30-99-90-1652 Laying & Testing Proced

ABU DHABI CRUDE OIL PIPELINE PROJECT
(ADCOP)
FOC
LAYING & TESTING PROCEDURE
30-99-90-1652
EPC CONTRACTOR: PROJECT MANAGEMENT CONSULTANT:

China Petroleum Engineering ILF Consulting Engineers
& Construction (Group) Corporation P.O.Box 73250
Abu Dhabi Branch
Abu Dhabi, UAE
P.O. Box 127345 CONSULTING
EN GI N EERS
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT

EPC Contractor Doc. No.: PAGE: 1 of 16
DOCUMENT No.: 30-99-90-1652 Rev. 0 Project No: E 30153 DATE: 13/08/2008
CONTENT PAGE
1 INTRODUCTION .................................................................................................................................4
1.1 Main Components of the ADCOP Pipeline System.............................................................................4
1.2 Scope of Procedure .............................................................................................................................4
1.3 Terms and Definitions..........................................................................................................................4
1.4 Abbreviations .......................................................................................................................................4
2 REFERENCES AND STANDARDS....................................................................................................5
2.1 Order of Preference .............................................................................................................................5
2.2 Reference Documents of the Project...................................................................................................5
2.3 International Standards........................................................................................................................5
3 GENERAL ...........................................................................................................................................6
4 TRANSPORT AND STORAGE...........................................................................................................6
5 DRAWINGS REVIEW AND DRUMS ASSIGNATION ........................................................................7
5.1 Drawings Review .................................................................................................................................7
5.2 Single-Reel Test ..................................................................................................................................7
5.3 FOC Drum Assignation........................................................................................................................7
6 FOC LAYING PROCEDURE ..............................................................................................................7
6.1 Pre-laying Inspection and Preparation ................................................................................................7
6.2 HDPE Conduit Pressure Re-test .........................................................................................................8
6.3 HDPE Conduit Passing-through Re-test .............................................................................................8
6.4 FOC Blowing........................................................................................................................................9
7 OPTICAL FIBER SPLICING AND TERMINATION ..........................................................................10
8 FOC RELAY SECTION TEST...........................................................................................................10
9 DOCUMENTATION...........................................................................................................................11
APPENDIX A: FOC SINGLE-REEL TEST FORM .........................................................................................12
APPENDIX B: FOC DRUM ASSIGNATION FORM.......................................................................................13
APPENDIX C: FOC POST-BLOWING TEST FORM .....................................................................................14
APPENDIX D: FOC SPLICING TEST FORM.................................................................................................14
APPENDIX E: FOC RELAY SECTION BI-DIRECTION TEST FORM...........................................................15
DOCUMENT TITLE : FOC

Project No: E 30153
PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT Page 3 of 16
DOCUMENT No.: 30-99-90-1652 Rev. 0 DATE :13/08/2008
1 INTRODUCTION
The United Arab Emirates (UAE) authorities assigned International Petroleum Investment Company
(IPIC) to execute the Abu Dhabi Crude Oil Pipeline (ADCOP) project which will facilitate the
transferring crude oil from the Habshan production facilities to the Fujairah main oil terminal (MOT) on
the eastern seaboard of UAE. The proposed pipeline is of approximately 404 km in length. The
pipeline shall be designed for transferring of 0.5~1.5 MMBBLD of crude oil.
1.1 Main Components of the ADCOP Pipeline System
Tie-in and manifold facility at MP 21
48” pipeline from ADCO Habshan production facilities to the Fujairah Main Oil Terminal as
mentioned above.
Main Pump Station (MPS) in Habshan area, with tie-in to the existing ADCO pipeline
network. MPS is equipped with custody metering facility, storage/buffer cum relief tanks,
electrically driven main oil transfer pumps and booster pumps.
Intermediate Pump Station (IPS) in Sweihan which contains electrically driven pumps,
station bypass and surge relief facility.
Main Oil Terminal (MOT) located at Fujairah north of the existing Vopak terminal which
will be equipped with tanks, pumps, pressure control system and utilities etc.
MOT loading facilities with 3 SPM’s, loading capacity 80000 bbl/hr each.
1.2 Scope of Procedure
Scope of this Procedure is to guide construction for Fibre Optic Cable (FOC) laying and testing
which shall be blown into HDPE cable conduit buried in the same trench as the pipeline for
ADCOP facilities. However, any additional procedures may be prepared and issued for
approval during the Project life-cycle if necessary or required.
This Procedure is applicable to the following FOC in the ADCOP project:
24 core, G.655 FO cable running from MP 21 Tie-in station to Habshan MPS.
24 core, G.655 FO cable running from Habshan MPS via BVS stations to Sweihan IPS and
from Sweihan IPS via BVS stations to Fujairah MOT.
1.3 Terms and Definitions
Client International Petroleum Investment Company (IPIC)
PMC ILF Consulting Engineers
FEED Consultant Worley Parsons
EPC Contractor China Petroleum Engineering & Construction Corporation
Abu Dhabi Branch (CPECC)
the Project Abu Dhabi Crude Oil Pipeline Project
may One possible course of action
shall/must/is to be A mandatory requirement
1.4 Abbreviations
ADCO Abu Dhabi Company for On-Shore Oil Operations
ADCOP Abu Dhabi Crude Oil Pipeline
Project No: E 30153
BVS Block Valve Station
dB Decibel
FAT Factory Access Test
FOC Fibre Optic Cable
HDPE High Density Polyethylene
LDPE Low Density Polyethylene
IPS Intermediate Pump Station
MP Mile Point
MPS Main Pump Station
ODF Optical Distribution Frame
OLTE Optical Line Termination Equipment
OTDR Optical Time Domain Reflectometer
ROW Right Of Way
SPM Single Point Mooring
TP Test Point
2 REFERENCES AND STANDARDS
2.1 Order of Preference

The preference for application of the Project Documents, Codes, Standards and Regulatory
requirements shall be as follows:
Drawings of the Project
Specifications of the Project
This Procedure
International Codes and Standards
2.2 Reference Documents of the Project
Document Number Description
24.84.39.0615 Specification for FOC Installation
24.84.39.0606 Specification for Fibre Optic Cable
24.84.68.0601 Fibre Optic Telecommunication System Specification
24.84.70.0601 Telecom System Architecture Drawing
30.99.91.0646 Environmental & Climatic Data for ADCOP Project
30.99.68.0005 Laying Telecom Cables in the Vicinity of
Pipes, Power Cables and Roads
2.3 International Standards
International Electro technical Commission (IEC)
IEC 60793-1 Part 1: Generic Specification for Opticaal Fibles
IEC 60794-1 General Specification for Optical Fibre Cables
IEC 60794-2 Product specifications for Optical Fibre Cables
IEC 60874 Connector for Optical Fibres and Cables
Project No: E 30153
IEC 1073 Splices for Optical Fibres and Cables
IEC 1218 Fibre Optic-Safety Guide
International Telecommunication Union Standards
ITU T G.655 Characteristics of a non-zero dispersion-shifted
Single-mode optical fibre and cable
International Standardization Organization
ISO 9001 3rd Ed, Quality management Systems-Requirements 2000
ISO 9003 Quality System-Model for Quality Assurance in
Final Inspection and test
3 GENERAL
The following guidelines and instructions shall be complied with strictly during the whole construction
of the FOC cable laying and testing.
Comply with FOC and FOC blowing machine manufacturers’ recommendation.
Don’t stand on FO cable and no vehicle shall be permitted to drive over it.
FO cable drums shall not be allowed to roll for moving.
FO cable drums shall not be laid flat.
FO cable drums shall be fixed against rolling off during transportation or storage.
A spreader bar must be used above the drum to avoid inward pressure on the top of the drum
flanges while lifting the drum by crane or other lifting device.
The ends of FO cable shall be kept sealed with heat shrinkable caps at all time unless
necessary to open for inspection, test or connection.
FO cable shall not be twisted, kinked or folded.
Bending radius of FO cable shall be not less than 20 times of its diameter or subject to vendor.
FO cable drums shall not be dropped on the ground directly while unloading.
The enough length of FO cable shall be remained for upcoming use such as test or splicing at
manholes and stations.
OTDR, splicing machine and other test instruments shall be certified and calibrated, and be
confirmed the calibration test certificate not older than one year.
Generally 0.5~1m of the FO cable end will be cut off for test or splicing.
All works shall be performed by full-skilled, experienced and qualified personnel.
4 TRANSPORT AND STORAGE
The following items shall be checked, inspected or test before FOC and its accessories to be installed
are transferred to the Site.
Check the identification number of FO cable drum.
Inspect documents provided by manufacturer such as FAT report, guidelines, specifications,
and pack lists etc.

Project No: E 30153
Ensure FO cable and its accessories are new and unused.
Confirm the ends of the FO cable are well capped and sealed.
Inspect carefully surface of the FO cable to ensure there no defects exist.
Don’t leave FO cable on site overnight.
No defective or damaged FOC with scar, carving vestige, obvious scrape, cut or fold etc shall
be delivered to the Site for installation without OTDR test and approval from PMC.
Tarpaulins or the like shall be used to cover the FO cable during transportation to the Site to
avoid direct sun light exposure.
FO cable and its accessories shall be stored in temperature-controlled warehouse, and storage
supports and stacking heights shall be selected to avoid deformation and water ingress.
5 DRAWINGS REVIEW AND DRUMS ASSIGNATION
5.1 Drawings Review

Prior to FOC laying the construction team shall review the design drawings with regard to the
cable route to identify and accurately locate the positions of crossings, manhole/splicing
chamber and conduit coupling as well as conduit laying position and installation type. And on
the basis of this review the quantities of the materials to be used shall be calculated and the
record shall be kept for comparison with the procured.
5.2 Single-Reel Test
Each core of optical fiber of every reel of cable shall be test before the cable is laid. The test
comprises attenuation and length of the optical fiber as well as the cable length. Compare the
length of each optical fiber with the cable length, if there exists any big difference, another
direction test or laser passing-through test shall be performed to determine what problem it is
and corresponding measures shall be taken to solve the problem. After testing the ends of FO
cable shall be marked as A and B by different color caps for laying purpose.
5.3 FOC Drum Assignation
Each qualified FOC drum shall be identified and designated unique number which shall be
marked on the two sideboards of the drum. Subsequently an assignation form shall be
developed to make a plan for FOC laying section along the designed route. The location of the
FOC splicing chamber, crossing, manhole, conduit connection, and accessibility shall be taken
into account when preparing this assignation form.
6 FOC LAYING PROCEDURE
6.1 Pre-laying Inspection and Preparation

Check the FOC drum ID according to FOC drum assignation form to assure it is laid in the
right section.
Ensure the FO cable to be laid is free of any damage or defects.
Ensure the technicians available all time at the both ends of the laying section.

Project No: E 30153
Ensure the good communication between the two ends of the laying section during all
blowing time.
FOC drum shall be unloaded where is as close to blowing manhole as possible.
Air compressor, blowing jet and condenser shall be maintained regularly to keep them in
good condition.
Safety measures shall be taken to prevent any accidents happen.
6.2 HDPE Conduit Pressure Re-test
Pressure test shall be performed prior to blowing FO cable.
Inspect air compressor carefully on site to ensure it can work normally.
Connect tightly and correctly one end of the HDPE conduit to be test via the test device
equipped with pressure gauge to the pipe from the compressor.
Connect tightly another end of the HDPE conduit to be test with the corresponding
receiver.
Steel wire shall be used to make a connection for protection at two sides of the any
connection with conduits.
Take measures to anchor or fix the inductive pipe of the compressor.
No person shall be permitted to stay in dangerous place at both ends or stand on the line
route while testing.
Inspect the valves of the compressor, compressed-air-in and release to ensure the valve
of compressed-air-in open and the valves of the compressor and release close.
Startup the compressor, slowly open the compressor valve, monitor the read on the
pressure gauge of the test device. Close the compressed-air-in valve when the pressure
read increases up to 1MPa and shut down the compressor.
Observe the pressure-drop rate on the pressure gauge 30 minutes. If the rate is faster
than 0.05MPa/min, it proves some leakage point or points exist. Find them out with
detector and repair. After repair the same test shall be repeated.
Slowly open the compressed-air-in valve and then release valve to release the
compressed air.
Disconnect the receiver and test device with the conduit to prepare for passing-through
test.
6.3 HDPE Conduit Passing-through Re-test
Passing-through test shall be performed immediately after the pressure test passed.
Connect corresponding receiver tightly and correctly with the conduit to be test at one end.
Put inside conduit a clean foam mandrel with same size as or a little bit bigger than the
inner diameter of the conduit at another end, and then followed a soft wooden, plastic or
rubber pig with a diameter smaller than the conduit inner diameter.
Connect the test device tightly and correctly with the conduit.
Inspect the valves of the compressor, compressed-air-in and release to ensure the valve
of compressed-air-in open and the valves of the compressor and release close.

Project No: E 30153
Startup the compressor, slowly open the compressor valve, monitor the read on the
pressure gauge of the test device. Slowly and evenly increase the pressure to not more
than 0.5MPa.
Meanwhile observe whether both the foam mandrel and pig are launched successfully to
another end of the conduit. If not, it proves some block point or points exist. Find them out
with detector and repair. After repair the same test shall be repeated.
If both the foam mandrel and pig arrive at the receiving end successfully, close the
compressor valve, slowly open the release valve to release the compressed air over,
disconnect the receiver and test device, clean the receiver.
Repeat above steps until it is confirmed that the conduit is free of water, debris and any
other obstruction. A new foam mandrel shall be used at each time.
6.4 FOC Blowing
The cable blowing shall commence subsequently after both the pressure test and passing-
through test passed.
The use of additional lubricants during the cable installation shall be avoided since the
inner surface of the cable Conduit shall provide optimum sliding characteristics achieved
by longitudinal rills.
Inspect the blowing jet and condenser carefully to ensure they are in operable condition.
Mount the FOC drum on unwinding device stably.
Pull off FO cable from upside of drum by hand and lay a sheet of plastic along the cable
way to prevent the cable touching the ground directly.
Connect the cable conduit via the blowing jet with the compressor correctly and tightly.
Check again to ensure everything is ready for blowing cable.
Power on the compressor and condenser, observe the reads of the blowing jet pressure
gauge. Open the blowing valve of the blowing jet when the read reaches to the required
pressure, and then startup the delivery device of the blowing jet. Increase the delivery
speed slowly and evenly and control the speed within the scope specified by the blowing
jet.
The cable shall be kept clean, straight and horizontal before fed into the delivery device of
the blowing jet.
The dragging strength on the cable shall be not more than the specified by the cable.
If any damage to the cable found or the cable blocked blowing shall be stopped
immediately, and appropriate measures shall be taken to solve the problem.
Shut down the delivery device and then blowing valve of the blowing jet in time while the
planed cable has been blown successfully.
Close the valve of the compressor and power off the compressor, open the release valve to
release the compressed air over.
Coil the cable and mount it on the wall of the manhole, cap the end of the cable and seal
the end of the cable conduit at the receiving end.
Disconnect the blowing jet and cable conduit.
Project No: E 30153
Unwind the left cable by type “8” and turnover it to prepare for another direction blowing.
The HDPE conduits at blowing manhole shall be well coupled while completing the cable
blowing.
Each core of the optical fibre of the FO cable shall be test with OTDR to get the dB loss
data of post-laying.
7 OPTICAL FIBER SPLICING AND TERMINATION
Two adjacent section FO cables can be joined after they have been blown, or FO cable can be
terminated after it has been blown to station and when the shelter for telecommunication is
ready.
Splicing shall be done by well-trained and authorized persons only.
Splicing shall be done in controlled environment to assure splicing machine, FO cable, testing
equipments and accessories are placed in dust-free, temperature-controlled environment.
Sufficient length of cable shall be installed at all cable ends to reach the controlled environment.
Splicing shall be made by the use of a fusion splicing machine which shall be the core
alignment type and fully compliant with the optical fibre specification.
A Semi Automatic cleaver should be used for cutting the fibre to guarantee a plain cut at 90
degree.
Splicing along the cable route shall be done only at manhole location consistent with the design
drawings.
Optical fibre splicing shall be monitored with OTDR and optical talk sets shall be used to keep
contact between splicing operator and OTDR monitor.
The parameters of the splicing machine shall be set correctly according to the manufacturer’s
manual and the performance of the FO cable to be spliced.
The insertion loss resulted from splicing shall be less than 0.1dB.
Fibre optic splices shall be enclosed in the splice protection sleeves which shall be inserted in
the cassette of the splice enclosure.
The excess or loose bare fibre shall be organized and secured well in the splice tray.
Each splice enclosure shall be uniquely tagged for identification.
After splice enclosure has been successfully closed and mounted the chamber shall be
carefully cleaned up and closed.
8 FOC RELAY SECTION TEST
FOC relay section test can be performed after FO cables between two adjacent stations have
been blown, joined and terminated successfully.
FOC relay section test shall be done bi-directionally from ODF to ODF installed in stations.
Testing shall be done by well-trained and authorized persons only.
The parameters of OTDR shall be set correctly according to the manufacturer’s manual and the
performance of the FO cable to be test.
Project No: E 30153
Each core of the optical fibres shall be test, the loss of any event shall be less than 0.1dB and
average attenuation shall be not more than 0.25dB/km.
All connectors shall be capped immediately after testing finished.
9 DOCUMENTATION
All data such as splicing locations or distance, and test results shall be collected and recorded in time,
and filled into corresponding form or reports, and well-kept by full-time person.

Project No: E 30153
APPENDIX A: FOC SINGLE-REEL TEST FORM
FOC SINGLE-REEL TEST FORM
Drum ID from Manufacture Drum ID from Contractor
Inner End Mark/Meter Read A/1234 Outer End Mark/Meter Read B/5678
Cable Length (m) FOC Type 24/G.655
Visual Check Testing Direction A→B

Colour of Buffer Colour of Optic
No Attenuation at 1550nm dB/km Length of Optic Fibre
Tube Fibre
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Testing Date Operator
Representative of the
Representative of the Client
Contractor
Date Date

Project No: E 30153
APPENDIX B: FOC DRUM ASSIGNATION FORM
FOC DRUM ASSIGNATION FORM
AVAILABLE SECTION
NO. DRUM ID FOC TYPE SECTION TO INSTALL STATUS
LENGTH(m) DISTANCE(m)
1 24/G.655 A→B(for example) Ready for installation
2 Installed
3 Fully damaged
4 Partly damaged
10
11
12
13
14
15
16
ASSIGNATION DATE UP-DATED DATE PREPARED REVIEWED APPROVED REMARK

Project No: E 30153
APPENDIX C: FOC POST-BLOWING TEST FORM
FOC POST-BLOWING TEST FORM
Drum ID from Manufacture Drum ID from Contractor
Section Location MH→MH Section Length (m)
Cable Length (m) FOC Type 24/G.655

Colour of Buffer Colour of Optic Attenuation at 1550nm
No Length of Optic Fibre
Tube Fibre (dB/km)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Representative of the
Representative of the Client
Contractor
Date Date
APPENDIX D: FOC SPLICING TEST FORM

Project No: E 30153
FOC SPLICING TEST FORM
Splicing Location MHxx or xx Station Temperature (℃)
Testing Date FOC Type 24/G.655
No Colour of Buffer Tube Colour of Optic Fibre dB Loss Estimated by Splicer dB Loss From OTDR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Splicing Operator OTDR Monitor
Representative of the Client Representative of the Contractor
Date Date
APPENDIX E: FOC RELAY SECTION BI-DIRECTION TEST FORM

Project No: E 30153
FOC RELAY SECTION Bi-DIRECTION TEST FORM
Relay Section Location xx station－xx station Relay Section Distance (km)
Number of Joints FOC Type 24/G.655

A→B Average B→A Average
No Attenuation at Attenuation at 1550nm Length of Optic Fibre (km) Remark
1550nm (dB/km) (dB/km)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Representative of the Client Representative of the Contractor
Date Date

Project No: E 30153

30-99-90-1652 Laying & Testing Proced

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ABU DHABI CRUDE OIL PIPELINE PROJECT

EPC CONTRACTOR: PROJECT MANAGEMENT CONSULTANT:

PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT

DOCUMENT TITLE : FOC

2 REFERENCES AND STANDARDS

2.1 Order of Preference

4 TRANSPORT AND STORAGE

DOCUMENT TITLE : FOC

5 DRAWINGS REVIEW AND DRUMS ASSIGNATION

5.1 Drawings Review

6 FOC LAYING PROCEDURE

6.1 Pre-laying Inspection and Preparation

DOCUMENT TITLE : FOC

DOCUMENT TITLE : FOC

7 OPTICAL FIBER SPLICING AND TERMINATION

8 FOC RELAY SECTION TEST

DOCUMENT TITLE : FOC

FOC SINGLE-REEL TEST FORM

Drum ID from Manufacture Drum ID from Contractor

Cable Length (m) FOC Type 24/G.655

Visual Check Testing Direction A→B

DOCUMENT TITLE : FOC

FOC DRUM ASSIGNATION FORM

1 24/G.655 A→B(for example) Ready for installation

ASSIGNATION DATE UP-DATED DATE PREPARED REVIEWED APPROVED REMARK

DOCUMENT TITLE : FOC

FOC POST-BLOWING TEST FORM

Drum ID from Manufacture Drum ID from Contractor

Section Location MH→MH Section Length (m)

Cable Length (m) FOC Type 24/G.655

APPENDIX D: FOC SPLICING TEST FORM

Splicing Location MHxx or xx Station Temperature (℃)

Testing Date FOC Type 24/G.655

Representative of the Client Representative of the Contractor

APPENDIX E: FOC RELAY SECTION BI-DIRECTION TEST FORM

DOCUMENT TITLE : FOC

Relay Section Location xx station－xx station Relay Section Distance (km)

Number of Joints FOC Type 24/G.655

Representative of the Client Representative of the Contractor

DOCUMENT TITLE : FOC

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