12-mgdp-t-1037-0 (spec for fiber optic cable)

Project Title

MEHAR GAS DEVELOPMENT PROJECT

Area Location Discipline Document No Rev. Page 12 MGDP T 1037 0 2 of 32

VECO Doc. No. 20298-01-EJ12-017

TABLE OF CONTENTS 1.0 INTRODUCTION.............................................................................................................4 1.1 Scope..............................................................................................................................4 1.2 Definitions .......................................................................................................................4 1.3 Abbreviations...................................................................................................................4 1.4 Environmental Conditions................................................................................................5 2.0 CODES AND STANDARDS............................................................................................6 2.1 General ...........................................................................................................................6 2.2 Reference Standards.......................................................................................................6 3.0 MEHAR APPLICATION ..................................................................................................8 4.0 SCOPE OF WORK / SUPPLY.........................................................................................8 5.0 FIBRE OPTIC CABLE ....................................................................................................9 5.1 Design.............................................................................................................................9 5.2 Fibre Optical Cable Construction ...................................................................................10 5.3 Installation .....................................................................................................................12 6.0 PATCH PANELS ..........................................................................................................16 7.0 CONNECTORS.............................................................................................................16 8.0 FO TERMINATION BOXES ..........................................................................................17 9.0 STRAIGHT JOINT KITS................................................................................................17 10.0 INSPECTION AND TESTING .......................................................................................17 10.1 General .........................................................................................................................17 10.2 Factory Test for FO Cable .............................................................................................18 10.3 Site Testing for FO Cable ..............................................................................................19 11.0 IDENTIFICATION AND MARKING ...............................................................................20 11.1 FO Cable.......................................................................................................................20 11.2 Cable Drum ...................................................................................................................20 12.0 PACKING......................................................................................................................21 12.1 FO Cable.......................................................................................................................21 12.2 FO Termination Boxes...................................................................................................21 13.0 DOCUMENTATION.......................................................................................................22 13.1 Product Manual .............................................................................................................22 13.2 Manufacturer’s Test Results ..........................................................................................23

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13.3 Acceptance Test Results...............................................................................................23 14.0 SPARE PARTS AND SPECIAL TOOLS.......................................................................23 15.0 SITE SERVICES ...........................................................................................................23

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1.0 INTRODUCTION

1.1 Scope

This specification covers the basic minimum requirements for the Fiber Optic Cables and Fiber Optic Termination Boxes for the MEHAR Gas Development Project.

The VENDOR shall use this specification to establish the detail design and final selection of Fiber optic cable and Fiber Optic Termination Boxes in his proposal.

This specification shall not be considered all-inclusive. The VENDOR shall submit full technical details of his standard equipment, which meet the requirements herein. Aspects of the requirements, which cannot be met, shall be identified and variances explained.

VENDOR shall supply redundant Fiber optic cable for flow lines and trunk lines mentioned in sec 3.0 and shown in the overall telecom block diagram. The EPCC contractor shall be responsible to verify the actual lengths during detail engineering.

1.2 Definitions

COMPANY Petronas Carigali Pakistan Limited (PCPL) or any Third Party assigned by the COMPANY

ENGINEER Party which carries all or part of the design, engineering of the PROJECT. VECO Engineering, Abu Dhabi is the ENGINEER.

EPCC CONTRACTOR Party which carries out all or part of the design, engineering, procurement, construction, commissioning or management, of the PROJECT. EPCC CONTRACTOR includes his approved, MANUFACTURERS, SUPPLIERS, VENDORS and SUBCONTRACTORS.

MANUFACTURER/SUPPLIER/VENDOR Party/ies, which manufacture and/or supply materials, equipment and services to perform the duties as specified by the CONTRACTOR in the scope of supply.

PROJECT MEHAR GAS DEVELOPMENT PROJECT

1.3 Abbreviations

dB Decibel

EPCC Engineering, Procurement and Construction Contractor

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FAT Factory Acceptance Test

FDF Fiber Distribution Frame

FOC Fiber Optic Cable

FOTE Fiber Optic Transmission Equipment

GPF Gas Processing Facility

GRP Glass Reinforced Plastic

HDPE High-Density Polyethylene

OTDR Optical Time Domain Reflectometer

PE Polyethylene

PVC Polyvinyl Chloride

SAT Site Acceptance Test

SDH Synchronous Digital Hierarchy

1.4 Environmental Conditions

Wellhead facilities, Gathering stations and GPF area has been tentatively selected at a location about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province. The environment is arid the terrain is mountain.

The Environmental conditions are: Maximum ambient temperature : 55ºC Minimum ambient temperature : 0.5ºC Wet bulb temperature (design) : 30ºC Soil temperature (0.5 m below) : Min: 20ºC : Max: 40ºC Water level (1.5 m depth) : (Hold) Relative humidity (max / nor / min) : 90 / 65 / 20% Direction of prevailing wind : From South to North Wind velocity (max / normal) : (Hold)/ 2.9 knots Elevation above mean sea level (GPF) : 54m (Site-IV) / 56m (Site-l) Average barometric Pressure : 1001.2 mbar (29.56 inches of

Mercury)

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Ice/Snow : None Seismic zone : Zone 2B, upper moderate with

ground acceleration of 0.2 (Hold) Annual rainfall min. : 63.3 mm (year 2006) Annual rainfall max. : 139.9 mm (year 2005).

2.0 CODES AND STANDARDS

2.1 General

Codes, specifications and standards referred to within this specification, form a part of the requirements of this specification in a manner and to the extent specified within those codes and standards. Unless otherwise specified, the latest edition or revision to these codes specifications, and standards in force at the time of request for quotation and/or Purchase Order shall apply.

No deviations from the Codes and Standards listed in this document will be allowed unless such deviations are clearly identified in the bids, with the reasoning. In addition, they must be approved in writing by COMPANY.

All the applicable codes and standards shall be of the latest edition at the time of order.

2.2 Reference Standards

The following shall be the minimum, but not limited to, reference standards for this specification

IEC 60331-25 Test for electric cables under fire condition-Part 25 procedure and requirement.

IEC 60793-1-1 Optical Fibers Part 1-1: Generic specification-General

IEC 60793-1-2 Optical Fibers Part 1-2: Generic specification-section 2 measuring methods for dimensions.

IEC 60793-1-3 Optical Fibers Part 1-3: Generic specification-section 2 measuring methods for mechanical characteristic.

IEC 60793-1-4 Optical Fibers Part 1-4: Generic specification-section 2 measuring methods for transmission & optical characteristic.

IEC 60793-1-5 Optical Fibers Part 1-5: Generic specification-section 2 measuring methods for transmission & optical characteristic.

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IEC 60793-2 Optical Fibers-Part 2: Product Specification

IEC 60794-1-1 Optical Fibers Part 1-1: Generic specification-General

IEC 60794-1-2 Optical Fibers Part 1-1: Generic specification-Basic optical cable test procedures.

IEC 60794-3 Optical Fibers Part 3:Duct, buried and aerials cables-sectional specification.

IEC 60793-1-20 to 60793-1-53

All relevant parts

ISO 9001: 2000 Quality Management system-Requirements

ITU-T G.652 Characteristics of a single-mode optical fibre and cable

ITU-T G.653 Characteristics of a dispersion-shifted single-mode optical fibre and cable

ITU-T G.654 Characteristics of a cut-off shifted single-mode optical fibre and cable

ITU-T G.703 Physical/electrical characteristics of hierarchical digital interfaces

ITU-T G.707 Network node interface for the synchronous digital hierarchy (SDH) Replaces 1993 versions of ITU-T G.707, G.708, G.709

ITU-T G.708 Sub STM-0 network node interface for the synchronous digital hierarchy (SDH)

ITU-T G.709 Interfaces for the Optical Transport Network (OTN)

ITU-T G.781 Synchronization layer functions

ITU-T G.783 Characteristics of synchronous digital hierarchy (SDH) equipment functional blocks

ITU-T G.784 Synchronous digital hierarchy (SDH) management

ITU-T G.785 Characteristics of a flexible multiplexer in a synchronous digital hierarchy environment

ITU-T G.803 Architecture of transport networks based on the synchronous digital hierarchy (SDH)

ITU-T G.811 Timing characteristics of primary reference clocks

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ITU-T G.812 Timing requirements of slave clocks suitable for

use as node clocks in synchronization networks

ITU-T G.813 Timing characteristics of SDH equipment slave clocks (SEC)

ITU-T G.822 Controlled slip rate objectives on an international digital connection

ITU-T G.823 The control of jitter and wander within digital networks which are based on the 2048 kbit/s hierarchy

ITU-T G.824 The control of jitter and wander within digital networks which are based on the 1544 kbit/s hierarchy

ITU-T G.825 The control of jitter and wander within digital networks which are based on the synchronous digital hierarchy (SDH)

ITU-T G.826 End-to-end error performance parameters and objectives for international, constant bit-rate digital paths and connections

ITU-T G.841 Types and characteristics of SDH network protection architectures

PTS 32.71.00.11 Telecommunication Standards

3.0 MEHAR APPLICATION

Under MEHAR project following are the requirements of fiber optic cable:

• Wellhead surface facilities;

• Gathering Stations;

• Gas Processing Facility.

4.0 SCOPE OF WORK / SUPPLY

The VENDOR shall provide fiber optic cable and FO termination boxes, in accordance with the specifications and the datasheets referred herein. VENDOR’S overall scope shall include the following as a minimum:

• Project management & reporting;

• Supply of all FO Cable & FO Termination Boxes;

• Inspection & Testing at FAT and SAT;

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• Packing, transportation and delivery at site;

• Site services;

• Drawings and documentation for new system including as built.

Any other material required not listed above but required for successful operation, commissioning and maintenance of the supplied material/equipment shall be supplied by the VENDOR at no extra cost.

VENDOR shall indicate the space & power supply requirements for the FO termination boxes.

5.0 FIBRE OPTIC CABLE

5.1 Design

FO Cable to be offered shall be designed such as to have a service life of not less than 20 years in the working conditions and installation environment prevailing in the location about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province. It shall also fully satisfy the safety, health and environmental requirements enforced by the laws established in Pakistan. The binding delivery quantities, upon awarding the CONTRACT shall be determined based on the actual cable routes, and therefore the prices shall be adjusted accordingly.

FO Cable shall be designed in accordance with the latest issues of IEC & ITU-T Publications as listed under section 2.2.

No fibre splices are allowed in any continuous length of cable.

The cables shall be suitable for in-door and outdoor use, either directly buried in the ground or laid in ducts/cable trays. All outdoor cables shall be suitable for direct buried installation and shall be provided with corrugated steel tape coated on both side (zabaton or equal) for moisture barrier.

The cables may be exposed to the direct rays of the sun at the termination gantries, etc. The cable outer sheath shall be capable of withstanding such exposure continuously without any detrimental effect.

The Fibre optic cable shall have optical Fibers of the single-mode type. The Fibre cores shall be laid loose in buffer tubes. Water blocking compound shall be provided inside the buffer tubes as well as in the interstices between these buffer tubes. The construction of the cable shall be such as not to allow water/moisture penetration either longitudinally or axially.

The Fibre cores shall be made of ultra pure fused silica glass suitable for operation at 1310 nm and 1550 nm wave lengths. The design shall be generally as per the latest versions of recommendations and specifications made by International Committees/Organizations such as ITU-T and IEC, and others which might be referred to, if required, for the conventional single mode Fibre optic cable. It shall provide low dispersion values for the entire possible wavelength range above the cut-off wavelength

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of the cabled Fibre, which should not be more than 1270 nm.

The VENDOR shall submit, along with his Proposal, supporting documents comparing test conditions and measurement results especially at 1310 nm and 1550 nm wave lengths.

Optical fibres from different manufacturer shall not be mixed in the same cable unless approved by COMPANY. However, Optical fibres shall have high level of splice compatibility with optical fibres from other manufacturers.

5.2 Fibre Optical Cable Construction

5.2.1 Configuration

Unless otherwise stated in project documents, the core configuration shall be 4 tubes with 8 fibres each. Each fibre shall be protected with a dual layer acrylate coating.

5.2.2 Central Strength Member

In the centre of the Fibre Optic Cable, a rod made of; preferably, Glass Reinforced Plastic (GRP) shall be placed, around which the buffer tubes which, house the Fibres are to be stranded. It must serve a dual function, acting as both a tensile strength element and as an anti-buckling member.

The central member must be free of imperfections that degrade its performance and must be stiff enough to prevent the cable from kinking at its minimum bend radius.

5.2.3 Buffer Tube

The Fibre Optic Cable shall have loose buffer tubes to accommodate the Fibre cores which, shall be distributed among these tubes equally. The buffer tube must hold its shape, be tough, not susceptible to ageing and be very flexible, so that it can be handled without noticeable stressing the optical Fibres.

The buffer tube shall be composed of an inner layer with very low friction coefficient and an outer layer to shield the Fibre against mechanical influences. The design of the loose buffer shall be in such a way that the elongation of the cable under normal operating conditions does not result in increase in the attenuation beyond the limits specified by the above mentioned standards.

For the technical requirements of loose buffer tubes reference shall be made to DIN VDE 0888 in connection with dimensions, colour codes and temperature range.

5.2.4 Buffer Tube Filling Compound

The buffer tubes and the interstices among them shall be filled with a slightly thixotropic and chemically neutral compound. This is to prevent water from entering the buffer and running through it which may affect the Fibre and result in attenuation increases.

The buffer tube-filling compound must be non-toxic and dermatologically safe. It must free from foreign matter, chemically and mechanically compatible with all cable components, non-nutritive to fungus, non-hygroscopic, electrically non-conductive, shall

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not contain highly inflammable materials and shall have relatively low thermal coefficient.

The buffer tube-filling compound shall not corrode the Fibre or cause it to swell. It also shall not drip out at the temperature range of: -5°C to + 55°C and shall be easy to wipe and wash off without leaving residue that would make it difficult to connect the Fibres.

5.2.5 The Cable Core

The buffer tubes with the fillers, stranded around a GRP (glass-reinforced plastic) central member shall form the core of the Fibre Optical Cable. The GRP member shall serve both, as a support (buckling protection against kink) and as a strain relief member.

The stranding shall be in such a way, that the bending radius will be as low as possible and the optical Fibres having a well defined free space within which strain, buckling, pressure and bending stresses will have no influence on the transmission characteristics.

The stranded buffer tubes/fillers around the GRP member with the moisture resistant compound in the empty interstices among them are wrapped by the core covering which consists of at least one layer of non-hygroscopic tape, applied helically or longitudinally with an overlap.

5.2.6 Inner Sheath

A PE sheath layer shall be extruded above the core covering with a thickness of not less than 1.5 mm.

5.2.7 Aramide Layer

An aramide yarns layer is laid above the PE inner sheath layer to serve mainly as strength member.

5.2.8 Intermediate Sheath

The intermediate sheath shall consist of high-density polyethylene compound (black) with a thickness of not less than 1.0 mm

5.2.9 Armouring

The armouring shall consist of a corrugated galvanised steel tape applied longitudinally with an overlap. The tape thickness shall not be less than 0.2 mm.

5.2.10 Outer Sheath

The outer sheath (HDPE) layer shall be covered by a semi-conductive layer. The thickness of the outer sheath shall not be less than 1.5 mm.

5.2.11 Colour Coding of the Fibre/Buffer Tube

The colour coding shall be generally in compliance with Standard EIA-A-359 and shall be indicated by VENDOR in his proposal.

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5.3 Installation

Installation of the cables is by CONTRACTOR i.e. outside SUPPLIER scope. Termination shall be in VENDOR’s scope. Following subsections indicates the minimum installation requirements. After placement of Purchase Order, SUPPLIER shall provide complete “installation procedure, instructions and precautions” for CONTACTOR use.

The paragraphs which follow below are guidelines only; a detailed method statement shall be prepared by EPCC Contractor which shall be approved by COMPANY.

CONTRACTOR shall install FOC in the same trunklines / flow line trench where applicable.

The minimum horizontal separation between the FOC centerline and pipeline outside shall be at least 0.3 meters. The FOC shall be laid on a bed of fine sand, which shall have minimum depth of 150 mm.

To keep the transmission losses along the length of the FOC as small as possible, the number of FOC splices throughout the whole length of the pipeline shall be minimized.

The FOC shall be laid in 4” UPVC (Hard Type) pipes with concrete cementing at topside at all road crossings with the depth of 1.3 meter from the ground level.

Installation of the FOC adequate ropes shall remain in conduits for future use. All underground ducts shall be jointed to prevent the ingress of foreign bodies. Building entry ducts shall be sealed to prevent the ingress of gasses and water. The design of conduit shall allow installation and removal of the FOC as required without any risk of damage.

After installation of FOC, the first 100 mm of back-fill material shall be fine sand. A cable marker tape, for cable route identification, shall then be laid and another 300 mm of fine sand shall cover the marker tape, original soil cover of 300 mm shall then be filled above the fine sand and bricks shall be laid above this for FOC protection (effectively the bricks shall be 700mm above the FOC). The rest of the trench shall then be filled back with original soil.

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5.3.1 Installation in same trench

The FOC shall be laid in the same trench as the pipeline. A typical method is shown in the following sketch (actual trench details shall be followed in cable routing layout)

5.3.2 Installation of redundant cable

To obtain redundancy, separate Fibre optic cables shall be laid on both sides of Pipe with minimum horizontal separation of 0.3 m between the FOC centerline and pipeline outside.

Inside GPF, FOC shall be routed separately and in different direction so that there will be no possibility of damaging the redundant FOC at the same time.

5.3.3 Laying

The ITU-T Recommendation L.1 “Construction, Installation and Protection of Cables and Other Elements of Outside Plants” shall be followed as a minimum.

It is good practice to pass the pulling sled through the trench to ensure that it is clear before the conduit pull is attempted. Immediately after it is determined that the trench is clear, the conduit pull should begin.

Great care shall be taken when laying the optical fibre cable either directly buried in the ground or into PVC conduits (where specified).

All cable and duct are to be fully supported throughout its entire run. Installation underground in PVC-conduits/ducts shall include the provision of pulling pits spaced not more than 50 meters apart and at both sides of road crossings.

At no time shall more than 400 pounds of tension be placed on any fiber cable while it is being pulled. It is preferred that all fiber cable be pulled with hand power only. If power winches or mechanical advantage devices are used to pull cable, a tensionometer must be used to insure that maximum tension is not exceeded. Alternatively, a "mechanical fuse" rated at 350 pounds may be included in the linkage. Torsion shall be avoided by the use of a swivel at the cable end. While under tension, a minimum bend radius of 20

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times the outside cable diameter will be maintained through the use of pulleys and sheaves where required. After pulling, no bend may have a radius, at rest, of less than 10 times the outside cable diameter. In case of laying in ducts, separate ducts shall be used for each optical fibre cable.

5.3.4 Cable in Concrete Trenches, Troughs, etc.

The Fibre Optic Cables shall be laid either separately or along the cable routes buried directly in the ground or in separate PVC conduits of 0.2 m minimum internal diameter each, at the same depth of the power cables and adjacent to them.

All cables installed in reinforced concrete trenches/troughs shall be supported by means of suitable spacers. For cable movements the snaked laying of cables is required. The cables shall be laid in a regular snaked form in the horizontal or vertical planes and they shall be secured at regular intervals by clamps or straps, subject to the approval of the COMPANY. The distance between the fixing points and the straps must take into account electro-dynamic stresses under short circuit conditions.

They shall run in a neat and orderly manner and the crossing of cables within the trench/trough shall be avoided as far as possible. Cables of different voltages shall be kept separate. On completion of the cable laying all concrete trenches supplied under this Contract shall be inspected, and the CONTRACTOR shall be responsible for the replacement of any broken parts at no additional cost.

5.3.5 Cable Markers

Cable markers of an approved type shall be provided by EPCC Contractor along each route of buried cables, to be erected after the reinstatement has been carried out.

The markers shall indicate the nominal power cable voltage and the telecom cable installed along the power cable (either Protection/Telephone or Fibre Optic Cable or both), COMPANY name, the name of the circuit, the depth of cable burial and distance of trench and joints/termination boxes from the markers as well as the joint numbers.

Markers shall be installed at all joint positions, at all places where the route changes the direction, and on straight routes at distances not exceeding 30 meters. The location of the markers shall be approved by COMPANY.

Each cable, when completely installed, shall have permanently attached to it at each end and at intermediate positions as may be considered necessary by COMPANY as well as in cable pits and at the entry to building blocks, non corrodible metal plates upon which shall be engraved or stamped the identification number of the cable.

Also where cables enter or leave ducts or pipes, the above mentioned identification markers shall be fitted.

The materials of all markers, labels and clamps shall be such as to withstand the climatic conditions prevailing on site.

Samples with details of all markers proposed to be used shall be submitted for COMPANY approval before cable installation work commences. The joint markers shall

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differ from the markers for the cable routes.

In general, the cables laid direct in ground shall be accompanied by minimum 0.3 m wide red warning tapes, marked bi lingual (Arabic/English) in minimum 30 mm high black letters, indicating the name of COMPANY and the circuit's name as well as the word "D A N G E R".

In some sections yellow warning tapes are required and the CONTRACTOR shall apply for approval of the warning tapes at an early stage of the project in order to avoid shortage of warning tapes and delay of reinstatement of the cable trench.

5.3.6 Splicing/Non Permanent Joints/Straight Joints

Splicing of the optical fibre cable either along the route or at the terminals shall be carried out in such a way to have minimum losses (maximum average loss of any individual splice is ≤ 0.05 dB).

The non permanent connectors are located at the route ends only. These connectors shall have a minimum attenuation (losses of connector and bulkhead together with the pigtail splice loss shall not be more than 0.3 dB) and shall comply with the latest technology at the time of the Contract Agreement's date.

Straight joints shall be made and buried in the ground at suitable locations and in such a way as to match the soil conditions at Site, subject to the approval of COMPANY.

VENDOR shall provide all necessary equipment, material and also perform the above activity.

5.3.7 Fibre Optic Cable Splicing and Termination (Substation End)

The optical fibre cables shall be terminated at easily accessible terminal blocks inside distribution/termination boxes. The fibres shall be terminated in low loss, screw-on type of connectors suitable for withstanding high voltage hazards.

The connectors shall be fixed inside the termination box on connector holder, which shall allow easy access to each of the connectors. The Patch cord cable's length shall be 10m and shall be provided with suitable male connector in order to form screw-on type. The loss of connector bulkhead and pig tail splice shall not be more than 0.3 dB. The sheath and any armouring shall be stripped and then affixed to the termination box. Finally, the buffer fibres are affixed in special fibre splice trays (plastic or metal) and stripped with sufficient extra length.

The fibres are stored on these trays and spliced to the departing fibres or to the pigtails. The Pigtails then shall be terminated by the female connectors.

VENDOR shall provide all necessary equipment, material and also perform the above activity.

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6.0 PATCH PANELS

Patch panels are required at every termination point. All the spare fibres shall be terminated at the patch panels. Patch panels shall be supplied with patch cords as required. The patch panel shall be 19″ rack mounting type, constructed of aluminium.

The fibre optic cable will be the main communications backbone for the complete plant and it will be used by multiple systems. Hence, the patch panels will be the central termination and distribution units. The individual cores shall then be used for specific systems.

All details for the same shall be provided by EPCC during detailed engineering.

7.0 CONNECTORS

Connectors for fibre optic cable shall be typically ST/SC type metal connectors for use on tight-buffered cable. They shall be supplied with all appropriate hardware, including sleeves and adapters. The connectors shall be low loss type.

ST connectors shall be in accordance with IEC 60874-10 and SC connectors shall be in accordance with IEC 60874-14.

CONTRACTOR to ensure the use of system specific connectors if any.

Optical parameters of connectors with pigtails:

Insertion loss : Maximum 0.3 dB Per connector plus fiber loss

Return loss : Better than 40 dB

Temperature Dependency : < 0.3 dB From – 20 to + 60

Change in connection loss with passage of time at 60°C for 100 hrs

: it should be < 0.3 dB

Change in connection loss due to vibration

: < 0.05 dB

Reproducibility of Connection loss by repeated Connection and Disconnection for 500 times.

: < 0.3 dB

Change in Connection loss in relation to Tensile strength

: 1. Loaded : - 50 dB 2. Unloaded : - 30 dB

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8.0 FO TERMINATION BOXES

FO termination box shall be suitable for indoor installation. It shall be suitable for terminating of two (2) fiber optic cables, each with 32 fibers.

Enclosure shall be of 316 SS or GRP and the ingress protection shall be minimum IP 65.

Enclosure shall be supplied complete with FO connectors, connector holders, splice holders, boots, 316 SS gland plate, lamp (240 VAC, 50 Hz energy saving), mounting accessories, etc.

Cable entry for the FO termination box shall be at the bottom and sides of the enclosure. Cable entry shall be via removable gland plate. 316 SS breather drain shall be provided at the bottom of the enclosure.

VENDOR shall provide all accessories for the FO termination box.

9.0 STRAIGHT JOINT KITS

Joint kits are to be provided by the VENDOR, the joint kits shall be in-line straight joint type suitable for above ground, direct buried or underground chamber installation. It shall be suitable for jointing and branching of two (2) fiber optic cables, each with 32 fibers.

Joint kit shall be supplied complete with splice trays, splice protectors, cable entry kit, and blank entry kit. Material of the enclosure shall be GRP and ingress protection shall be IP 65. Enclosure shall be also provided with pole and wall mounting bracket in 316 SS.

Patch cord cables shall be complete with end connectors and boots.

10.0 INSPECTION AND TESTING

10.1 General

Inspection & Test Plan shall be submitted for COMPANY approval.

The EPCC / VENDOR shall be responsible for the inspection and testing at site.

FO cables and FO termination boxes shall be subject to inspection by COMPANY and or (TPA) appointed by the COMPANY as per the approved Inspection & Test Plan.

It is prior requirement to any final inspection that the drawings be certified / approved by the COMPANY where appropriate. VENDOR shall complete all internal shop tests prior to final inspection and provide the copy of internal shop test reports for review / verification.

VENDOR shall notify the COMPANY, at least fifteen (15) calendar days in advance for each scheduled witnessed inspection.

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Acceptance of shop tests shall not constitute a waiver of requirements to meet service requirements under specified conditions and final guarantee for material design, workmanship and performance.

Cables / equipments shall not be dispatched by the VENDOR until it is released by COMPANY or his authorized representative.

10.2 Factory Test for FO Cable

The following routine tests must be performed by VENDOR on all individual lengths of the cable:

Test Name Requirements

Cable Geometry Sheath thickness, cable construction, colour coding.

Optical Attenuation OTDR test at 1310 and 1550 nm.

Optical Length Length in meters as measured with an OTDR

Apart from above, the VENDOR must provide test reports for the IEC 60794-1 series of cable tests noted below, all the tests should be performed such that the loss of “dB” with respect to a distance of at least 500 meter is recorded on the test reports. The tests must have been performed on an identical or similar construction to the one being offered and with equal or higher fibre count. In the absence of pre-existing test reports, the VENDOR must perform the tests on an actual length of cable manufactured and submit the type test reports to for COMPANY’s approval.

10.2.1 Water Penetration

A sample of cable must be tested for water penetration to IEC 60794-1-F5 with a 1m head of pressure for a period of 24 hours. The water pressure shall be applied to the cut end of the cable in an “L-test” configuration.

10.2.2 Crush Resistance

The test shall be performed per IEC 60794-1-E3 according to the compressive load requirements shown above.

After release of the compressive load, an increase in optical attenuation greater than 0.1 dB at 1550 nm shall constitute a failure.

10.2.3 Impact

The test shall be performed per IEC 60794-1-E4 (Figure 7a) according to the impact load requirements shown above.

After impact, a permanent or temporary increase in optical attenuation value greater than 0.1 dB at 1550 nm shall constitute a failure.

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10.2.4 Bending

The cable must be subjected to a bending radius of 12 times the diameter of the cable for 4 complete turns according to IEC 60794-1-E11, test method E11A.

During or after bending, a permanent or temporary increase in optical attenuation value greater than 0.1 dB at 1550 nm shall constitute failure.

10.2.5 Stress-Strain

The test must be carried out in accordance with IEC 60794-1-E1 to determine the tensile characteristics of the cable under load and to verify the fibre strain margin within the cable.

The maximum change in the optical attenuation at the cables rated maximum working tension shall be no greater than 0.1 dB at 1550 nm.

10.2.6 Thermal Cycling

The cable shall be tested to determine the temperature dependence of attenuation. The test shall be performed according to IEC 60794-1-F1.

The optical fibres shall maintain mechanical and optical integrity when exposed to operational temperature extremes of minus 40°C to plus 70°C. The attenuation increase shall be less than 0.1 dB/km at 1550 nm.

10.2.7 Torsion

The cable must be subjected to 10 twists of 180°C on a 1 meter cable sample, according to IEC 60794-1-E7. A permanent or temporary increase in optical attenuation value greater than 0.1 dB at 1550 nm shall constitute failure.

10.3 Site Testing for FO Cable

At site, VENDOR shall perform tests on the fibre optic cable at 1310 nm and 1550 nm at his own expense. The tests shall be as acceptance criteria for the COMPANY / CONTRACTOR to ensure free drum handling damages on the cable. The tests shall be conduced for both 1310 nm and 1550 nm using:

• Optical Time Domain Reflectometer (OTDR);

• Light/laser source and power meter.

The output of the tests shall be:

• OTDR curves and the loss details for each core;

• Attenuation (optical power loss) for each core.

The tests shall be conducted under the witness of the COMPANY / CONTRACTOR or their representative. In addition to the optical characteristics, the physical characteristics of the cable will be included in the acceptance testing, such as any abnormalities in construction, bulges or kinks, etc.

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If the tests showed any of the following damages, then the VENDOR shall take full responsibility for replacing the whole affected cable drum(s) at his own expense:

• more attenuation (optical loss - dB/km) than what it specified

• Macrobends

• Microbends, or/and

• Non-continuity in the FOC

11.0 IDENTIFICATION AND MARKING

11.1 FO Cable

Outer sheath of the FO cable shall be marked with following information at regular one meter interval:

• Fiber Optic Cable

• Manufacturer's name

• Year of manufacturing

• Fiber Count

• Length of cable (meters)

• PROPERTY OF PCPL

11.2 Cable Drum

All cable drums shall have their identification reference clearly stenciled on the outside of both flanges. Drum identification labels shall be attached on the outside and inside of the drum flange. Labels shall be robust and non-fading and give the following information:

• Drum identification number

• Cable identification

• Cable quantity

• Project Number & Purchaser’s Name

• Purchase Order number

• Total weight of cable and drum

Each cable drum shall also be provided with a permanently fastened nameplate of Manufacturer's name and trade mark.

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12.0 PACKING

12.1 FO Cable

The VENDOR shall be entirely responsible for the adequacy of the packing for, shipment and storage on site. Drums shall be encased to prevent damage. Packages shall not be shipped unprotected.

During loading the VENDOR shall witness the loading and bracing to satisfy himself that all reasonable precautions have been taken to prevent damage occurs during transit.

Preparation for shipment and packing will be subject to inspection and rejection by COMPANY's/CONTRACTOR's inspectors. All costs occasioned by such rejection shall be to the account of the VENDOR.

Cables shall be drummed in maximum continuous lengths on wooden non returnable cable drums. Cable shall be supplied in single length. Length tolerance shall be on positive (+ve side).

Length tolerance is +5% with a maximum of +50 meters in each length provided.

The inside ends (ISE) and outside end (OSE) of the cable shall be sealed with a heat shrinkable end cap. The ends shall be firmly fixed to the reel to prevent transit and handling damage.

All cable drums shall have their identification reference clearly stenciled on the outside of both flanges. Drum identification labels shall be attached on the outside and inside of the drum flange.

12.2 FO Termination Boxes

Preservation and export packing for FO termination boxes shall be in accordance with the MANUFACTURER's/VENDOR's standards.

VENDOR shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers.

Interior shall be protected, while door and seal with petroleum jelly. Apply jelly to door seal before closing to make a more efficient seal. Glass shall be protected with waterproof, cloth-backed duct tape.

All openings such as conduit connections shall be capped, plugged or sealed with waterproof, cloth-backed tape.

Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the job site.

Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and spare parts shall be identified by item number and service and marked with

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CONTRACTOR’S order number, tag number, and weight, both inside and outside of each individual package or container. A bill of material shall be enclosed in each package or container of parts.

One complete set of the installation, operation, and maintenance instructions shall be packed in the boxes or crates with equipment. This is in addition to the number called for in the Purchase Order.

13.0 DOCUMENTATION

The VENDOR shall include in his bid sufficient technical details on components and materials offered including manufacturer's exact model numbers, specifications and description sheets, preliminary schematic/ dimensional drawings, etc. and any other details to support their compliance statements.

The VENDOR shall provide full component details, assembly and construction drawings and details for CONTRACTOR/ COMPANY approval after placement of order. VENDOR shall provide following documentation, as minimum:

• Project schedule, quality control plan and ITP;

• Drawing and document schedule;

• Product specifications, catalogs & data sheets (required with bid also);

• Cable assembly, FO termination boxes drawings with dimensions, weight, etc.;

• Connection / wiring drawing for FO termination boxes;

• ROW (Right Of Way) FO cable path drawings from

- Wellhead(WH) to Gas Processing Facility(GPF);

- Wellhead(WH) to Gathering Station(GS);

- Gathering Station(GS) to Gas Processing Facility(GPF);

• Power requirement (required with bid also);

• Factory and Site Acceptance Test procedures;

• Installation, Operation and Maintenance Manual;

• List of recommended spare parts for 2 years operation;

• Certificates, Inspection and Test Reports;

• Guarantee/Warrantee;

• VENDOR data book.

Vendor shall also comply with the requirements of documentation specified in PCPL procedure CSP-03.

13.1 Product Manual

VENDOR shall provide Product manual with a complete product description also

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including the product handling guideline.

13.2 Manufacturer’s Test Results

VENDOR shall provide the following test results:

• Tensile strength test;

• Abrasion test;

• Impact test;

• Repeated Bending;

• Torsion test;

• Kink test;

• Cable bend test;

• Temperature cycling.

13.3 Acceptance Test Results

Completed copies of the acceptance test results shall be provided for reference.

14.0 SPARE PARTS AND SPECIAL TOOLS

Spare parts for commissioning and start up shall be as per VENDOR recommendation and included in VENDOR Scope. This shall include small parts, fragile parts, construction allowances for bulk materials etc. which may be worn, damaged or lost during transportation, construction, commissioning period. Spare parts necessary for repairing damaged parts shall also be included.

A list of recommended spare parts for two years trouble free operation shall be provided. VENDOR shall fill in SPIR forms and submit electronic & hard copies of the same for CONTRACTOR / COMPANY final review and acceptance.

15.0 SITE SERVICES

All work at site shall be strictly executed according to COMPANY site rules and regulations. All site work will be done by the CONTRACTOR.

VENDOR shall provide the services of an experienced FIELD ENGINEER during the fiber optic cable termination, testing and commissioning.

VENDOR shall provide the test equipments and the Site Acceptance Test reports. For testing to be carried out at site, refer section 8.0.

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TYPICAL CONSTRUCTION & CROSS SECTION OF FO CABLE

No Description Material

1 Loose Buffer Tube Thermo Plastic Polyester

2 Filling Compound Jelly

3 Wrapping-1 Plastic Tape

4 Inner Sheath PE

5 Peripheral Strength Member Armide Yarns

6 Strength Member GRP

7 Intermediate Sheath PE

8 Wrapping-2 Plastic Tape

9 Armouring Galvanized Corrugate Steel Tape

10 Outer Sheath HDPE

11 Conductive Layer Semi-conductive

No Description Dim.

A1 Approximate Diameter Outer of Loose Buffer Tube 2.5 mm

A2 Approximate Diameter Over Armour 17 mm

A3 Approximate Overall Diameter 20 mm

t1 Nominal Thickness, Inner Sheath 1.5 mm

t2 Nominal Thickness, Intermediate Sheath 1.0 mm

t3 Nominal Thickness, Outer Sheath 1.5 mm

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DATA SHEET: FIBER OPTIC CABLE

Sl. Description Unit Required Proposed

1.0 GENERAL

1.1 Manufacturer

a • name *

b • country of origin *

1.2 Applicable Standards IEC, ITU-T

1.3 Type

1.4 Type Test

a • carried out Yes/no Yes

b • in the year Year *

1.5 Testing station *

a • name *

b • country *

2.0 CONSTRUCTION DATA

2.1 Central Strength Member

a • material (nonmetallic) GRP

b • diameter (min ) *

2.2 Buffer Tube Construction

a • buffer tube (with loose fibers in jelly compound)

Yes/no Yes

b • number of tubes (min.) 4

c • material Thermoplastic Polyester

d • inner diameter minimum mm *

e • outer diameter mm *

f • thickness of the buffer tube (min.) mm 0.4

g • tube filling compound PE

2.3 Optical fibers

a • number of fibers (9 CCTV,9 RTU, 1 TELEPHONE + 60 % SPARE)

Nos. 32 ( 8 / Tube)

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b • mode SM

c • material high grade silica

d • core diameter mm *

e • core concentricity error mm <1

f • numerical aperture (nominal Value ) *

g • cladding diameter mm 125 +/- 3

h • cladding non-circularity % <2

2.4 Protective coating (Primary layer above the cladding):

a • material UV cured acrylate

b • thickness (min.) mm 0.25

2.5 Water blocking compound Yes/no Yes

2.6 Wrapping cover around the tubes Yes/no Yes

2.7 Inner sheath

a • material PE (Natural)

b • nominal thickness mm 1.5

2.8 Strength member reinforcing layer

a • material *

b • nominal thickness mm *

2.9 Intermediate sheath

a • material HDPE (black)

b • thickness mm 1

2.10 Armour

a • material Corrugated steel Tape

b • thickness mm 0.2

2.11 Outer sheath

a • material PE (black)

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b • min. thickness mm 1.5

c • conductive coating ( graphite ) Yes/no Yes

d • overall diameter mm *

3.0 OPTICAL / ELECTRICAL DATA

3.1 Mode field diameter mm *

3.2 Transmission mode SM

3.3 Numerical aperture *

3.4 Cut off wave length nm <1270

3.5 Dispersion at 1300 nm ps/nm.km <3.5

3.6 Attenuation at 1310 nm

a • on reel at factory / site, before installation

dB/km <0.35

b • after installation, including all splices dB/km <0.4

3.7 Attenuation at 1550 nm

a • on reel at factory / site, before installation

dB/km <0.25

b • after installation, including all splices dB/km <0.3

3.8 Difference in attenuation coefficient when measured from both ends

dB 0.05

3.9 Voltage withstand between armour and ground for (1 minute )

kV DC 10

3.10 Marking along cable length every 1 m Yes/no Yes

4.0 OTHER PERFORMANCE DATA

4.1 First commercial operation of the offered cable type

a • in the year *

b • reference list/sheet attached Yes/no Yes

4.2 Minimum permissible bending radius D

a • in ducts m *

b • adjacent to joints or terminals m *

4.3 Maximum permissible pulling force kN

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4.4 Nominal delivery length per drum m 4000 By EPCC

a • tolerance on length of cable per drum % +5% or +50 m

5.0 REEL

5.1 Manufacturer

a • name *


5.2 Material

a • wooden (non-returnable) Yes/no Yes

b • steel with screwed lagging (returnable)

Yes/no No

5.3 Overall dimensions

a • flange diameter mm *

b • core diameter mm *

c • width mm *

5.4 Reel spindle hole diameter mm *

5.5 Weights

a • maximum gross weight of a full drum kg *

b • empty drums kg *

6.0 DELIVERABLES

6.1 Whether all type test reports enclosed Yes/no Yes

6.2 Whether technical literature enclosed Yes/no Yes

6.3 Whether relevant drawings enclosed Yes/no Yes

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NOTES:

1. Data marked as * shall be filled by VENDOR.

2. VENDOR shall provide the complete the data sheets and submit it with the proposal.

3. Data sheet shall be filled-in by typing (handwritten data and/or information are not acceptable). If a particular item is not applicable, the letters NA (Not Applicable) shall be typed in the space provided. For any data not duly inserted in the data sheets, the most unfavourable data stated in other submitted Proposal will be used for evaluation purposes.

4. If there are deviations from or additions to the Technical Specification and the Technical Data Sheets, these and any further explanations must be stated on extra sheets only. All those points in which the Specifications and/or Technical Data Sheets cannot be fulfilled shall be stated and explained separately.

5. VENDOR may offer better values than required, (e.g. for test voltage levels, ratings at ambient temperature etc.).

6. In case expressions "or equivalent", "or similar" etc. are used for manufacturer's names, these deviations are understood to come into force only after approval of PURCHASER.

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DATA SHEET: FIBER OPTIC CABLE ACCESSORIES

Sl. Description Unit Required (Minimum)

Proposed

1.0 TERMINATION BOX 1.1 Type test



c • testing station name *

d • testing station country *

1.2 Manufacturer

a • name *


1.3 Standards IEC

1.4 Material Stainless steel

1.5 Steel thickness (minimum)

a • door mm 2

b • side/top/rear panels mm 1.5

1.6 Surface finish

a • colour (for metal box) *

b • total paint thickness (minimum) µm 80

1.7 Ingress Protection

a • indoor IP 52

b • outdoor IP 55W

1.8 Splice loss max. (when measured from both sides)

dB 0.05

1.9 Connector loss, max. dB 0.3

1.10 Insect proof Yes/no Yes

1.11 Connectors

a • type of connector FC-PC

b • connector holder Yes/no Yes

c • connector holder capacity (number of connectors that can be accommodated)

Nos. 40 (Minimum)

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Proposed

1.12 Splice

a • type fusion splice

b • splice holder Capacity (number of splices can be accommodated), min

Nos. 40


1.14 Termination box dimension (width x depth x height)

mm *

1.15 Number of cable entries (main FOC cables) 2

1.16 Gland plate for FOC patch cords to equipment

a • Material Stainless steel

b • Dimension (width x depth x height) mm

1.17 Lamp for indoor cabinets Yes/no Yes

1.18 Cabinet mounting

a • On pedestal Yes/no Yes

b • Wall mounting Yes/no Yes

2.0 STRAIGHT JOINT

2.1 Type test



c • testing station name *

d • testing station country *

2.2 Manufacturer *

a • name *

b • country of manufacturer

2.3 Standards IEC

2.4 Material 316 SS

2.5 Ingress Protection IP 65


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Proposed

a • connector holder Yes/no Yes

b • connector holder capacity (number of fiber)

Nos. 40

2.7 Splice

a • type Fusion splice

b • splice holder Yes/no Yes

c • splice holder capacity (number of splices)

No. *

2.8 Method of sealing

a • Compound Yes/no *

b • Internal pressure Yes/no *

2.9 Temperature range °C 0 to 55

2.10 Number of cables entries 2

2.11 Dimensions (width x depth x height) mm

3.0 DELIVERABLES

3.1 Whether all type test reports enclosed Yes/no Yes

3.2 Whether technical literature enclosed Yes/no Yes

3.3 Whether tables giving rating factors for variation in standard conditions of installation enclosed

Yes/no Yes

3.4 Whether relevant drawings enclosed Yes/no Yes

12-mgdp-t-1037-0 (spec for fiber optic cable)

Documents

fo cable

fibre optic cable

fo termination boxes

mehar application

site testing

reference standards

scope of work supply

mgdp t