Documente Academic
Documente Profesional
Documente Cultură
(PHASE-II)
NATURAL GAS PIPELINE PROJECT
JOB PROCEDURE FOR OPTICAL FIBRE CABLE BLOWING AND HDPE DUCT LAYING JOINTING
&TESTING
DOCUMENT NO. : GAIL-MEC-IECCL-KKBMPL-ML -21 Rev. No. 00 P a g e 1 of 13
Revision Status:
Review &
00 20.10.16 SHIJI K K
Approval
TABLE OF CONTENTS
1.0 PURPOSE.................................................................................................................................
2.0 SCOPE......................................................................................................................................
3.0 REFERENCES..........................................................................................................................
4.0 RESPONSIBILITY.....................................................................................................................
1.0 PURPOSE
The purpose of this procedure is to lay guidelines and requirements and to establish a method
to control the OFC laying and jointing activity to be used in the 30 pipeline construction works
for KOCHI KOOTTANAD BANGALORE-MANGALORE PROJECT (PHASE-II)(SECTION-I)
(KKMBPL) by IECCL
2.0 SCOPE
The scope covers testing of OFC drums, optical fibre cable blowing and HDPE duct laying
jointing &testing and guidelines for testing of OFC between the repeater station including
joints, site acceptance testing & commissioning for construction of Section-I for the KOCHI
KOOTTANAD BANGALORE-MANGALORE PROJECT (PHASE-II) 9SECTION I) (KKMBPL)
3.0 REFERENCES
4.0 RESPONSIBILITY
Project Manager - Shall report to Project Director.
5.0 METHODOLOGY
GENERAL REQUIREMENT
IECCL shall carry out all works related to the OFC installation, jointing and testing. All
material likes OFC cable, HDPE conduit and other associated works shall be under IECCL
scope for successful completion of the OFC installation. IECCL shall also include obtaining
all statutory, approvals, crossings approval, appraisal and taking cognizance of site-
conditions, Government rules and regulations / laws. All procedures and precautions as
required for pipeline laying, shall be followed for OFC laying. IECCL shall plan the cable-
laying operation such that to the extent possible, complete drum-length of cable can be laid
without cutting in-between by preparing OFC alignment sheets.
The cable shall be laid through permanently lubricated HDPE conduit preferably on the
same side of the pipeline along the entire length of pipeline route and crossing of the
pipeline shall be avoided(except at the repeater stations and as per exigencies arising due to
site conditions).
Permanently Pre lubricated HDPE conduits shall be laid for installation of Optical Fibre
Cable. The conduits shall be continuous in length of 1 km. The HDPE laying will follow
lowering of pipeline. HDPE conduit should be laid in the pipeline trench bed along with OFC
as per Dwg./Sketch The duct shall be placed over 50 mm soft padding of sand or soft soil
The OFC can be laid using a mobile reel system or a fixed reel system depending on the
characteristics of each section.
LAYING
4. Move the trailer slowly along the trench route and uncoil the duct from the bottom of the
reel/drum and place into the trench. Avoid any overspinning of the duct while uncoiling it
from the drum.
HDPE Pipes should be laid straight as much as possible without snaking or
waving.
Minimum bending radius of fibre optic cable and duct to be taken into account.
Trench bottom for HDPE duct shall be clean, smooth and free from stones. Proper care shall
be taken so that there no kinks, loops, twist in the duct while laying. Feed the HDPE Pipes
directly into the trench without entanglement so that HDPE Pipes are laid without cris
crossing. HDPE Pipe ends should be cut with the help of HDPE Pipe cutter and after proper
coupling; coupler should be tighten with C-spanner.
Before blowing of optical fiber cable in the laid permanently lubricated HDPE conduits will be
tested for proper laying, crush, deformity and pressure testing. IECCL shall be fully
responsible for any obstruction and deformity in the laid HDPE conduit and shall have to
remove the obstruction /deformity of any kind before blowing optical fiber cable into the duct.
Include method of HDPE duct laying as testing of HDPE duct after laying as per tender
specification
CROSSINGS
CROSSING BY BORING
For pipeline crossing executed through using pipes or by boring/ jacking/HDD/Thrust Boring
methods
In case of crossing to be done with boring/ jacking/ HDD/ Thrust Boring the OFC shall be laid
in HDPE conduit shall be double duct in crossing in a steel conduit. Easy-to-install cable
sealing plug shall be used to seal the ends of the conduit to prevent the ingress of water, dirt
and rodents, which may damage of OFC Cable. The two ends of each conduit shall be sealed
immediately after installation of double duct in crossing and re-sealed when the cable has
been installed inside the conduit.
At bends and leading-in-points, a flexible PVC pipe may be used for protection and
maintenance of the required bending radius of minimum 20 time outer diameter of the cable.
To verify the air tightness, pressure inside the duct should be brought up to 10 bar for 2
minutes. A pressure drop of 0 to 0.5 bar per minute of the test is acceptable.
After pressure testing duct ends should be sealed with the help of duct plugs to prevent
entering of any dirt and water inside it.
OFC JOINTING
The cable blowing pit as described above will be used as Optical fiber Cable jointing pit every
2 or 4 km nominal distance because the OFC drum length is of 2/4 kM , so at every 2/4 kM
nominal distance this pit will be used to enclosed the OFC jointing enclosed of OFC jointing
enclosure. Contractor has to leave 20m coil of Optical Fiber Cable from both sides of the
jointing pit i.e. total 40 m of OFC will be coiled in jointing pit. Similarly the Contractor has to
leave total 20 m of OFC in the blowing pit
JOINTING
BACKFILLING
250 mm padding of sand / soft soil shall be done covering the HDPE conduit and then a
warning mat (shall be placed. After proper padding of the warning mat for min 100mm, the
trench shall be backfilled.
CABLE MARKER
Cable marker (300 mm metal plate) shall be provided on the pipeline marker itself, at
approx, every kilometer and at crossing.
The IECCL shall suitably paint on these metal plates the following
JOINT MARKERS
All jointing locations shall be marked with proper identification markers sketch in tender
document these markers shall be installed approximately 1mtr away from the jointing pit in the
direction as per the instruction of EIC/Owner.
ELECTRONIC JOINT LOCATION MARKERS
The electronic markers shall be lightweight and shall have a passive tuned resonant circuit,
enclosed and sealed within a casing. The marker locator shall be able to locate the electronic
markers from a distance of 2.2m minimum with the help of audio and visual signals. The
markers shall be of color suitable for Oil & Gas application.
The marker locator and the probe shall be able to work in saline atmosphere in coastal area
and shall be protected against corrosion.
TERMINATION
After entering the telecom room the cable shall be secured on `Steel Mesh or `Wire Mesh by
the help ties (-15 cable being kept in turns in oval from) this mesh shall have suitable chemical
coating/ painted to prevent corrosion. In case of painting, the color shall march the wall color.
Further, the cable shall be terminated of Fiber Termination Closure (FTC)
The FTC shall give grounding arrangement for all the metallic layers of the cable. The cable
shall be specified to pigtails on trays provided in the FTC. The connector side for the pigtails
shall be secured with suitable coupler/ through adapter provided as integral part of the FTC
itself. The FTC shall have trays suitable splicing maximum of 6 Fibers per tray. The
arrangement inside the FTC should be simple and in straight line.
FTC should have entry points for a minimum of 2 No. of Optical Cable (armored/ non-
armored) of diameter up to 20 mm with cable clamps to avoid entry of rodents/ dust in
general. It should have a minimum of 2 Nos. of outlets for taking out 24 Nos. Pigtail. The
outlets should have cable clamps.
Grounding arrangement should be provided with the FTC. It should include as minimum 2
Nos. grounding shield bonds with nut and bolts for fixing to the armor of the OFC. 2 Nos. of
grounding cable of green color with suitable length & lugs clamped to its end for connecting
the armor of OFC with the grounding terminal of the FTC.
The single mode fiber pigtails and connectors should meet the TU-T recommendations G-652
& G-655 as required.
Optical Fiber Cable, connections & pigtails shall be fully compatible and matching to each
other.
The OF cable shall be properly earthed at each telecom room for lighting protection as per the
scheme given in sheet.
OTDR measurement for the splice loss, the OTDR tests shall be performed on each station of
the link bi-directional and average of the two readings shall be taken as the test result.
OTDR test shall be undertaken on each fibre, results shall be recorded on the recording
format.
The attenuation in the fibre cable length between the two repeater stations will be measured
with the help of an optical source and a power meter. Optical power will be launched from one
end and measurements will be taken from the other end. The average of the attenuation
measured from both the sides will be taken and the following procedure will be followed
The optical light source will be switched ON and it will be left in ON position to stabilize for half
an hour.
Pigtails will be spliced to the fibre of the cable for which the measurement has to be taken.
Optical power will be launched by splicing the patch cord to the fibres under test at the both
ends. The measurement will be recorded at the receiving station.
Neither the patch cord connector from the power source shall be removed nor the power
source switched off.
Testing will be done from both ends and average will be calculated (for both 1310 nm and
1550 nm).
FOR END TO END LOSS MEASUREMENTS BY LOSS TEST SETUP THE FOLLOWING
PROCEDURE TO BE FOLLOWED:
Connect one unit to one end of the fibre, connect the other end to the other unit, switch on the
instruments, and activate the unit at the transmitting side. At the far end the instrument self
adjusts to the source wavelength. The far end unit also receives information on the reference
output power level.
Average loss of each fiber shall be less than the average loss of estimated.
Note: In case on any conflict between the above procedure and project specification
the later shall govern, without any prejudice to the terms and conditions of the
contract.