec)

Sterlite AERIAL-LITE OPGW Cable Series

Aluminum Clad Central Steel Tube Design

ACS Wires

Aluminum Cladded Steel Tube Fibers In Filling Jelly

PRODUCT DESCRIPTION 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 (kA. sec) 39 47 47 Effective Area Overall Diameter (mm) (mm) 59 65 81 Weight (kg/km) UTS(KN) DC Residence @ @ 20degC(ohm/km)

12.5 13.4 11.8

530 545 437

78 88 69

0.9 0.6 0.6

Issued: April 2012 Supercedes: April 2011

Sterlite AERIAL-LITE OPGW Cable Series

Central Core Aluminum Sheathed Tube Design

Auminium Tube Thermal Barrier FRP PBT Tube With Fibers ACS Wires

PRODUCT DESCRIPTION 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. PRODUCT FEATURES 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. PRODUCT APPLICATION 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. 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 SPECIFICATIONS Fiber Count 24 48 Product Code 24B1-90 [102;41] 24B1-90 [102;41] Fault Current (kA.sec) 41 41 Effective Area (mm) 90 90 Overall Diameter (mm) 13.2 13.2 Weight (kg/km) 581 581 UTS (KN) 102 102 DC Resistance @ 20degC(ohm/km) 0.7605 0.7605

Issued: April 2012 Supercedes: April 2011

Sterlite AERIAL-LITE OPGW Cable Series

Central Steel Tube Design

ACS Wire Steel Loose Tube Jelly Filled Fiber Optical Fiber

PRODUCT DESCRIPTION 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. PRODUCT FEATURES 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. PRODUCT APPLICATION A perfect solution for easy installation, short hauls and basic layouts which need minimum design complications. 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. Or Bundle binders for each 12 fiber. Operating temperature range: -40 C to +85 C Installation temperature range: -20 C to +70 C TYPICAL PRODUCT SPECIFICATIONS Fiber Count 12 24 48 Product Code 12B1-81 [64;40] 24B1-81 [64;40] 48B1-81 [64;40] Fault Current (kA2.sec) 40 40 40 Effective Area (mm2) 81 81 81 Overall Diameter (mm) 12.3 12.3 12.3 Weight (kg/km) 490 490 490 UTS (KN) 64 64 64 DC Resistance @ 20degC(ohm/km) 0.72 0.72 0.72

Issued: April 2012 Supercedes: April 2011

Sterlite AERIAL-LITE OPGW Cable Series

High Fault-Current Design

Aluminium Alloy Wires Steel Tube With Fibers ACS Wires

PRODUCT DESCRIPTION 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. PRODUCT FEATURES 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. PRODUCT APPLICATION Ideal design for transmission lines with very high fault current requirements. 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: -30 C to +70 C TYPICAL PRODUCT SPECIFICATION Fiber Count 24 48 96 Product Code 24B1-180[103;464] 48B1-180[103;464] 96B1-120 [76;146] Fault Current (kA. sec) 464 464 146 Effective Area Overall Diameter (mm) (mm) 180 180 120 Weight (kg/km) UTS(KN) DC Residence @ @ 20degC(ohm/km)

17.90 17.90 14.5

756 756 504

103 103 76

0.2344 0.2344 0.3434

Issued: April 2012 Supercedes: April 2011

Sterlite AERIAL-LITE OPGW Cable Series

High Strength Design

Al Alloy Wires Steel Tube With Fibers ACS Wires ACS Wires

PRODUCT DESCRIPTION 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. PRODUCT FEATURES 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. PRODUCT APPLICATION Ideal design for transmission lines above 400 kV. 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 48 96 Product Code 24B1-82 [81;41] 48B1-86 [83;43] 96B1-100[96;82] Fault Current (kA. sec) 41 43 82 Effective Area Overall Diameter (mm) (mm) 82 86 100 Weight (kg/km) UTS(KN) DC Residence @ @ 20degC(ohm/km)

12 12.5 13.7

420 520 548

81 83 96

0.61 0.73 0.55

Issued: April 2012 Supercedes: April 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).

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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

Issued: April 2012 Supercedes: April 2011

Sterlite OPGW Accessories

Vibration Dampers

Down Lead Clamps

PRODUCT DESCRIPTION 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. PRODUCT APPLICATION 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.

PRODUCT DESCRIPTION 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. PRODUCT APPLICATION 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. PRODUCT BENEFITS The product is custom made for each cable produced by Sterlite. The 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.

Splice Enclosure

Suspension Assemblies
Optional Ground Point Bolt EPDIM Insert Armor Rods

Fiber Cable

Reinforcing Rods

PRODUCT DESCRIPTION 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.

PRODUCT DESCRIPTION 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. PRODUCT APPLICATION 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. PRODUCT BENEFITS 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.

PRODUCT APPLICATION 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. PRODUCT BENEFITS The product is custom made for each cable produced by Sterlite. The design of the Splice Enclosure set is paid utmost attention for hassle free installation and utmost compatibility with the cable being offered by Sterlite.

Issued: April 2012 Supercedes: April 2011

Tension Assemblies
Anchor Shackle Extension Link

Clevis Thimble

Dead End

Reinforcing Rods

OPGW Cable

Ground Clamp

PRODUCT DESCRIPTION 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. PRODUCT APPLICATION 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. PRODUCT BENEFITS 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. 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 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

Issued: April 2012 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