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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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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

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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13.3

Acceptance Test Results

 

23

14.0

SPARE PARTS AND SPECIAL TOOLS

23

15.0

SITE SERVICES

 

23

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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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

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT  

MEHAR GAS DEVELOPMENT PROJECT

 
MEHAR GAS DEVELOPMENT PROJECT  

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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)

 

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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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.

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

 

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MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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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-

IEC 60794-3

Basic optical cable test procedures. 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 digital interfaces

characteristics

of

hierarchical

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

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

 

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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;

 

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

 

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MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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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

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

 

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MEHAR GAS DEVELOPMENT PROJECT

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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

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

 

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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.

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

 

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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.

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

 

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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)

trench details shall be followed in cable routing layout) 5.3.2 Installation of redundant cable   To

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

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

 

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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.

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

 

Project Title

   
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

Area

Location

 

Discipline

 

Document No

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Page

12

 

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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 19rack 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

:

< 0.05 dB

vibration

 

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

:

< 0.3 dB

 

:

1. Loaded

: - 50 dB

 

Change in Connection loss in relation to Tensile strength

2. Unloaded : - 30 dB

 

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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Document No

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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.

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

Area

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Document No

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12

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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.

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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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.

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

Area

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Discipline

Document No

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MGDP

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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.

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

Area

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Discipline

Document No

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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

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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Document No

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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

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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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.

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

 

Project Title

   
MEHAR GAS DEVELOPMENT PROJECT  

MEHAR GAS DEVELOPMENT PROJECT

 
MEHAR GAS DEVELOPMENT PROJECT  

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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

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

   

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MEHAR GAS DEVELOPMENT PROJECT

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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)

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

 

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MEHAR GAS DEVELOPMENT PROJECT

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DATA SHEET:

FIBER OPTIC CABLE

 

Sl.

 

Description

 

Unit

 

Required

Proposed

 

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)

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

 

Project Title

   
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

Area

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Discipline

 

Document No

 

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12

 

MGDP

   

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DATA SHEET:

FIBER OPTIC CABLE

 

Sl.

 

Description

 

Unit

 

Required

Proposed

 

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

dB/km

 

<0.35

installation

   

b

after installation, including all splices

dB/km

 

<0.4

3.7

Attenuation at 1550 nm

   

a

on

reel

at

factory

/

site,

before

dB/km

 

<0.25

installation

   

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

 

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

 

Project Title

 
MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

MEHAR GAS DEVELOPMENT PROJECT

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DATA SHEET:

FIBER OPTIC CABLE

 

Sl.

 

Description

 

Unit

 

Required

Proposed

 

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

 

*

b

country of origin

*

5.2

Material

 

a

wooden (non-returnable)

 

Yes/no

 

Yes

b

steel

with

screwed

lagging

Yes/no

No

(returnable)

   

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