Professional Documents
Culture Documents
INSTALLATION PROCEDURE
ALONG
FOR
TABLE OF CONTENTS
1. SCOPE............................................................................................................................................................3
2. GENERAL......................................................................................................................................................3
6. MATERIALS..................................................................................................................................................5
7. EQUIPMENT.................................................................................................................................................6
9. LAYING AT CROSSINGS...........................................................................................................................9
1. SCOPE
This document describes the general installation procedures for Fiber Optic Cables
alongside the proposed 24” Crude Pipeline from Mina Al Fahal to Sohar for Oman
Gas Company.
2. GENERAL
Generally Fiber Optic Cables are installed employing the same equipment and
techniques used in the installation of copper cables.
However additional precautions are to be taken in the installation of Fiber Optic
Cables with respect to the fiber strength and bend radius. Although the tensile strength
of the glass fibers are much more superior than that of metallic wires of same size,
surface cracks and flaws, if any, in the fiber tend to grow with the applied tensile load
and ultimately break either immediately or during their service life.
Bends in the route introduces additional stress during installation and the stress
remains even after installation is completed. Bends introduces additional optical
losses. These losses may be recoverable or non-recoverable depending on the radius of
the bends.
Hence all FOC installation work shall be done in thorough and workman like manner
and in accordance with the plans, specifications and construction drawings. Unplanned
joints in the Fiber Optic Cables due to damages increase the fiber loss. These
additional losses unless accounted for in the power budget will affect the transmission
quality.
OHI Telecommunications meets or exceeds all the requirements of Fiber Optic Cable
installation in all aspects of the Project right from transportation to commissioning.
The cable manufacturers shall provide the following installation parameters which are
required for proper planning of the installation.
Nominal drum lengths (meters)
Cable Diameter (mm)
Cable weight (kg/km)
Drum Size (Flange diameter, Width and /or Barrel diameter in meters)
Empty drum weight (kg)
Maximum Pulling Tension (Newton)
Minimum bending radius at Maximum Pulling Tension (times cable diameter)
Minimum bending radius at Zero Tension (times cable diameter)
3. ROUTES OF THE FIBER OPTIC CABLES
The route of the fiber optic cable shall be alongside the proposed 24” Pipeline from
Mina Al Fahal to Sohar and shall be laid in the same trench. The estimated length is
270km 12 Block Valve Stations (BVS). In addition a FOC shall be installed in
separate trench from the warehouse of OGC at Mabella from the nearest BVS
approximately for a distance of 1km. Another FOC shall be laid in separate trench
from the OGC Control center at Al Khuwair approximately for 500m.
OHI Telecommunications Co LLC
OGC – MAF SHOHAR 24” CRUDE PIPELINE PROJECT
Since the FOC will be installed in the same trench with the Pipeline, separate route
survey and design documentation for the FOC may not be required. However in order
to keep the number of joints to the minimum, a Drum Allocation Plan and Splice
Position List shall be prepared based on the supplied drum lengths. The planned splice
locations shall be physically verified at the site so that the splices were not located in
the middle of road or wadi. The final design splice positions shall be marked on the
construction drawings (alignment sheets) of the pipeline.
A separate route survey and design shall be carried out for the other two routes where
the FOC will be installed in exclusive trench.
4. FOC DRUM HANDLING
All cables and accessory materials must be handled with care.
All Cable drums upon delivery shall be checked for apparent damages and a visual
inspection report shall be prepared.
All the cable drums shall be stored on a flat and firm surface.
A crane or forklift shall be used to place FOC drums into position
The drums shall be lifted into position, not bumped.
The Wooden battens on the drums shall remain in place so as to protect the cables
from extreme heat, direct sun light and dirt.
The drums shall be placed in rows with marked flanges to the same side and at such
intervals to facilitate access for testing and loading out.
Cable drums shall not be stacked on top of each other
Cable drums shall always be handled on their flanges.
Never carry the Cable drums on their sides, as this may cause tangling of the cable.
Always the drums shall be placed in a vertical position resting on their battens and
never on their flanges.
In the event of battens being removed for inspection or testing purposes, they shall be
replaced immediately.
The drums must not be rolled off the truck
Never use hooks directly through the flange holes as this may cause damage to the
drums. Instead use a bar through the flange holes.
Always check the weight of the drum and ensure the lifting device has the required
capacity.
Never overload a lifting device in weight or reach or a combination of both.
Always lower the drums gently onto the ground or transport tray. Never drop drums.
Avoid impacts, which may damage the drums.
Each drum shall be secured to the truck by a continuous chain running through its
center hole.
OHI Telecommunications Co LLC
OGC – MAF SHOHAR 24” CRUDE PIPELINE PROJECT
The drums shall be restrained from rolling off the truck by suitable methods. By
placing wooden wedges or blocks under the drums on either sides of the point of
contact shall prevent movement of the drums while they are transported in trucks.
When placing drums on uneven or sloping ground take necessary precaution against
rolling and ensure an appropriate stopping device is available.
Avoid the use of nails on cable drums, as flange thickness may vary.
While moving the drum for short distances, always roll the drum in the direction of the
arrow marked on the flange of the drum. Never roll in the opposite direction, as this
will loosen the cable wind.
Drums of same lengths shall be stored together in the same row.
Drums returned to the store with balance cable must be stored in a separate area. The
length of the cable remaining on the drum must be clearly indicated by paint on the
flange of the drum.
All empty drums shall be removed from the site as and when they become empty and
returned to store for disposal.
When drums are stored for a considerable time, it is advisable to keep them off a damp
surface to avoid damage to the wooden drum by rodents or decay.
5. HANDLING OF FIBER OPTIC CABLE
The cable shall not be dragged along the ground or trench as this may cause abrasion
and damage to the outer sheath and may result in kinks in the cable, if it gets stuck in
debris, rock or similar. Always ensure that there are enough people available to hold
the cable so that it does not drag along the ground.
No traffic of whatever nature shall be permitted to cross over the cables. No
construction plant, trucks or even light vehicles shall be allowed to drive over the
cable. Personnel shall not be permitted to step on the cables.
When the cable is being uncoiled, care shall be taken to ensure that the coils left on the
drum do not cross over one another.
All cable ends shall be protected at all times with temporary end caps in order to keep
moisture and dirt away from the fibers and prevent the filling compound escaping.
These end caps are of the heat shrink type specially formulated for sealing applications
for all commonly used cables. Use suitable size end caps.
6. MATERIALS
Fiber Optic Cable:
36Core Single Mode Non-Dispersion Shifted (G652) armored cable suitable for direct
burial as per OGC Specifications. We propose to procure the cable from M/S Oman
Fiber Optic Co, Sultanate of Oman.
Warning Tape:
Generally made of plastic (50mm width x 2mm thick) and supplied in 200m rolls. The
color of the tape shall be Yellow and the markings shall be as per OGC specifications.
Warning Tape shall be used for all FOC installation whether in separate trench or in
the pipeline trench.
Warning Board:
Generally made of plastic (200mm width x 5mm thick) and supplied in 100m rolls.
The color of the Board shall be Yellow and the markings shall be as per OGC
OHI Telecommunications Co LLC
OGC – MAF SHOHAR 24” CRUDE PIPELINE PROJECT
specifications. Warning Board shall be installed for all FOC installation in separate
trench.
Duct Pipes:
Although HDPE Conduits are specified for all crossings, we propose as an alternative,
110mm PVC pipes with 3mm wall thickness and 6m length (as per Omantel
Specifications) for all crossings. These pipes are manufactured in Sultanate of Oman
and are widely used for FOC installation by Omantel and other Ministries.
Splicing Kits:
Splice Kits shall be re-enterable, watertight, lightweight, and corrosion resistant and
made of impact resistant plastic. The kit shall have in-built splice organization trays
and shall be suitable for both straight and multiple branch splices. No special tools
shall be required to close or open the kit. We propose use 2178S Joint Enclosures
manufactured by 3M.
Patch Panels:
The Patch Panels shall be wall mounted or rack mounted. Where the equipment rack
has sufficient space to accommodate and entry for leading the FOC, a rack mount ODF
can be used. Larger installations require separate rack for housing the ODF. For
smaller installations wall mounted ODF will be sufficient. The ODF shall be equipped
with the required number connectors (same as that of the equipment), mounting plates,
pigtails and splice organizer trays. We propose to use 3M’s wall mounted or rack
mounted ODF. All connectors shall be FC/PC.
Electronic Joint Ball Markers:
Electronic ball markers with a detection range of greater than 1m shall be buried at
each joint location to permit detection from the surface. We propose to use 3M’s ball
markers for this purpose.
Joint Handholes:
Although direct burial of FOC joints are specified, we propose prefabricated
Handholes for housing the FOC Joint and the slacks as per Omantel’s specifications.
This method is widely used by Omantel and other Ministries in Sultanate of Oman.
7. EQUIPMENT
For Handling and Lifting Cable Drums:
Crane or fork lift with Valid Safe Working Load Certificate (SWL)
Spreader bars for lifting the cable drums
Sling wire ropes and hook with valid SWL Certificate
One spreader bar is to be placed through the drum spindle holes and slings will link it
to another spreader bar positioned above the drum. The spreader bars are to be slightly
longer than the width of the cable drum. This combination will prevent the edges of
the cable drum flange from being damaged by the wire slings. A damaged flange may
result in a damaged cable sheath.
pushed into the space between the spindle hole and the spindle, and the collars which
have locking screws, keep the cones in place. This arrangement prevents the drum
from sliding along the spindle.
In addition a separate 4 Wheel Drive Vehicle is required for dispensing warning tapes,
Protective Tapes, Protective Concrete slabs and Cable marker tapes.
For Cable Pulling:
A mandrel slightly less than the diameter of the conduit is necessary for testing the
conduit before the cable is pulled into the pipe.
Normally cable pulling will be done over small lengths along the route, which would
not warrant a specialized fiber optic winch. In most cases the cable will be pulled in by
manual labour.
A specialized fiber optic winch will be used for pulling long lengths of Fiber Optic
Cables. For safe cable pulling operation a mechanical fuse made of aluminum will be
used. The mechanical fuse will fail just below the permitted maximum pulling tension.
8. LAYING OF FIBRE OPTIC CABLE
Since the Fiber Optic Cable will be laid in the same trench of pipeline, the cable laying
shall be scheduled to match with the pipeline schedule, particularly the lowering-in
and sand bedding and padding.
The sequence in which the cable drums are laid and the selection of which cable drum
to lay first depends on the continuous length of trench available to receive the cable.
(The continuous length of trench in which the pipeline has been lowered-in and sand
padding is completed) Normally the length of the trench that is ready for cable laying
shall be more than the length of the selected cable drum.
The position of FOC in relation to pipeline will be at 2 o’clock position or 10 o’clock
position as specified in the construction drawings.
The minimum nearest distance between the pipeline and the FOC shall be 300 mm and
the minimum distance between the trench wall and the cable shall be 200mm.
The starting point of cable laying shall be the location of a joint. The selected location
must be suitable for having a joint. It should not be at crossings or Wadi plains.
All the FOC splices shall be located 3 meters away from the center of the pipeline axis
and shall be located on the same side as that of the cable itself to avoid crossing with
the pipeline.
Once the exact location for the splice is known the excavation for the splice pit and the
access trench shall be carried out. The width of the trench is 300 mm and the depth is
1100 mm. The size of the joint pit shall be 1600x1600mm.
Physically check the distances between the selected splicing points, the drum number
and the drum length and verify these details with the Drum Allocation and Splice
Position List.
Confirm that pre-installation test conducted on the FOC drum has been approved.
If the cable laying is carried out by more than one spread then the meeting points of
the spreads shall coincide with the splice point.
The FOC shall be laid on a 100mm thick bedding layer. The bedding shall be
composed of screened material not exceeding 5mm diameter and free from stones,
metals, vegetation, hard object or any other deleterious material.
OHI Telecommunications Co LLC
OGC – MAF SHOHAR 24” CRUDE PIPELINE PROJECT
A 6 x 6 flat bed truck, equipped with a Hiab crane shall be used to transport the cable
drum from Camp store to site.
This truck shall also be fitted with a suitable frame and rotary spindle. The spindle will
be inserted through the drum eye, lifted by the Hiab crane and placed on the seat of the
frame, and in such a orientation that during cable uncoiling, the drum will rotate in the
direction opposite to the direction of the arrow indicated on its flange.
Each spindle must be equipped with two cones and two collars. The cones are pushed
into the space between the spindle hole and the spindle, and the collars which have
locking screws, keep the cones in place. This arrangement prevents the drum from
sliding along the spindle.
The laying truck will be positioned at the starting point and alongside the trench. The
wooden battens are then removed. About 50-75m of cable will be uncoiled and carried
on the shoulders of the laying crew who will carry this length beyond the starting point
so as to provide sufficient length (normally 15 meters) for cable splicing. If the starting
point is terminal station care shall be taken to leave sufficient length of cable to reach
the ODF or Patch Panel. After this, the cable is brought down until it rests on the
bedding at its intended final position. The cable left for splicing shall be coiled in
figure eight and kept in the splice pit and protected as per approved method.
The laying truck will then start moving slowly alongside the trench and at a speed
matching the walking speed of the laying crew. Concurrently, the laying crew moves
up just behind the truck and carry the uncoiled cable on their shoulders. The man
farthest from the truck, after lowering the part he is carrying, shall climb outside the
trench and take first position just behind the truck.
At no time shall the cable be dragged on the ground or on the bedding. Particular
attention shall be paid at the location where the cable enters the trench for fear of
abrading the cable against trench wall.
It is also to be ensured that the cable is manually spooled off the drum, the drum will
be turned by hand and the cable laid without any tension, directly into the trench. At
no stage the cable is to be pulled off the drum.
As the cable is lowered into the trench, the axis of the cable shall appear as a gently
sinusoidal line with respect to the horizontal plane. This is to allow for some soil
movement over time after back filling.
As soon as the cable is laid, it shall be covered with padding material up to 200mm
above the cable. The padding material shall be of the same quality and gradation as
that of the bedding material.
Approved warning tape shall be installed on top of the sand cover and 400mm above
the cable.
After laying the warning tape the trench shall be back filled to a height slightly above
the natural ground except at crossings, all in accordance with the cross sectional details
indicated in construction drawings. The remaining excavated material shall be
crowned on top of the pipeline to form the specified windrow except at locations of
cable joints.
OHI Telecommunications Co LLC
OGC – MAF SHOHAR 24” CRUDE PIPELINE PROJECT
9. LAYING AT CROSSINGS
There will be number obstructions along the route such as at road and wadi crossings
and crossings with existing underground cable and pipelines.
At such crossings the FOC shall be laid through conduits. Installation of conduit shall
be done prior to cable laying operations. It is necessary to pass the cable through the
conduit without cutting the cable. Cut should be allowed for long crossings where a
drum cable length falls within the crossing so as to avoid keeping a joint in the
crossing section. This may involve additional joints and they should be accounted for
in the power budget design. However this may not occur when a Drum Allocation Plan
and Splice Position List have been prepared in advance.
After laying the cable up to the crossing/obstruction, the remaining cable on the drum
is taken off the drum and coiled on the ground in a large “figure eight” formation.
When the cable is coiled onto the ground, care must be taken to ensure that the ground
is free of sharp rocks or obstacles, which could damage the cable. It is preferred that
the ground is level and that an area of 20m by 10m is available.
The end of the cable is taken off the drum and directed under the obstruction or pulled
through the conduit. At the other side it is to be re-coiled onto the drum or manually
handled into the trench depending upon the length of remaining cable.
Cable length up to 750 meters would be handled by walking the cable away from the
obstruction/conduit until the joint location is reached.
Care should be taken to employ sufficient men so that the cable does not touch the
ground or is dragged along the trench.
Cable length in excess of 750 meters would normally be re-coiled onto the drum and
the laying operation continued as usual.
10. LONG LENGTH PULLING THROUGH CONDUITS
Where cable is to be pulled into a long length conduit, a mechanical fuse will be
inserted between the cable and the pulling rope. The mechanical fuse is designed to
break before the permitted cable tensile load is reached. The recommended mechanical
fuse should break down at a maximum of 3.7 kN tensile force. The cable is rated to 4
kN tensile force. This will allow the cable to be pulled mechanically to a distance in
excess of 1000 meters without running the risk of damaging the cable.
A suitable cable swivel is used to prevent twisting of the cable
Before cable pulling, the conduit is to be tested using a suitable mandrel whose
diameter is slightly less that the conduit internal diameter.
Attach the mandrel with the draw wire or pulling rope that is already exists in the
conduit. Also attach a draw wire or pulling rope at the other end of the mandrel. This is
in case the draw wire inside the conduit breaks, the mandrel can be pulled back.
Splitting of duct and placing the cable at the time laying is normally to be avoided.
However in some cases depending upon the site conditions and if Company Inspector
agrees it at site, splitting the duct and placing the cable may be considered as a special
case. This is to avoid possible damage to the cable while pulling through the duct
and/or avoiding cutting of the cable and introducing unnecessary joints in the cable.
Cable pulling assembly:
Secure the cable grip to the cable end.
OHI Telecommunications Co LLC
OGC – MAF SHOHAR 24” CRUDE PIPELINE PROJECT
cover of concrete tiles 300x200x40mm are placed over the sand bedding A further
layer of fine filling material of 50 mm thick shall be placed over the tiles.
The normal back filling material shall be compacted in layer up to 150 mm below the
natural surface level. At this stage the warning tape shall be laid and remaining back
filling completed. Cables shall be clearly labeled upon entry to the joint with the
destination of each cable. Marking shall be permanent which will not deteriorate
during the lifetime of the system.
Electronic ball markers with a detection range of greater than 1 meter shall be buried at
each joint location to permit detection from the surface. The ball marker will be placed
on the concrete tiles and just above the joint.
Above ground joint markers will be installed besides each joint location. These
markers will be erected opposite the center of the splice and ideally will be placed at a
standard distance of 1 meter.
FOC Splice shall be housed in re-enterable fully weather sealed enclosures with a fiber
management system using trays. Splitting of a single tube between trays shall not be
allowed. The tubes and bare fibers shall be installed with sufficient slack to permit
removal for maintenance. The minimum bending radius for bare fibers shall be greater
than 40mm. All joints shall be clearly numbered in an overall numbering scheme,
which shall be detailed in the as-built documentation. These numbers shall also appear
on surface joint marking posts as described above. All fibers shall be jointed through
on optical sections. All joints shall be carried out in a dust free and shaded
environment. A specialized splice vehicle shall be used.
Although direct burial of FOC joints are specified, we recommend as alternative, using
prefabricated handholes for housing the FOC Joint and slack. Housing the joint in
handhole will facilitate ease of opening and closing of joints for testing without
digging which may be difficult especially in the pipeline route.
Separate Route Markers and Joint markers shall be installed where the FOC is installed
in separate trench. These markers shall be installed after the completion of the cable
installation and generally after the trench has been back filled and compacted.
To enable the machines to complete the back filling operation, temporary “off set”
pegs will be placed in the ground with a recorded measurement to the cable. This
measurement will then be used to establish the markers 1 meter from the cable after
the machines have finished their activities.
The locations of these markers shall be recorded on the as-built route alignment
drawings.
The markers shall be installed at:
1. Intervals not exceeding 250 meters in unpopulated areas.
2. Intervals not exceeding 100 meters in populated areas.
3. Each change of direction of the route of the FOC
4. Both ends of the duct carrying the FOC.
The Cable drums shall be restrained from rolling off transport trucks or at storage
areas. Adequate wooden wedges and blocks shall be used to prevent such rolling
The supervisor and labour force involved with handling of drums and cable laying
shall be made aware of the risks involved, particularly the risks of uncontrolled rolling
of drums.
Involved personnel shall be made aware of the risks of pulling the cable underneath
existing live pipelines and cables such as but not limited to the risks of stepping on
existing line cables and pipeline, Excavation and earth dumping on these existing
utilities and Suspending new cable from existing utilities.
All work locations are to be reinstated to as near as possible to its original state.
On completion of laying, all the empty cable drums shall be transported back to the
main camp for eventual disposal.
All other debris and waste shall be collected and disposed off in the approved solid
waste disposal pit.