OPGW Optical Cable Fusion Splicing Solution

OPGW fusion splicing requires precise fiber preparation, careful removal of metallic layers, fusion with a splicer, and secure protection in closures to maintain both optical and grounding functions.

Overview of OPGW Cables

OPGW cables combine grounding and communication functions, housing optical fibers within a metallic conductor for high-voltage transmission lines. Common types include Central Tube (OPGW C/CA), Aluminum Pipe (OPGW AP), and Stranded Type (OPGW S), each with fibers housed in stainless steel, aluminum, or PVC tubes . These cables are installed above power conductors to protect against lightning while providing telecommunication capabilities.

Preparation and Safety

1. Establish an equal potential zone using temporary ground cables, conductive mats, and removable hot-sticks to prevent electrical hazards .
2. Stretch and mark the cable over 2–2.5 meters, wrapping tape at the marking points to secure strands during cutting .
3. Remove metallic layers carefully:
   • Use a metal saw or mini grinder to cut aluminum strands circumferentially.
   • Unwrap and remove outer and inner stranded wires.
   • For metal loose tubes, inner strands should extend ~10 mm longer than outer strands to expose the fiber tubes .

Fiber End Preparation

• Strip the fiber coating using the three-character method: flat, stable, and fast.
• Expose ~5 cm of fiber, bending the remaining fiber to increase strength and prevent slipping.
• Clean and cleave the fiber precisely to ensure a high-quality end face, which is critical for low-loss fusion splicing (<0.02 dB) and reliable connections .

Fusion Splicing

• Use a precision fusion splicer, preferably AI-integrated for high-core-count fibers (48–144 cores) and harsh field conditions.
• Align fibers carefully and perform the splice according to the splicer's specifications.
• Coiling and securing fibers in trays or transportation tubes is essential for mechanical stability .

Protection and Closure

• Apply heat-shrink sleeves or high-durability protective consumables to seal the splice.
• Install the splice in a joint closure (aluminum alloy or pre-molded with neoprene gaskets) to ensure moisture resistance and mechanical protection.
• Anchor the closure to the tower using galvanized steel clamps or stainless steel hardware, compatible with various tower types .

Testing and Verification

• Perform OTDR (Optical Time-Domain Reflectometer) testing to verify splice quality and ensure minimal optical loss.
• Inspect both optical and electrical continuity to confirm the dual functionality of the OPGW cable .

Best Practices

• Always wear gloves, face shields, and protective equipment during metallic layer removal.
• Maintain a stable and clean workspace, especially when working at height or in windy conditions.
• Use standardized protective sleeves and trays to ensure long-term durability.
• Consider high-precision, battery-powered fusion splicers for field operations to improve efficiency and reduce errors . By following these steps, OPGW fusion splicing can be performed safely and efficiently, ensuring both telecommunication performance and electrical grounding integrity.