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CONTENTS
1. INTRODUCTION ............................................................................................................................. 3
2. SCOPE .............................................................................................................................................. 4
3. REGULATIONS ................................................................................................................................ 5
6. MANUFACTURE .............................................................................................................................. 8
6.1. QUALITY ............................................................................................................................... 8
6.1.1. Optical nucleus ......................................................................................................................................... 8
6.1.2. Wire shield .................................................................................................................................................. 9
6.2. NOMINAL LENGTH OF THE CONTINUOUS STRIP ........................................................................ 9
6.3. TECHNICAL FEATURES OF THE WIRE ....................................................................................... 9
9. REJECTION .................................................................................................................................... 18
9.1. REJECTION OF THE WIRE SHIELDING..................................................................................... 18
9.2. REJECTION OF FINISHED WIRE, ITS PACKAGING AND IDENTIFICATION ...................................... 18
9.3. INDIVIDUAL TESTS ............................................................................................................... 18
1. Introduction
To vacate and withdraw the power produced by this Power Plant, either to the new
projects of BHP Billiton or SING, the construction of a 2 x 220kV and 15km in length
transmission line is needed, which will link the Kelar Power Plant with the upcoming
KAPATUR splitting substation, located approximately 11km east of the Bay of Mejillones.
Construction of this transmission line is the responsibility of the ALUSA Company, which
has retained the services of SDI for the development of engineering details thereof, such
project is referred to as 2 x 220 kV Kelar-Kapatur Transmission Line.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 4 of 28
2. Scope
The goal of this document is established basic conditions for the earth wire supply with
optical fiber OPGW (Optical Ground Wire).
It is considered inside the activities, the design, manufactured, tests and technical
information correspondent, as the established in this specification.
The supplier, as part of its technical offer, should complete the technical sheet included in
annex II.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 5 of 28
3. Regulations
The project design should be performed according with the latest edition of the relevant
regulations, laws and/or publications:
Standards
ITU-T G 650 Definition and Test Methods for the Relevant Parameters of Single Mode
Optical Fiber Cable.
ITU-T G 655 Characteristics of a Non Zero Dispersion Shifted Single Mode Optical
Fiber Cable.
IEC 60794-4 Optical Fiber Cables: Aerial Optical Cables along Electrical Power Lines.
IEEE 1138 Standard Construction of Composite Fiber Optic Ground-Wire for Use on
Electric Utility Power Lines.
IEC 60104 Aluminum - magnesium - silicon alloy wire for overhead line conductors
Institutions:
Additionally, it should meet the quality and safety standards provided by BHP BILLITON
as long as such requirements are not less or in conflict with those standards and
regulations already mentioned.
In case of conflicting between the mentioned institutional regulations and the proportioned
standards, the conflict will be communicated promptly to BHP BILLITON for its clarification.
In general, the more stringent criterion will be favored.
Nonetheless, the final decision on the predominant criteria is only of responsibility of BHP
Billiton.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 6 of 28
4. Electrical System
The electrical system in which the Project will operate has the following main features:
The values of environmental parameters considered in the installations design are listed
in Table 1.
6. Manufacture
6.1. Quality
The wire, including reel and packaging, must be new and of first use. Also, the used
materials in their manufacture must be new, recently manufactured and in general, frees
of any kind of imperfection or defect.
The optical nucleus and the wire shielding must form an integrated unit (the wire) and
must be dimensioned for the protection of the optical fibers against degradation on its
mechanical and optical features caused by external factors, like, vibration, wind,
temperature variations, currents of short-circuit, atmospheric discharges and any other
environmental factor that can produce hydrogen.
The optical nucleus should be constituted by the optical unit, protection shield and an
aluminum tube.
The aluminum tube should presented a finish free of superficial defects and strange
matters. The dimensions of the tube should be uniforms to its transverse section and
along its length. For confer impermeability to the optical nucleus, the tube must be
manufactured by a extrusion process and welding points are not permitted.
The wire must support inherent mechanical stresses of the installation, operation and
maintenance process of the electric line, as well as bending of the wire to the guaranteed
minimum radius, without an increase of attenuation of the fibers.
The optical unit should be designed to house and protect the optical fibers of possible
damages caused by external stresses as crushing, bending, traction and torsion. Also
should protect against moisture.
The optical unit should be totally dielectric and its configuration must be loose type.
The optical fibers inside the wire must provide continuity without internal joints and may
not exceed a maximum of twelve (12) per group.
The wire design should guarantee that the fiber do not suffer stresses along its useful
life.
Tensioning elements of non metallic material must be used to limit traction stresses in the
optical fibers housed inside the optical unit.
The interstices of the optical unit must be filled with a compound to inhibit the penetration
of external moisture or any water migration, along the optical unit.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 9 of 28
The filling compound used must be compatible with all the components with which it will
contact and must absorb and/or inhibit the hydrogen production on the interior of the wire.
Also, must be chemically stable at the temperature range of -5C to 80C, dermatological
safe and non toxic.
The shielding of the wires, together with the aluminum tube, should be optimized to allow
circulation of the short-circuited current without alterations in the optical fibers features.
Also, must be designed to support the mechanical requests of a conventional earth wire,
besides of assure the minimum resistance to not cause deformation in the optical fibers.
The wire direction to the exterior charge is right handed and the wire surface and the
surface of all wires must be cylindrical, free of superficial defects and strange matters, and
be soft to touch.
The components of the wire (except the optical nucleus) must be performed before the
wiring, so that by cutting a piece of wire of length equal to 1,5 of the wiring pitch, this
keeps its original shape.
The cover of the wires of steel must be concentric to this, soft to touch, continuous and
uniform.
The thickness of the aluminum layer, at any point, cannot be lower than ten percent (10%)
of the nominal radius of the wire.
There shall not be joints of any kind on the finish wires or during the final drawing.
If a wire is cut during wiring, will be sufficient to end at that point the pulling process of the
wire. This pulling can be included in the supply always that meets with its length as
described in the specifications.
The length of the continuous strip of the wire must be indicated by the manufacturer.
Nonetheless, this quantity shall be 3.000 m as minimum and with a tolerance not higher
than +2% in excess.
The main features of the wire used on the electrical line is shown in Table 2.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 10 of 28
Surface 87 mm
Diameter 12,6 mm
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Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 11 of 28
Table 2. Main features of the earth wire with optical fiber of 87 mm (Continuation)
Weight 0,394 kg/m
MECHANICALS
Sag 1,5%
The fibers and housing should have a color coding to facilitate identification and location
in any of both extremes of the wire.
The color coding of the housing and of the fiber must meet the EIA/TIA-598 normative.
The color pigment must be compatible with the rest of materials that make up the wire,
also be stable color (should not fade when cleaning) and not be susceptible to migration.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 12 of 28
Samsung Engineering Co., Ltd., reserves the right to inspect the wire manufacturing, for
which the manufacturer must give all the facilities to which its authorized representative
develops the inspection without inconvenience.
It is manufacturer responsibility notify within thirty (30) days before perform the wire tests,
for which a Samsung Engineering Co., Ltd inspector can participate of the process.
The manufacturer must develop under their responsibility, the required tests in this
specification and also those not indicated but stipulated in the regulations and publications
applicable, assuming all costs, direct and indirect, for the realization of the tests, including
all materials, elements and equipments required, as well as the items subjected to the
test.
The non-compliance of any of the performed tests will be sufficient cause to reject the
sampled batch.
7.2. Sampling
All wire samples, finish wire and reel, must be selected randomly by the authorized
representative of Samsung Engineering Co., Ltd.
For wire shielding tests, before wiring process, sample must performed according ASTM
B 415 for aluminum wire covered with steel publication and IEC 60104 for aluminum alloy
wires publication.
For verification condition tests of the shield wire and finish wire surfaces, the sampling
must performed in the same way than the sampling for verification of dimensions test and
permissible variations established in ASTM B 145 and ASTM B 416 for aluminum cover
by steel wire publication and IEC 60104 for aluminum alloy wires publication.
The reel of the finished wire, presented for approval, is split in batch of ten (10) reels
each, considering the fraction as other batch.
Of each batch, one (1) reel is randomly selected to represent the entire batch and from it
the enough sample for perform all tests is taken. The same selected reel represents the
entire batch in the entire identification and verification of packaging.
The packaging should allow access to both extremes of the wire, in order to perform the
optical fibers tests without unroll the wire.
For optical unit tests, should be measure, at least, the average attenuation of the optical
fiber for each of the strands of all selected reels. The attenuation values must comply with
the indicated in this specification.
For the test of rupture resistance of the entire wire , must be take one (1) sample of each
hundred (100) metric tons (or fraction) of each batch of finished wire presented for
approval.
7.3. Tests
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 13 of 28
All routine tests established in IEC 60793 and IEC 60794 publications that corresponds to
the optical fiber must be performed.
Verification of dimensions
Verification of surface status
Mechanical resistance
Other tests specified in ASTM B 415 publication
Other tests specified in IEC 60104 publication
Verification of dimensions:
Cross section of the entire wire
Unitary weight of the entire wire
External diameter of the entire wire
External diameter of each wire layer
Span of each wire layer
All necessary inspections must performed to verify the compliance of the stipulated
requirements in this specification for the wire, packaging and reel identification.
7.5. Protocols
Inside the seven (7) following days to the perform of the tests, the manufacturer, must
deliver to the authorized representative of Samsung Engineering Co., Ltd., three (3)
copies of the tests protocols. The protocols must include:
8.1. Reels
The construction of the reels must be permit to resist all the daily requests founded during
fabrication, transport, loading and unloading, delivery, distribution along the line and the
process of wire tensioning.
The entire finished wire, must not occupy the entire reels.
A minimum free space of 5 cm must be fixed between the last layer of the wire and the
interior of the covered installed of the reel.
The central axis hole of the reels, is provided of metallic bushings attached to the reel
sides and its minimum internal diameter must be 7 cm.
The reels are provided by five (5) bolts or steel tensors, which are set on the sides
(flanges) of the drum to the reel. The bolts or steel tensors must not protrude from the
sides (flanges), accepting until 1 cm of protruding.
The reels must be detachable, i.e. its sides (flanges) must be able to separate to the
drum.
The wire protection in the reels must be adequate to ensure the conservation of the good
conditions of the wire, in adverse weather conditions (moisture and temperature) and in
long storage periods.
On the drum must be placed one or more layers of waterproof, non corrosive paper or
other material with similar properties, with a minimum total thickness of 0,5 mm.
On the interior of the reel sides (flanges) must be placed a layer of non corrosive and
abrasiveness resistant cardboard, or other material with a minimum thickness of 1,5 mm.
Between the last exterior layer and the previous layer (partially or completely) of the wire
must be placed as minimum, a layer of waterproof and non corrosive paper or other
material with similar properties.
The exposed surface of the rolled wire must be covered with a cardboard layer or other
material, abrasiveness resistant and non corrosive, with a minimum thickness of 2 mm.
This layer must be placed at least with metallic tape or similar, that can be removed
without damage the wire.
All the exposal surfaces of the reels, protruding parts, bolts, tensors and bushings must
be painted with aluminum paint before the wire is rolled in the reels.
The reels must be entirely covered by a wooden lathing. The lathing must be placed on
the side (flanges) of the reel with nails, bolts or other system to prevent lateral sliding.
The lathing length is equal to the width of the reel , must be placed with at least two (2)
metallic tapes.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 16 of 28
8.3. Packaging
In each reel must be placed only a single continuous line of finished wire.
The finished wire must be packaging in metallic non-returnable reels. The wooden reels
are not allowable.
To prevent damage during transport and laying, the finished wire must be rolled and
tightly wrapped in the reels but without use of bumps. The extremes of the continuous line
of finished wire must be anchored securely to the reel.
The reels must be completely covered with wood lathing. The used wood for the lathing
must be of a minimum thickness of 3,8 cm and only used good quality dry wood. The
wood must not have crust neither insect galleries detected.
This wood must receive bactericidal, fungicide and preservative treatments, and
accomplish with the International Standards for Phytosanitary Measures ISPM N 15 of
the FAO. In addition, the phytosanitary certificates of the process of the wood parts used
must be included. This treatment must be performed before rolling the wire.
All import of wood to the country must be authorized by the Agricultural and Livestock
Service (SAG in Spanish), according to the resolution N 133/2005 and their
modification N 2859/2007, both of the Agricultural Ministry, which established
quarantine regulations for the entry of wood packagings.
Nonetheless all used wood in the packaging has been treated in their origin port, the
manufacturer must hire a fumigation service at the landing port (or in place) of all
packaging that contained wood, if so requested by the SAG.
In particular, the fumigation must be performed with aluminum phosphide and not with
methyl bromide, due to which chemical, in moisture presence, hydrolyze and is corrosive
to some metals as aluminum and zinc.
If the used wood in the packaging is contaminated, the recommendation is remove and
replace with wood that meets the requirements of the sanitary authority.
The supplier is the responsible of ensuring these conditions and therefore is responsible,
at its own cost, of any procedure, penalty, retention or other requirements by national
authorities.
Additionally, packaging must be able to resist the effects of prolonged outdoor storage,
and under severe atmospheric conditions.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 17 of 28
8.4. Identification
All and each one of the reels must be clearly identified with a material resistant card and
securely attached to the wire extreme, inside the reel, with the following information:
Samsung Engineering Co., Ltd., will require additional information if necessary and will be
added to the identification card.
In each reel must be clearly indicated with an arrow, the sense in which the wire can be
roll without the wire release.
After the reel is reviewed and approved, the identification card must be signed and
stamped for the authorized representative of Samsung Engineering Co., Ltd.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 18 of 28
9. Rejection
In general, will be rejected all the wires that non comply with the criteria indicated in
ASTM B 415 publication for aluminum wires covered with steel and IEC 60104 publication
for alloy aluminum wires, concerning to wire superficial status, dimensions, allowable
variations, etc.
In the case of optical fibers, will be rejected all the reels that contains strands with
average attenuation values higher than the indicated in this specification.
If a batch is rejected, the manufacturer has the right to test the rest of the reels in the
batch individually (with the same tests conditions that justified the rejection) and after
supply and/or use those reels that comply the requirements of this specification.
DOCUMENT NUMBER
Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 19 of 28
The manufacturer must deliver to Samsung Engineering Co., Ltd., inside the fifteen (15)
days following the emission purchase order, the following information:
All layouts delivered must be definite, to scale and in accordance to the International
System of Units.
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Technical Specification E-TL-TS-S002
for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 20 of 28
The manufacturer must deliver all the stress-strain-creep curves of the wire, with the
following information:
12. Waranties
Attachment I
N 133 SAG Resolution
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for Ground Wire Revision 0
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Issue Date : 16-Jun-2015 Page 23 of 28
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for Ground Wire Revision 0
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Attachment II
Data sheet OPGW 87
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for Ground Wire Revision 0
OPGW
Issue Date : 16-Jun-2015 Page 27 of 28
Data sheet
SDI
Earth wire Technical Specification OPGW
E-TL-TS-S002 BHP Billiton - Lnea 2x220 kV Kelar - Kapatur
Page 1 of 2 Earth wire with optical fiber Transmission lines
Data
SDI
Earth wire Technical Specification OPGW
E-TL-TS-S002 BHP Billiton Sheet
- Lnea 2x220 kV Kelar - Kapatur
Page 2 of 2 Earth wire with optical fiber Transmission lines
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