Telekom Handbook for Cabling Works

SPECIFICATION LINES WE FO 001 ISSUE APRIL, 1995

FIBER OPTIC UNIT LOCAL NETWORK HEADQUARTERS 17th FLOOR, WISMA TELEKOM TELEKOM MALAYSIA BERHAD 59200 JALAN PANTAI BAHARU KUALA LUMPUR

Specification Lines WE FO 001 Issue April, 1995

SECTION I

GENERAL

NO.

1.

CONTENTS

SCOPE

Local Network Headquarters Telekom Malaysia Berhad

PAGE

1


GENERAL 1.

SCOPE The specification covers all aspects of optical fibre cable installation for: a) b) c) d) e)

underground overhead direct burial on vertical racking/in riser on horizontal racking/cable tray

Other aspects of optical fibre cable works procedure included are splicing of fibre ends, preparation of mechanical jointing closure, installation of Fibre Termination Box and Fibre Distribution Panel. Another associated part describes the Acceptance Test and Commissioning procedures for optical fibre cable and equipment. The Fibre-In-The-Loop (FITL) projects use single mode optical fibre cables of loose and ribbon fibres. The optical fibre cable length supplied to TM shall be within one (1) to three (3) Km for each drum. It shall also be provided with manufacturer's test report and free from physical damage.


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SECTION II

DEFINITIONS

NO.

CONTENTS

PAGE

1.

DIGITAL DISTRIBUTION FRAME (DDF)

1

2.

FIBRE DISTRIBUTION FRAME (FDF)

1

3.

FIBRE TERMINATION BOX (FTB)

1

4.

HORIZONTAL RACKING

1

5.

INTERNAL CABLE

1

6.

MAIN DISTRIBUTION FRAME (MDF)

1

7.

RIPPING

1

8.

SUBDUCT

1

9.

SUBSCRIBER DISTRIBUTION FRAME (SDF)

1

10.

SUPERSTRUCTURE

1

11.

TUNNEL

1

12.

VERTICAL RACKING

1



DEFINITIONS 1.

Digital Distribution Frame (DDF): A connection frame that provides flexibility for interfacing the digital signal line (2/8/34/140 Mb/s digital signal) on coaxial cable.

2.

Fibre Distribution Frame (FDF): A frame in the central office that provides flexibility for interfacing between the external cable and the terminal equipment.

3.

Fibre Termination Box (FTB): A box where external optical cable is spliced to the fibre cord cable.

4.

Horizontal racking: A flat metallic surface for laying and anchoring optical cables in horizontal plane or known as cable tray.

5.

Internal cable: Connecting cables between termination box and equipments up to MDF termination blocks.

6.

Main Distribution Frame (MDF): The point of interconnect between telephone exchange equipment and local network cable pairs.

7.

Ripping: Process of breaking the soil along the plough line to facilitate installation of direct buried optical cable.

8.

Subduct: A 32 mm diameter PVC or HDPE pipe provided by TM to facilitate installation of optical fibre cable.

9.

Subscriber Distribution Frame (SDF): The distribution frame in subscriber's premises on which the local cable pairs and internal cables both terminate.

10.

Superstructure: A steel frame to hold equipment rack in equipment room within the MDF.

11.

Tunnel: A cable passage large enough to permit entry by personnel.

12.

Vertical racking: A flat metallic surface for laying and anchoring optical cables in vertical plane or known as ladder racking.


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SECTION III

INSTALLATION OF PVC SUBDUCTS

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

MATERIALS

1

3.

INSTALLATION PROCEDURE

1

4.

TESTING

3

5.

TYPICAL SUBDUCT INSTALLATION

3

Local Network Headquarters Telekom Malaysia


INSTALLATION OF PVC SUBDUCTS 1.

GENERAL This specification describes the items required and practices for installing PVC subducts into a 4-inch ducts. Positions of ducts to be installed with subducts shall follow the normal selection for installing copper cable that is starting from the lowest layer on extreme sides and working its way up.

2.

MATERIAL

2.1.

Items supplied by TM The following items shall be supplied by Pengurusan Bahan:i. PVC subduct ii. Flange holder (Plate B) iii. End cap

2.2.

Items supplied by Contractor I. Tape PVC 19 mm self adhesive ii. Adhesive - Solvent cement iii. Cotton waste iv. Mechanical aids and tools for laying subducts

2.3.

Quality of material All materials unless otherwise specified are to be in accordance with the British Standard Instruction or its equivalent in so far as those specifications apply.

3.

INSTALLATION PROCEDURE 3.1

Preparation of worksite and manhole Work procedure shall be as specified for normal cable laying. Refer to Specification Lines WE 303.

Local Network Hedaquartes Telekom Malaysia Berhad

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Specification Lines WE FO 001 Issue April, 1995 3.2

Preparation of Ducts Ducts should first be cleared of obstructions. Rodding of allotted ducts (avoid blocking the entry to other ducts) should be done using rod sweep cane, PVC rods or any approved equipment. Clean the ducts by using mandrel cutting, brushes and cleaning disc and remove obstructions where encountered. The test mandrel used for testing shall be of 457mm in length and 83mm in diameter, the cylindrical brush shall be 108mm in diameter. All duct ends must be intact and straight.

3.3

Preparations of Subducts i)

Jointing of Subducts The spigot of the subducts shall be wiped clean. The solvent cement shall be applied to the spigot as well as the end of another subduct. The end of the subduct where the solvent cement were applied shall be positioned and pressure applied for the two subducts to be jointed. In no circumstances shall dirt or grit be allowed to enter the joints.

ii)

Bunching of subducts Bunch the three (3) subducts together firmly by twining/lacing using an adhesive tape and place into position as shown in Figure 1.

iii)

Cutting of subducts Subducts shall only be cut where necessary at right angles to the bore preferably with a saw in a simple cutting motion according to the requirements of the work. Inside edges of cut subducts shall be thoroughly rounded off or so dressed before being put into position that they can be no possibility of damage to optical fibre cables from the edges.

3.4

Laying of Subducts i)

Drawing of subducts into duct The pulling-in (3 subducts at the same time) can be done manually or with a cable-pulling trailer depending on the distance between manholes. The pulling-in of subducts is made in the same way as for the pulling-in of cables.

ii)

To prevent the subducts from twisting, attach swivel to the subducts as shown in Figure 2.

iii)

Fixing of Subducts at the Manhole


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Specification Lines WE FO 001 Issue April, 1995 Hold the subducts as shown in Figure 3 using the PVC plate B. Two PVC plates are required in each manhole. Each of the PVC plate (Flange Holder) is placed at the duct mouth with each subduct inserted and adhered with solvent cement into each of the three holes of the plate. Screw each corner of the plate to the manhole wall to secure the subducts from creepage. iii)

Make a 1 inch slit at the side of each subduct mouth and slide the end of nylon rope to prevent it from moving into the subduct before closing with the end cap.

iv)

Ensure end caps are tightly fitted to the subduct mouth. These end caps shall be removed for cable installation.

v)

Fixing of Subducts at the Cable Chamber One PVC plate B shall be installed at the duct mouth and screwed to the cable chamber as shown in Figure 4.

4.

5.

TESTING i)

On completion of the subduct line between any two jointing chambers or sites thereof, rod each and every subduct laid using rod sweep cane, PVC rods or any approved equipment.

ii)

All tests shall be carried out in the presence of the Superintendent Officer and if any obstruction or defects is discovered, it shall be rectified forwith to his satisfaction.

TYPICAL SUBDUCT INSTALLATION A typical installation of a subduct section is as illustrated in Figure 5.


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SECTION IV

INSTALLATION OF CORRUGATED SUBDUCTS FOR OPTICAL FIBRE CABLE

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

MATERIALS

1

3.

INSTALLATION PROCEDURE

1

4.

ACCEPTANCE TESTING

3

5.

END CAP SOCKET

3



INSTALLATION OF CORRUGATED SUBDUCTS FOR OPTICAL FIBRE CABLE 1.

GENERAL This specification describes the practice for installation of corrugated subduct into a 4 inch duct. Subducts are installed to facilitate drawing and installing of optical cable. The position of ducts to be installed with subducts shall follow the installation of PVC subduct.

2.

MATERIAL

2.1

Items supplied by TM The following items shall be supplied by Pengurusan Bahan:i. HDPE Corrugated Subduct for optical cable. (Completed with draw rope pre-installed). ii. Flange holder (PVC Plate B). iii. End cap. iv. O-ring.

2.2

Items supplied by Contractor i. Tape PVC 19mm self adhesive ii. Cotton waste iii. Adhesive iv. Mechanical aids and tools for laying of subducts.

2.3

Quality of materials All materials unless otherwise specified are to be accordance with the British Standard Instruction or its equivalent in so far as those specifications apply.

3. INSTALLATION PROCEDURE 3.1

Preparation of worksite and manhole Work procedure shall be as described for normal cable laying. Refer to specification Lines WE 303.


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Specification Lines WE FO 001 Issue April, 1995 3.2

Preparation of ducts Ducts should first be cleared of obstructions. Rodding of allotted ducts (avoid blocking of entry to other ducts) should be done using rod sweep cane, PVC rods or any approved equipment. Clean the ducts by using mandrel cutting, brushes and cleaning disc and remove obstructions where encountered. The test mandrel used for testing shall be 457mm in length and 83mm in diameter, the cylindrical brush shall be 108mm in diameter. All duct ends must be intact and straight.

3.3

Preparation of subducts i)

3.4

3.5

Prior to laying, three (3) subducts shall be bunched together by wrapping tightly with three layers of adhesive tape at every 1.5 meter along the bunch as shown in Fig. 1.

Laying of subducts into ducts 3.4.1

Drawing of subducts into duct is done by manual pulling in the direction of main duct joints. The allowable maximum pulling tension is 80 KN.

3.4.2

Both duct and manhole entrance must have subduct protector as protection for the HDPE corrugated subducts when pulling.

3.4.3

Ensure that subducts are not twisted during pulling by attaching swivel to the pulling end as shown in Figure 2.

3.4.4

All three subducts must be pulled at the same time.

3.4.5

Cutting subducts i.

Ensure sufficient nylon rope for pulling optic cable before cutting the subducts of the required length.

ii.

Subducts shall only be cut at right angles to the bore with a sharp blade around the subduct according to the requirements of the work and ensure no deformation during cutting.

Termination of subducts at the manhole i.

Insert an O-ring over each subduct 70 mm from its ends.

ii.

Insert the three subducts into PVC plate B.

iii.

Secure PVC plate by bolting two of its diagonal corners to the manhole wall.

iv.

Again insert the O-ring over the subducts at the front of the plate and ensure that the plate is closely fitted to the duct entrance.


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Specification Lines WE FO 001 Issue April, 1995 v.

Make a 1 inch slit at the side of each subduct mouth and slide the end of nylon rope to prevent it from moving into the subduct before closing with the end cap.

vi.

Ensure end caps ere tightly fitted to the subduct mouth.

Refer to Figure 3 for the arrangement of accessories at manhole. Two PVC plates, twelve O-rings and twelve (depending on quantity of spare subducts) end caps are required in each manhole. 3.6

Termination of subducts at cable chamber 3.6.1

4.

5.

Follow procedure 3.4 (i) to (iii). Then, subducts must be cut in line with the duct mouth as shown in Figure 4.

ACCEPTANCE TESTING 4.1.

On completion of the subduct line between any jointing chambers or sites thereof, test each subduct lines by using a mandrel as shown in Figure 5. Installation can only be approved once a complete length of subducts is installed with the complete accessories and sufficient nylon rope for further cable installation is available.

4.2.

All installation shall be carried out in the presence of the Superintendent Officer and if any obstruction or defect is discovered, it shall be rectified forwith to his satisfaction.

END CAP SOCKET After every subduct lines are installed and tested, fix the end caps to the subduct ends for protection. The end caps shall be removed for cable installation.

6. Figure 6 shows the installation of a subduct section.


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SECTION V

INSTALLATION OF OPTICAL FIBRE CABLE INTO SUBDUCTS

CONTENTS

NO.

PAGE

1.

GENERAL

1

2.

TOOLS AND MATERIALS

1

3.

PRECAUTIONS

3

4.

METHOD OF CABLE LAYING INTO SUBDUCTS

5

5.

LABELING

12



INSTALLATION OF OPTICAL FIBRE CABLE INTO SUBDUCTS

1.

GENERAL This specification describes the practices for optical fibre cable installation in subducts and the precautions taken during its handling. Its jointing and splicing specifications are described in Section IX and X respectively.

2.

TOOLS AND MATERIALS The following main tools and materials (with their usage) are required for installation of optical fibre cable into subduct.

2.1.

Tools & devices

No.

Tools & Devices

Usage

1

Safety Cone.

Traffic safety device or warning.

2

Barrier & Barricades.


3

Flags.


4

Canvas Tent & Frame G.I.

For workmen working shade.

5

Flashing Light.

Traffic warning device at night.

6

Manhole Key.

For opening the manhole cover.

7

Gas Detector.

8

Water Pump.

To detect any dangerous gases present in manhole. To pump out water in manhole.

9

Portable Generator.

10

Exhaust Fan/Blower.

To supply electrical power (e.g. for a blower power supply) To send in fresh air into the manhole.

11

Cable Jack

For cable drum jacking.

12

Rodding Tools (PVC Type). For rodding through a duct or subduct.

13

Cable Cutter.

To cut the cable neatly and easily.

14

Cable Grip.

To grip the cable pulling end.

15

Shackle.

To connect the cable pulling end and the pulling


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Specification Lines WE FO 001 Issue April, 1995 No.

Tools & Devices

Usage rope.

16

Swivel

To prevent cable twisting during pulling work.

17

Pulling rope.

For pulling the cable.

18

Cable Roller

To guide cable into duct or subduct.

19

To prevent the cable or duct socket from damage when pulling cable into duct/subduct. To measure the pulling tension.

22

Cable Protecting Bend (cable guide). Tension Meter (Dynamometer). PVC Sheeting (6m x 3m). Transceiver/Walkie talkie.

23

Pliers, cutting nippers, etc.

20 21

2.2.

For cable protection while working on “Figure 8”. To communicate between positions of cable sending and pulling ends during cable laying work. General usage.

Materials

No

Materials

Usage

1.

PVC Tape.

For protection of cable grip and installation or miscellaneous use.

2.

Galvanized Iron Wire.

For binding the cable grip and installation or miscellaneous use.

3a.

Cable Bracket of Fixed Type (Cable Bearer). For supporting the optical fibre cable in the manhole.

4.

Cable Bracket of Sliding Type (Cable Bearer Bracket). Closure Supporting Plate.

5.

Anti-Floating Device

To prevent the Cable Bearer Bracket from moving (floating).

6a.

Cable Tie #3

For fixing optical fibre cables to the cable bearer bracket. Also used to secure both ends of marking tape wrapped around optic cable.

b.


To support the joint closure on the Cable Bearer Bracket.

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Specification Lines WE FO 001 Issue April, 1995 No

3.

Materials

b.

Cable Tie #6

7. 8.

Protection Tubes (Helically Coiled) Orange Marking Tape

9.

Cotton Waste

Usage For fixing the joint closure to the closure supporting plate For protection of fibre cables carrying heavy traffic and important circuits. To differentiate fibre optic cables from copper cables. For miscellaneous use.

PRECAUTIONS 3.1

Handling of optical fibre cable drums a)

During loading or unloading, cable drum must not be subjected to any severe shock or damage and not to be rolled freely down a slope.

b)

Drums shall never be rolled at any distance for the purpose of transportation except for short movements around a manhole or cable jointing place. For short movements, drums shall always be rolled in the direction of the arrow marked on their flanges or battens.

c)

3.2

Drums shall always remain battened until just before the beginning of actual cable installation work.

Allowable tension and laying speed Cables shall be laid not exceeding a specified pulling tension. During cable installation, do not jerk the cable or stop immediately during pulling, but it shall always be kept under uniform pulling tension.

3.2.1

Allowable tension A maximum pulling force for the present contracts (Tomen,


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Marconi/Hesfibel , Opcom and Perwira Ericsson) are stated below: CONTRACT

NO. OF CORES

MAX. PULLING FORCE

TOMEN

4, 6, 8, 12, 24, 36 & 48

1.7 KN

MARCONI/

4, 6, 8, 12, 24, 36, 48 & 96

1.1 KN

OPCOM

4, 6, 8, 12, 24, 36, 48 & 96

2 KN

PERWIRA

4, 6, 8, 12, 24, 36, 48 & 96

2.5 KN

HESFIBEL

ERICSSON Table 1

3.2.2

Adjustment of pulling tension Pulling force shall be handled by manual manpower or a suitable pulling equipment such as fibre cable winch. During cable pulling the tension between the head pulling end and intermediate pulling end shall be synchronised where communication among workmen in manhole sections can be done by using transceivers.

3.2.3

Laying speed The laying speed shall be less than 15 m/min.

3.3

Permissible cable bending radius Optical fibre cable shall be handled very carefully and keeping as large a curvature as possible. During cable laying, the minimum bending radius of cables shall be more than 20 times of the outer cable diameter. When setting the cable, the bending radius may be reduced to 10 times the outer cable diameter.


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3.4

Length of cable end for jointing Before cutting the fibre cable, sufficient overlap length of 150 cm shall be given for jointing cable ends. See Fig. 1.

4.

METHOD OF CABLE LAYING INTO SUBDUCTS

4.1

Checks and investigations before cable laying The following tasks shall be performed before starting of cable laying:4.1.1. Confirmation of manhole Confirm the position, type and span of the manholes with the related subduct plans.

4.1.2. Preparation of worksite manhole. a)

Place the manhole guards, safety devices and warning sign such as fences, safety cones, flashing lights, red flags, sign posts, etc. around manhole before removing the manhole covers.

b)

When working in manhole, the first warning notice should be placed at 70 to 100 metres from hazard, but on high speed roads, it should be 100 to 200 metres ahead. Where one half of a high speed road is closed, it should be 400 to 500 metres ahead. Position the flagmen when necessary.

c)

Test for the present explosive gases, asphyxiating gases, toxic gases and stagnant water in manhole by using a gas detector or other suitable means. If required, necessary actions (before workmen enters the manhole) shall be taken for easy and safe work performance as follows: i.

Pumping water out of manhole and cleaning.

ii.

Ventilation to get rid of harmful gases.

4.1.3. Identification and confirmation of duct and subduct.


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Specification Lines WE FO 001 Issue April, 1995 a)

Check the position of duct and subducts where cables are to be installed.

b)

Confirm the draw rope (nylon rope for corrugated subduct) is installed. i. Cable test-piece passing (as described below) should be done if draw rope is available. -

A cable test-piece passing having the same diameter as the outer cable diameter or more with a length of about 2 m is passed through the subduct to check the degree of scratches received by the sheath of the cable test-piece. The cable test-piece is coated with black enamel to facilitate easy inspection for scratches. Also swivels are attached to it at both ends. The inspection results gives a basis for the judgement of subduct conditions and whether the cable can be laid into the subduct smoothly or not.

ii. If the draw rope is not available, rodding process should proceed as follows before cable test-piece passing is done. -

When the top end of the rod (e.g. rigid PVC pipes) reaches an adjacent manhole, a pulling rope is attached to their tail end. This pulling rope shall be passed through the subduct by pulling the rod out of the subduct.

-

For a short section duct, rodding may be achieved with a pulling rope directly inserted into the subduct.

Suitable remedial measures such as alteration or repair should be taken after consultation with the Superintendent Officer when it is impossible to perform rodding due to a damaged or clogged duct or subducts, having a level difference, etc. 4.1.4. Existing cable rearrangement Due to changes in bends, fixing positions or other works in a manhole, the existing cable shall not be rearranged unless necessary. Adequate protective measures shall be taken as required for existing cables installed in the relevant manholes.

4.1.5. Cable drum confirmation


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Specification Lines WE FO 001 Issue April, 1995 The cable drum number, cable piece length, cable size and cable pulling end (clockwise and counterclockwise) shall be confirmed by comparing with straight line diagram or other related design drawings. 4.2.

4.3.

Positioning of cable drum a)

The cable drum setting position is determined when considering the cable laying direction. The cable drum shall be placed on the same side of the manhole as the cable laying direction, and in line with the duct/subduct so that the cable can be reeled-out into the sub-duct in a smooth curve without being kinked. Figure 2 shows the setting position for a cable drum.

b)

The cable drum is jacked up using cable jacks. It is important to make the drum shaft horizontal by adjusting the cable jacks.

c)

The firmly fitted battens on the cable drum shall be removed carefully to prevent cable damage.

Attachment of pulling rope to cable end The running end of a cable is called the pulling end which must endure the pulling tension. The method of attaching the pulling end is classified into the categories according to the type of cable used as follows: a)

For a pulling end not provided with pulling eye, a cable grip, shackle, swivel and a pulling rope are attached as shown in Figure 3a. The cable grip and tension member in a cable should be embodied together to keep allowable pulling tension of fibre cores.

b)

For a pulling end provided with a pulling eye at the cable factory or at installation site, a cable grip is not used. A shackle, a swivel and a pulling rope can be attached directly to the pulling eye as described in Figure 3b. To prevent cable twisting during cable laying, a swivel should always be used in the position between the cable grip (or pulling eye) and the pulling rope.

4.4.

Cable laying 4.4.1. Liaison arrangement


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Specification Lines WE FO 001 Issue April, 1995 During cable laying, liaison men should be placed between the lead-in and take-out manholes to maintain close communication by using transceiver or other device to cope with the cable laying work. 4.4.2. Reeling-out cable a)

When reeling-out cable, use cable roller at the lead-in manhole and cable protecting bend (cable guide) at the subduct mouth for cable protection as illustrated in Figure 4.

b)

The presence of cable damage should be carefully checked while the cable is being reeled out.

4.4.3. Laying method. There are three methods of laying the optical fibre cable(as described in Figure 5): i. ii. iii. 4.4.3.1.

Unidirectional pulling. Bi-directional pulling. Intermediate manual pulling. Unidirectional pulling This method is applicable for pulling short length of cable within 1 km. It can be pulled manually or by using an automatic mechanism such as fibre cable winch. a. Manual pulling method To pull optic cable manually, workmen shall be placed at every manhole to assist the pulling operation under the specified pulling tension (as described in Table 1) towards the splice location. In this case, preparing cable in the form of ‘Figure 8’ is not required. b. Automatic pulling method (using fibre cable winch) This method is still under feasibility study. When the method is found suitable and approved, the detail work procedure and the relevant specification will be added.

4.4.3.2.

Bi-directional Pulling This method is recommended for considerably complicated cable routes having curves or level difference of subducts at


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Specification Lines WE FO 001 Issue April, 1995 pull through manholes and installation of cable lengths greater than 1 km. a. Bi-directional pulling method i. Place the cable drum at the midpoint of the cable length (to be located at the nearest manhole). ii. Pull the cable towards one of the splice locations into subducts in continuous operation. iii. Uncoil the shorter cable length for the second pull on a PVC sheeting placed on the ground in the form of ‘Figure 8’ on top of the other so that cable is not twisted and damaged. A suitable space measuring about 6m x 3m is necessary for uncoiling the cable. This operation is shown in Figure 6. iv. Pull the cable end of the uncoiled cable into the opposite direction.

4.4.3.3.

Intermediate manual pull This method is recommended for pulling cable in straight route and distance greater than 1 km by using manual pulling method. However, the other method is by using an automatic mechanism as described in ‘4.4.3.1.b’ above. a. Manual pulling method: i. Place the cable drum at the end of the cable length (to be located at the nearest manhole. Refer to Fig. 2). ii. Attach the pulling rope to the cable end. iii. Pull the cable towards one of the splice locations into subduct in continuous operation. iv. After pulling the cable through four or five manholes (average of 1 km distance), make ‘Figure of 8’ until all the cable is uncoiled. v. Pull the cable towards the splice location as described in para a(iii). For the cable length is greater than 2 km per drum, repeat the procedure as described in para a(iv).


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A manual pulling method is as shown in Fig. 7.

4.4.4. Checks and treatment after cable laying: a.

Storing excess cable After the cable length has been laid into the subduct, sufficient excess length for jointing, testing and restoration should be stored at each jointing manholes.

The formula for cable allowance calculation for each cable end is as follows: No.

Location

Formula

1.

Jointing manhole

3L + 2W + H

2.

Pull-through manhole

2H + L

3.

Pull through manhole (Potential growth areas) 3L + 2W + 2H

where,

b.

L = length of manhole/joint box W = width of manhole/joint box H = height of manhole/joint box Cable setting in manhole The cables should be set in the manhole in conformity with the following principles:i.

Cables entering/leaving the manhole should be avoided from crossing and cables shall be given a well protected position (refer to Figure 8 and 9).

ii.

During positioning of cables, bend when required and with careful attention given to the permissible bending radius.

iii.

When bending cable, the following cable length should be kept straight. - minimum 6 cm from a duct inlet. - minimum 6 cm from a cable joint end.


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Specification Lines WE FO 001 Issue April, 1995 iv.

All cables passing through manholes must be tied together to the cable bearer bracket by using cable tie no. 3. Refer to Figure 9.

v.

A cable joint should be kept horizontal as much as possible.

vi.

At jointing manhole, four additional cable bearers (to be installed at both end walls) must be installed to support the cable.Refer to Appendix I for its details. Lay and tie the cable on the bearer bracket by using cable tie no. 3. Refer to Figure 8.

vii.

When a cable joint is partially located to one side of a manhole, the space between the cable joint end and the duct inlet should be kept at more than 60 cm.

viii.

A supporting plate shall be used to support the jointing closure which is placed between cable bearer brackets. The jointing closure is then tied to the supporting plate using cable tie no. 6.

ix.

An anti-floating device must be attached together to the cable bearer bracket to prevent the cable bearer bracket from floating during water level rise inside the manhole.

x.

In manholes constructed at both ends of a bridge, cable slack of more than 100 cm long should be provided to absorb cable creep caused by the expansion and contraction of the cable laid over the bridge because of temperature variations.

xi.

Anti-creepage devices shall be installed when necessary (along highways and hill stations) to prevent cable creepage.

xii.

The cable entries at cable chamber shall be sealed after each cable installation with duct sealing ring or duct plug/ SVT blocks (Isolectra contract - K 46920084) .

xiii.


In manholes or cable chamber which have many fibre cables (carrying heavy traffic and important circuits), the optical fibre cable shall be protected using helically coiled protectors or its equivalents at the required lengths such as at jointing closure, from subduct to cable bearer or other parts when necessary. For easy identification of optical without protection tubing, an orange marking tape shall be

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Specification Lines WE FO 001 Issue April, 1995 wrapped around the cable throughout its length in the manhole. See Figure 10. 4.4.5. Site clearing After cable laying and its treatment have been completed, the road surface and warning signs must be removed. Cart away all rubbish made after completion.

5.

LABELING Optical cable installed in manholes, cable chambers (both at entry and leaving points and every 10 m apart), carrier room and SDF room must be marked. The marking tag shall be made of metallic or plastic (waterproof) material. It shall be fitted 7 cm away from cable joints. The example of the marking tag drawing is shown in Figure 11. The marking tag shall consists of the following particulars: a) Type and size of cable b) Route name c) Contract number d) Date of installation e) Cable section code.

Note: Cable section code comprises of: a) Network code i.e. Nxx - where, ‘x’ is numeric b) Cable section number (Refer to Planning Specs PL 0301)


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TELEKOM MALAYSIA BERHAD SINGLE MODE OPTICAL TYPE FIBRE CABLE SIZE

12 CORES

ROUTE NAME

TAR – WISMA BERNAMA

CABLE SECTION CODE

N01 – 9

CONTRACT NUMBER

K 1062/91

DATE OF INSTALLATION

20 JAN 1993

FIG. 11 : SAMPLE OF MARKING TAG

Appendix I-a


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STANDARD ACCESSORIES REQUIRED FOR BOTH EXISTING AND NEW MANHOLES

The drawing of the specified height (H) and length (L) of accessories in Tables 1 and 2 shall be referred to figure 8a. Side Wall

Manhole Type H1

End Wall L1

H2

L2

JC9 & JC9C

800 mm

245 mm

240 mm

167 mm

R1B(M) & R2A

1280 mm

345 mm

560 mm

245 mm

R2A(M) & above

1280 mm

500 mm

560 mm

345 mm

Table 1 : Cable bearer and cable bearer brackets for existing manhole

Manhole Type

Side Wall H1

End Wall L1

H2

L2

JC9 & JC9C

800 mm

245 mm

240 mm

167 mm

R1B(M) & R2A

1520 mm

345 mm

560 mm

245 mm

R2A(M)

1520 mm

500 mm

560 mm

345 mm

Table 2 : cable bearer and cable bearer brackets for new manhole

Material requirement :-

a) High quality mild steel b) The surface shall be smooth and continuously hot-dip galvanised according to B.S. 729 with minimum thickness of 86 microns. Appendix I-b

Note :-

1.

For existing manholes, cable bearers and cable bearer brackets specified in Table 1 shall be installed above the duct nest whenever is required.


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Specification Lines WE FO 001 Issue April, 1995 2.

For new manholes, cable bearers and cable bearer brackets specified in Table 2 shall be installed above the duct nest as basic accessories.

3.

The cable bearer and cable bearer bracket sizes are as follows:Cable bearer

a) b) c) d) e)

Type 1 = Type 2 = Type N1 = Type N2 = Type N3 =

800 mm 1280 mm 240 mm (new) 560 mm (new) 1520 mm (new)

Cable bearer bracket

a) b) c) d)

Bracket No. 6 = 167 mm Bracket No. 8 = 245 mm Bracket No. 12 = 345 mm Bracket No. 8 = 500 mm


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SECTION VI

INSTALLATION OF AERIAL OPTICAL FIBRE CABLE

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

TOOLS AND MATERIALS

1

3.

GENERAL PRECAUTION

2

4.

SITE PREPARATION BEFORE INSTALLATION OF AERIAL CABLE

3

5.

TECHNICAL REQUIREMENTS FOR CABLE ERECTION

3

6.

PRECAUTIONS DURING INSTALLATION PROCESS

4

7.

PROCEDURE OF INSTALLATION

5

8.

TERMINATION OF IB OPTICAL CABLE

6

9.

TENSIONING AND SAGGING

6

10.

INSTALLATION OF AERIAL CABLE JOINT

7

11.

INTEGRAL BEARER WIRE EARTH SYSTEMS

8

12.

LABELING OF OPTICAL FIBRE CABLE

9


Specification Lines WE FO 001 Issue April, 1995 INSTALLATION OF AERIAL OPTICAL FIBRE CABLE

1.

GENERAL The specification below describes the details of installation of aerial optical fibre cable and the precautions to be taken during installation of the cables to avoid any mishandling and damaging of optical fibre cable. Its jointing and splicing procedures are described in Section IX and X respectively.

2.

TOOLS AND MATERIALS The following main tools and materials are required for aerial IB optical fibre cable installation. 2.1. No.

Tools Tools & Mechanical Aids

Usage

1.

Cable Cutter.

2.

Bearer Wire Grip.

For cutting cable or bearer wire of optical fibre cable. To grip bearer wire cable for tensioning.

3.

Cable Grip.

To grip the cable pulling end.

4.

Swivel.

To prevent twisting when cable is installed.

5.

Cable Pulley no. 2. Cable Pulley no. 4.

6.

Pulling Rope.

For reducing the stress on the cable while tensioning at intermediate and corner poles. For pulling the cable.

7.

Cable Jacking

For cable drum jacking.

8.

Cable Trailer.

For carrying cable drum to the site.

9.

Crowbar.

For temporary anchor when tensioning the cable.

10.

Dynamometer / Tension Meter.

To measure cable tension.

11.

Tirfor TU 16 Machine.

For tensioning of IB optical fibre cable.

12.

Cable Tensioning Hoist.

12.

PVC Sheeting. (6m X 3m)

For tensioning short spans of cable termination. For holding tensioned cable temporarily. For cable protection while working on “Figure 8”.


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2.2 No.

Materials

Usage

1.

PVC Tape.

2.

Bracket Tabular Pole

For protection of IB optical fibre cable sheath and for miscellaneous use. For mounting of IB cable suspension clamp to pole.

3.

Cable Clamp.

For holding the optical fibre bearer wire on pole.

4.

Steel Clamp.

For clamping GI pipe (riser) to pole.

5.

Support Hook.

6.

Thimble Small Open.

7.

Preformed Grip.

8.

Preformed Splice.

For mounting of IB cable clamp to bracket tabular pole. To attach the IB optical fibre cable bearer wire with bracket tabular pole. To anchor the bearer wire of IB optical fibre cable on the bracket tabular pole. To joint the bearer wire. To joint the bearer wire of IB optical fibre cable.

9.

Openable Wire Jointing Connector. Line Spacer (Steel type).

10.

11. 12.

3.

Materials:

Cable Tie no. 3 Cable Tie no. 6 GI Support Wire

For connecting bearer wire to earth. To hold optical cables at jointing locations and prevent the cable from swinging and twisting during strong wind. For tying cable at termination points. For tying jointing closure at termination points. To support jointing closure between pole span at jointing point.

GENERAL PRECAUTION To reduce the pulling tension, bi-directional pulling in the form of ‘Figure 8’ is chosen for the installation of aerial optical cable. When working on ‘Figure 8’, a PVC sheeting with minimum size 6m x 3m shall be used to protect the cable from damage. Fig. 1 shows this operation. Other general precautions are similar to the laying of optical fibre cable into sub-ducts.

4.

SITE PREPARATION BEFORE INSTALLATION OF AERIAL CABLE


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5.

i.

Provide the safety guards and warning sign in order to provide safeguards and warning for pedestrians and vehicles.

ii.

Where the aerial cable route is expected to pass over private land, get the owner's agreement in advance and care should be taken to minimise their inconvenience.

iii.

Before erecting cable all permanent staying must be completed, fit temporary stays where necessary at intermediate terminating points. Ensure that all poles are safe to climb.

iv.

Fit the necessary fittings on the poles and place cable pulleys with the opening sides as near as possible to the pole fittings.

v.

Note the location of all power wires crossing the route and take the necessary precautions to ensure safe working condition during erection of the cable.

TECHNICAL REQUIREMENTS FOR CABLE ERECTION i.

Aerial cable shall be suspended on the side of the pole facing the road. New cable shall be suspended underneath the existing cable on pole line. In case of new pole, the aerial cable shall be suspended 230mm from the top of the pole (first hole of concrete pole).

ii.

The minimum clearance from the ground to the lowest point of the cable at the different locations stated below shall be as follows:NO

LOCATION

MIN. DISTANCE

1.

Along road.

4.5 m.

2.

At road crossing.

5.5 m.

3.

At railway crossing.

6.7 m above rail

4.

From power cables : a) Less than 600 Volt b) More than 600 Volt

60 cm. 200 cm.

Table 1 iii.

The allowable sag of optical fibre cable for average span of 40 to 50 meters shall be up to 1 meter (2% of the span length) between the poles. Note:In the case of using Kevlar optical integral bearer cable, the span between the poles shall be according to the specified recommendation by the supplier.


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Specification Lines WE FO 001 Issue April, 1995 iv.

The erection tension shall be selected so as not to exceed 50% of the tensile strength of the suspension strand under the most unfavorable loading conditions. A maximum pulling force for the present contracts (Tomen, Marconi/Hesfibel Opcom and Perwira Ericsson) are stated below: CONTRACT

NO. OF CORES

MAX. PULLING FORCE

TOMEN

4,6,8,12,24&36

8 KN

MARCONI/HESFIBEL

4,6,8,12,24&36

1.1 KN

OPCOM

4,6,8,12,24&36

15 KN

PERWIRA ERICSSON

4,6,8,12,24,36&48

9KN

Table 2

6.

7.

v.

Suspension strands (bearer wire) shall be electrically continuous throughout the cable length.

vi.

Splicing shall be carried out immediately after placing the cable. The splices shall always be located in the vicinity of the pole.

PRECAUTIONS DURING INSTALLATION PROCESS i.

Uncoiled fibre cables shall always be lifted up when carrying it. Do not drag cables on the ground, nor contact the fibre cable with power lines, trees, buildings etc. during erection. When working near power lines adequate safety measures should be taken.

ii.

All cables shall be handled with care to avoid damaging the insulation. Do not tread on cable, pull over rough ground, fences or run over it with vehicles.

iii.

The laying speed shall be lower than 15 meter per minute. The bending radius of cable should be kept at more than 20 times the outer cable diameter.

PROCEDURE OF INSTALLATION The length of cable laid depends upon the span lengths, terrain and other field conditions. However, in straight sections, a maximum of seven spans or approximately 350 meters shall usually be laid at any one time.


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Comment [x1]:

Specification Lines WE FO 001 Issue April, 1995 A supervisor must be positioned to places where abrasion against buildings, trees, ground and especially power lines is anticipated. It is recommended to plant another pole or take other adequate counter measures in such places. i.

There are two methods of placing the cable drum: a. The cable drum is placed on vehicle/cable trailer. As the vehicle moves along the road side, the cable pulling end is carefully uncoiled and laid onto the ground. The cable shall be carefully lifted by hand. It must not be dragged along the road or run over by other vehicles. b. For a cable drum length of 3 km and straight route, place the cable drum at the midpoint of the cable length. Carefully pull the cable towards one of splice location, then make a ‘Figure of 8’ until all the cable is uncoiled.

ii.

The cable is raised and placed onto the pulley which is attached to the pole manually (as in Figure 2).

iii.

Terminate the free end (pulling end) of the cable and ensure sufficient length is available for testing and splicing as described in para 8 below.

iv.

Using a Tensioning Hoist or Tirfor TU 16 Machine with Dynamometer, follow the procedure as described in para 9 for cable tensioning and sagging.

v.

Fixing of Bearer Wire to cable clamp. Bearer wire shall be fixed to the cable clamp as follows:-

8.

a)

Insert the bearer wire to the bearer wire fixing groove provided in the clamp.

b)

Tighten it with two clamp bolts.

c)

Fix the fitting bolts to the clamp as shown in Figure 3.

d)

Fix it to the support hook attached to bracket tubular pole as shown in Figure 4.

TERMINATION OF IB OPTICAL CABLE At the end of cable installation, terminate the bearer wire with preformed grip as shown in Fig. 5(a) and 5(b) at the following: a.

Beginning and the end of route;


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b.

Distribution poles;

c.

Angle poles where deviation of the route is greater than 45o;

d.

All river and railway crossings;

e.

Poles where two cables are jointed;

f.

Each end of isolated long spans greater than 200 m.

8.1

Through double termination The bearer wire is terminated on both sides of pole with thimbles and preformed grip. Whenever possible, the IB optical fibre cable is terminated without cutting the cable as shown in Figure 6.

8.2

Connection of Bearer Wires. When connecting the bearer wires of IB optical fibre cable, use a preformed splice or preformed grip as shown in Fig.7(a) and 7(b).

9.

TENSIONING AND SAGGING i.

ii.

The procedure of cable tensioning shall be as follows: a.

Ensure that the bearer wire at the starting point is first terminated with preformed grip as in Fig. 5b.

b.

After binding the pulling rope on the top of the pole and grasping the bearer wire with a cable grip, attach cable tensioning hoist (as shown in Figure 8) between the pulling rope and cable grip. Refer Fig. 9.

c.

The metal pulleys shall remain on the poles except those at the starting and ending points. Tensioning of the bearer wire shall be controlled by the cable tensioning hoist until a balanced tension can be obtained as specified in Table 2.

d.

In order to obtain the correct sag of each span, measure the depth of the sagging and adjust the tension with the cable tensioning hoist by repeating it several times.

For a long section of termination, attach the Tirfor TU 16 Machine and Dynamometer as illustrated in Figure 10 for tensioning the cable.


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Specification Lines WE FO 001 Issue April, 1995 iii.

After completing the tensioning work and tearing the bearer wire from the cable web at the ending point, the preformed grip shall be stranded firmly on the peeled bearer wire in same manner as mentioned in para 9(i) above.

iv.

Removing of all temporary stays, struts and pulleys. The maximum pulling force of optical fibre cable for aerial installation, 4 to 48 cores must follow the specified force as in Table 2.

10.

INSTALLATION OF AERIAL CABLE JOINT The three major activities are as follows: a. b. c.

Preparation of sufficient cable length for jointing. Fixing of support wire for holding jointing closure. Installation of jointing closure.

10.1.

Excess cable for jointing. In this case, sufficient cable length must be left for jointing as shown in Table 3 and Figure 11. Extra Length on Light-Source side

1300 cm

Extra Length on Light-Receiving side

1400 cm

Table 3 10.2

Fixing support wire for holding jointing closure. a.

Install bracket tabular poles and stays 50 cm below the aerial cable at both poles of the jointing position.

b.

Fix GI stranded supporting wire between the poles and securely fasten to the poles.

Refer to Fig.12. 10.3

Install joint closure. Splicing is performed at ground level. Method of splicing is similar to other splicing of optical cables. (Refer to Section X for splicing of fibre ends). After IB optical fibre cable is jointed, the closure is brought up and tied to the support wire about 50 cm below the aerial cable by using cable tie no.6.


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Specification Lines WE FO 001 Issue April, 1995 The extra maintenance length cable is arranged in a loop formation and a steel line spacer is installed on both sides of closure to prevent cable bending beyond permissible radius. The fixing of closure is as shown in Figure 13.

11.

INTEGRAL BEARER WIRE EARTH SYSTEMS i.

The importance of earthing system for aerial optical cable installation is to prevent power surge along the metallic conductor at both ends of a cable route and jointing locations.

ii.

The required grounding locations shall be as follows:a. b. c. d.

iii.

Dead-end or terminal pole Poles holding supporting wire for jointing closures At every interval of approximately 250 m Other locations than those mentioned above where grounding is considered to be necessary from the electrical point of view.

Jointing the bearer wires at terminating points. The bearer wires on either side of a terminating point shall be jointed to each other to provide the necessary continuity. The connection could be done by a suitable size openable wire jointing connectors, type HD 10 or HD 12A.

iv.

12.

Connecting earth wire to bearer wire. a.

Connect `tail' of bearer wire to an earth wire 7/1.04 mm (tinned) with a suitable size bimetallic openable wire jointing connector as shown in Fig. 14.

b.

At the identified earthing locations, slide the bearer wire through the riser to the earth.

c.

At the existing copper route, earthing can be done by connecting the optical fibre bearer wire to the copper bearer wire.

LABELLING OF OPTICAL FIBRE CABLE All optical fibre cables should be labeled using the identification tag (collet) so that they can be easily identified.


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12.1

Label information. The label should contain the following information: i. ii. iii. iv. v.

Type and size of cable. Route name. Contract number. Date of installation. Cable section code.

Note: Cable section code comprises of: a) Network code i.e. Nxx - where, ‘x’ is numeric b) Cable section code 12.2

Fixing of labels The labels are fitted at: i. ii. iii. iv.

Starting points. Every 350 meters or 7 spans (both sides). Every jointing points. Ending points.


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SECTION VII

INSTALLATION OF DIRECT BURIED OPTICAL CABLE

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

PRECAUTIONS

1

3.

ROUTE DESIGN

2

4.

TRENCHING

2

5.


3

6.

CABLE LAYING INTO TRENCH

5

7.

JOINT BOX

8

8.

CABLE JOINT

8

9.

EARTHING

8

10.

ARMOURING TREATMENT

8



INSTALLATION OF DIRECT BURIED OPTICAL CABLE 1.

GENERAL This section describes the methods and practices used in direct buried optical cable installation. This application is mostly used in providing services to rural areas.

2.

PREPARATIONS AND PRECAUTIONS The following preparations shall be made and precautions taken when installing direct buried optical cables. 2.1.

Permits Permits shall be required for the following works: a) b) c) d) e) f) g) h)

2.2

Excavation of land belonging to the highway authorities, local authorities and other road authorities. Excavation of private land. Temporary use of the roads or private land for construction work. Blasting (At Rocky Terrain). Jacking pipe under streets or railway. River or stream crossing. Bridge crossing. Temporary traffic close/diversion.

Safety a)

While excavation or cable laying work along or across highways, streets or alleys, special care must be taken to minimise traffic interference. It may be necessary to provide adequate structure to support ground opening suitable for any traffic which is likely to pass over it.

b)

All ground openings, construction materials, excavated soils, cable drum, machinery on streets, highways or other accessible locations shall be protected with standard warning devices, in compliance with the requirement of the Police Department, Public Works Department, the municipality or any local authority and the Rules of Traffic Ordinance 1958.


Page VII-1

Specification Lines WE FO 001 Issue April, 1995 c)

3.

Workmen working on the roadway shall wear blazed orange vests to alert traffic. All vehicles parked near the workmen must have suitable warning devices such as flashing or rotating amber lights.

ROUTE DESIGN Detail route survey is required to ascertain the following points in order to ensure smooth execution of the project. 3.1.

Location Select a permanent location for buried plant and consider factors such as right-of-way limitations, soil type, natural obstacles, other utilities and services, future road expansion and natural land movements. It is important to select cable routes on the same side of the road but opposite of power cables. As far as possible avoid crossing the road frequently.

3.2

Test Digging (Pilot holes) After confirming the cable route, test digging shall be executed along the route at every corner and at the places where other underground facilities are likely to exist.

3.3

Measuring Route Length After recognising the condition of the existing underground facilities, the suitable digging position must be determined.

4.

TRENCHING Trenching is usually the method used in areas where other buried facilities are located.

5.

4.1.

The machineries required for underground cabling such as excavators, trenching machines shall be decided according to local conditions including soil types.

4.2.

At the start of construction, verify clearly defined object such as edge of curb, pole, fire hydrant etc. for the centre line of excavation. Then indicate the direction and distance on the blue print.

4.3.

Before starting burying operations, avoid exposing or making contact with the underground facilities belonging to third parties.



Page VII-2


5.1.

Dimension of trench The size of trench shall have the following dimension:

Width Depth 5.2.

5.3.

5.4.

Normal Soil 20cm 80cm

Rocky Terrain 20cm 60cm

Installation in normal soil 5.2.1

In normal soil condition the optical cables shall be buried to a depth of 80cm and UPVC / concrete (complete with marker tape) slabs (as shown in Figure 1(a) and 1(b) or 1(c)) shall be buried continuously at a depth of 30cm below ground level along the cable length.

5.2.2

Cover the bottom of trench with 10cm sand before laying optical cable. Then fill up another 10cm to a total 20cm thick.

5.2.3

Backfill the trench with excavated earth free from stones and carefully compact it around the cable. Refer to Fig.2(a). Refer to Specification WE 304 - Construction of manholes, jointboxes and laying of ducts for definition and quality of soil.

Installation in Rocky Terrain 5.3.1.

Extreme care shall be taken when burying optical cable in rocky terrain. Avoid contact with rocks, stones and other similar heavy and sharp objects in the trench.

5.3.2.

The bottom of trench shall be covered with sand before laying the cable and cover the cable again with sand to a depth of 20cm from the bottom of trench. Refer to Fig. 2 (b).

5.3.3

In places where the original depth cannot be maintained for a long period, uPVC slabs shall be laid halfway in between ground level and sand. See Figure 2 (b).

Protection of Optical Buried Cable against existing utilities Before laying cables along highways or ordinary roads protective measures must be taken to protect the cable against damage at the crossing over water culverts and existing utilities such as water mains, sewage, etc. especially when digging the soil around them. i.

Where burying depth is between 40cm to 80cm, a layer of UPVC/concrete slabs shall be laid 30cm above the cables. The minimum clearance


Page VII-3

Specification Lines WE FO 001 Issue April, 1995 between optical fibre cable and the culvert shall be 15cm as shown in Fig. 3(a). ii.

In places where burying depth is between 20cm to 40cm, optical fibre cable is laid in 1 inch GI pipe until reaching the depth of 80cm as shown in Fig.3 (b). The minimum clearance between culvert and GI pipe shall be 15cm apart. Refer to Table 1 for the clearance with other utilities in laying of direct buried optical cable. Utilities Power Line Water Supply Pipes Sewage Pipes

Parallel

Crossing

30cm (Low Voltage) 100cm (High Voltage) 30cm

30cm 30cm 15cm

30cm

15cm

Table 1. Summary of clearance between existing facilities and optical buried cable.

5.5.

Preparation for cable Laying 5.5.1.

Reeling of Cable Drum The cable shall be reeled off from the cable drum according to the arrow mark indicating the direction of rotation of the drum.

5.5.2.

Arrangement of cable In case where more than two cables are laid in parallel, such as going into or coming out from the exchange, they shall be spaced at minimum by 10cm. These cables shall be tagged with collets for detail identification.


Page VII-4

Specification Lines WE FO 001 Issue April, 1995 5.5.3.

Bending radius Optical cables shall not be bent repeatedly and shall always be handled carefully according to the allowable bending radius (20 times of outside diameter) during installation. During preparation for jointing the optical cable bending may be reduced to 10 times the outer cable diameter. Optical cables shall never be twisted and to avoid it happening, use swivels during installation work. (Refer to section V - Laying of Optical Cable).

5.5.4.

Laying tension Optical cables shall be pulled with constant and smallest possible tension. Any impact shall be avoided. Allowable tension strength specified for each cable shall be followed. The allowable tension strength for present contract (Marconi & Hesfibel) are as stated below: CONTRACT

5.5.5.

NO. OF CORES

MAX. PULLING TENSION

MARCONI

4, 6, 8, 12, 24, 36, 48 & 96

1.1 KN

HESFIBEL

4, 6, 8, 12, 24, 36, 48 & 96

1.1 KN

Laying speed Laying speed of cables shall be less than 15m/minute.

6.

CABLE LAYING INTO TRENCH

6.1

Site investigation Before laying cables, investigation shall be made for the condition of trench. a) Confirm whether direct laying of cables into trench is possible or cable has to be first laid on the ground prior to laying in trench. b) Check and confirm whether any obstruction exist on the route of cable which requires detouring or passing underneath. c) Investigate bypass and underground surface conditions along cable route.


Page VII-5


6.2.

Selection of laying method Upon the results of foregoing investigation and in consideration of the location of drum placing and necessity of rollers, select the most suitable laying method from the following:a) Movable Cable Drum Method In cases where there are no obstruction in the trench, or conditions of bypass and/or ground surface allow easy cable laying in the trench. b) Fixed Cable Drum Method In cases where some obstructions exist in the trench and conditions of either bypass or ground surface is unfavourable to force cable route to detour or to pass underneath.

6.3.

6.4

Cable laying by Movable Cable Drum Method i)

Load cable on a truck equipped with fixed jacks or use cable carrier.

ii)

Cable shall be laid directly into the trench or onto road surface alongside the trench avoiding occurrence of twisting.

iii)

Utmost care shall be taken not to twist the cable when it is shifted into trench from ground level.

Cable laying by Fixed Drum Method i)

Setting of drum. a) Set cable drum at the selected positions such as beginning of trench or at the intermediate point (using ‘Figure 8’ technique). b) Axis of cable jack shall be set horizontally. c) Set cable drums correctly in consideration of cable laying direction.


Page VII-6

Specification Lines WE FO 001 Issue April, 1995 ii)

Preparation for pulling end. Similar method for cable pulling into sub-duct shall be applied. Refer to Section V.

iii)

Arrangement of rollers and wire rope. Rollers shall be arranged at 5m to 10m apart on ground surface along trench line. Pulling rope with its terminal wound to a winch is laid on the rollers.

iv)

Cable laying. a) Optical cable shall be pulled on to the rollers manually or by using suitable winch. b) A workman shall be assigned at the terminal and laying shall be continuously made with a speed of 15m/min. c) When excessive tension occurs, the trench, rollers and optical cable shall be checked and if there is no trouble, the cable shall be pulled very carefully by hand or machine. d) In case where rollers are arranged on the ground, utmost care shall be taken not to give twisting and/or extreme bending to the cable while laying it into the trench.

v)

Liaison between workmen during laying operation. a) Close contact between workmen at both cable ends shall be kept during operation to respond to any minor happening through transceivers or ATUR set. b) Observe carefully and ensure the cable sheath is not damaged when it passes the edge of excavation.

vi)

Post laying treatment and check. a) Check at both ends that sufficient lengths including for excess cable length have been provided for jointing. b) Check for exterior damage, and if any report the situation to the superintendent officer immediately.


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JOINT BOX It is recommended to use joint box JC9 (modified), drawing no. 19647, with concrete frame and cover for convenient access to install spare cable portion and closure. The cable inlet to the joint box shall be protected by PVC pipes up to a length of 2m measured from the joint box wall. A supporting plate shall be used to hold jointing closure. Refer to Fig. 4(a) and (b). Five cable ties no. 3 shall be used to hold the cables together and at the cable bearer brackets and one cable tie no. 6 shall be used to hold the closure with the supporting plate. Anti-floating device shall also be installed on cable bearer brackets to prevent it from floating when water in the manhole rises. All duct entry must be installed with duct sealing ring for protecting duct entry from silt and dirt from coming into joint boxes. When there is cable to be installed, loosen bolts, remove the rubber cable holder and push the cable into it. Refer details to Figure 4 (a, b, c, d,e and f) for cable arrangement in Joint Box.

8.

CABLE JOINTING The cable jointing closure shall be set on cable bearer bracket. Splicing work must be done above ground.

9.

EARTHING All directly buried optical cables shall be continuously connected through at each joint location (as described in para 10) and then earthed at both end of Central Office Terminal (COT) and Remote Terminal (RT). It is important to check and ensure the required exchange MDF and cabinet or customer’s premise have sufficient earth resistance for lightning protection system.

10.

ARMOURING TREATMENT Refer to section VII A for armouring treatment using Fujikura closure.


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SECTION VII A

TREATMENT OF ARMOURING FOR OPTICAL FIBRE CABLE

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

TREATMENT PLAN

1

3.

MATERIALS

1

4.

PROCEDURE

2



TREATMENT OF ARMOURING FOR OPTICAL FIBRE CABLE 1.

GENERAL This specification shall apply to the optical fibre cable jointing work usage Fujikura made closures.

It further describes the treatment and method of an electrical connection (bonding) between the armouring of the optical fibre cables to be jointed. The treatment made at the outside of closure will protect the water running between the armouring and inner cable into the closure when the outer sheath and armouring are broken without inner cable damage. The procedure in this specification applies to the steel wire armouring cable as well as thecorrugated metal armouring cable indicated in Figure 1. 2.

TREATMENT PLAN a) Figure 1 (a & b) represents the cable structure and the length of the completed treatment portion. b) Figure 2 represents the cable length to be prepared when using Fujikura’s standard closure type FSCO-SB (length: 600mm) When using another closure, the prepared length of cable shall change according to required closure’s dimension.

3.

MATERIALS The closure kit shall contain the following additional items :

4.

a)

Self-Bonding Tape (Fujikura’s FB-W Tape) This tape covers the connecting portion for water sealing.

b)

PVC Tape This tape is wound over the self-bonding tape for mechanical protection.

c)

Insulated Wire This wire connects the armouring of cable.

PROCEDURE

a)

Decide the jointing position. Remove the outer sheath and armouring to the required length.


Page VII A-1

Specification Lines WE FO 001 Issue April, 1995 Do not remove the inner sheath at this time. ( The treatment of the armouring connection is performed before splicing and assembling of the closure.) b)

Remove the outer sheath of the armouring, to connect the wire. If there is a painted compound between the outer sheath and armouring, clean this compound with solvent. (petrol, gasoline)

c)

Wind the stripped wire twice around the cleaned armouring. Fix the wound wire by soldering. Perform the soldering work quickly with a soldering iron (100 watts or more are required) before the inner sheath is melted.

d)

Wind two layers of self-bonding tape to shape the covering. Gradually fill the gaps between the outer sheath, armouring and inner cable by winding the self-bonding tape. Stretch the wire protruding position well.

e)

Wind two layers of the PVC tape and cover the shaped portion.

f)

Joint the inner cables and optical fibres.

g)

Complete.


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SECTION VIII

INSTALLATION OF OPTICAL FIBRE CABLE ON HORIZONTAL AND VERTICAL CABLE RACKING

NO.

CONTENTS

PAGE

1.

EXTERNAL OPTICAL FIBRE CABLE

1

2.

HORIZONTAL CABLE TRAY

2

3.

INSTALLATION OF LADDER RACKING FOR FIBRE TERMINATION BOX (FTB)

2

4.

INSTALLATION OF SUPERSTRUCTURE

2



INSTALLATION OF OPTICAL FIBRE CABLE ON HORIZONTAL AND VERTICAL CABLE RACKING 1.

EXTERNAL OPTICAL FIBRE CABLE 1.1.

All fibre optic cables to be installed in cable chamber/tunnel must be placed on horizontal racking (cable tray).

1.2.

In order to run fibre optic cables up to the different levels of the MDF/SDF rooms, all fibre cables must be tied to vertical (ladder) racking.

1.3.

External optical fibre cables to be terminated must be arranged neatly in one loop on the horizontal racking (at equipment room) and bring down along the ladder racking for termination with fibre cord cable. For Termination procedure proceed to SECTION XI.

1.4.

The material used for cable racking shall be made of galvanised mild steel with thickness of 3.5 mm (hollow iron) perforated type and with a finishing of enamel orange paint.

1.5.

The width of horizontal and vertical racking used in cable trench/tunnel is 150 mm. Refer to the diagram as shown in Figure 1.

1.6.

The horizontal racking shall be installed at a high position with 600 mm from the ceiling and 25mm away from the manhole wall.

1.7.

Optical fibre cables shall be placed and arranged neatly with one another and avoid it from overlapping (only one layer is allowed).

1.8.

The fibre cables are tied to the racking by using cable tie no. 1.

1.9.

In order to avoid maximum tensile load for the cable running on vertical rack, it shall be tied every meter and closer at the bends.

1.10.

The cable installed shall be labeled with TM's marking tags for fibre optic cables. Warning labels/orange tape shall be attached to the cables at exposed locations and between different floor levels. The arrangement of fibre optic cable inside both MDF/SDF stations is as shown in Figure 2


Page VIII-1


HORIZONTAL CABLE TRAY 2.1.

The cable trays arrangement used for installing internal cables at the equipment room shall be determined during station survey prior to preparation of infrastructure.

2.2.

The size of horizontal racking used is as shown in Figure 3 with the following specification: a) b) c) d)

3.

4.

Spacing between iron: 300 mm Width of cable tray: 300 mm Cross slats: 25 x 6 mm Hollow iron: 64 x 38 mm

INSTALLATION OF LADDER RACKING FOR FIBRE TERMINATION BOX (FTB) 3.1.

For installation of Termination Box at the MDF room, the ladder racking used shall be of the same material as stated in para 2.2 but its width is 600mm. The height is usually 2750mm for COT and 2100mm for RT (as shown in Figure 4).

3.2.

The location of the ladder racking shall be determined during the station survey.

INSTALLATION OF SUPERSTRUCTURE A superstructure is basically required to hold the frame of all electronics equipment to be installed at the MDF/SDF rooms. 4.1.

The size of superstructure is 64 x 38 mm and made of hollow iron with 2 mm thickness. Refer to Figure 5 for its details. Actual layout of the superstructure has to be determined during station survey whereby it depends on the location of the equipment to be installed.

4.2.

Installation of cable (horizontal) racking is as shown in Figure 6. This diagram shows that the superstructure can be part of the horizontal racking. The horizontal racking shall be installed 250 mm below the ceiling along the location of the equipment to be situated.


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SECTION IX

JOINTING OF OPTICAL FIBRE CABLE

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.


1

3.

CABLE JOINTING PROCEDURE

2




1.

GENERAL The fibre joints are of great importance to high quality transmission and low maintenance. These joints must have low, stable transmission loss over the entire life of the system and over a wide range of environmental conditions. 1.1

Joint Loss The average loss per splice shall not exceed 0.20 dB for RT links. Splices which do not comply with this limit shall be remade.

1.2

Jointing Method The preferred technique for fibre splicing is the arc fusion method. However, for local loop application, mechanical splice may be used when necessary and the quality of splices shall be maintained.

2.

JOINTING OF OPTICAL FIBRE CABLE 2.1

General precautions for preparing fibre jointing. a) When water is in a manhole, prevent water from flowing into the ducts. b) Jointing is best performed in an air-conditioned splicing van. Before doing any cabling work in the manhole, clear the interior of the manhole from any harmful gas. c) While continuing operation in the manhole, always ensure there is continued ventilation. d) Always handle optical fibre very carefully because it is very thin and fragile. Do not leave scrap fibre laying scattered and make sure dispose it properly by putting into a vinyl bag or the like. e) Use a cable cutter in cutting optical fibre cable and do not use a hacksaw. g) During the jointing work, take care to keep hands clean so that the optical fibre will not be soiled. h) Provide a spare length of at least 1 metre of optical fibre at each splice point.


Page IX-1

Specification Lines WE FO 001 Issue April, 1995 i) Take appropriate measures to reduce the bending losses when handling the spare lengths. j) Take precaution against fire or explosion. k) Do not move any cable other than the cables to be jointed. l) Ensure cable bearer brackets are available and installed with supporting plate for placing fibre jointing closure. m) Do not place the measuring equipment in the sunlight for a long time. n) Always check and keep jointing materials and tools from dust and dirt. o) Ensure jointing kits are available for jointing work.

3.

CABLE JOINTING PROCEDURE (Using Mechanical Jointing Closure

- Fujikura type)

a)

Determining jointing centre.

b)

Removing the cable sheath

c)

Fitting rubber clamps on cables

d)

Fitting rubber end blocks

e)

Treating cable tension members

f)

Splicing fibres

g)

Enclosing fibres into fibre tray

h)

Fixing cable tension members

i)

Mounting main sleeve

3.1

Procedure for making a Straight Fibre Joint 3.1.1.

To determine the jointing centre, place cables temporarily on the cable bracket. Apply PVC tape around the cable 75 cm from the centre of the joint. Refer to Figure 1.

3.1.2

a) Remove cable sheath 75 cm from cable ends with a lap cutter or any approved tool. Refer to Figure 2.


Page IX- 2


b) Remove core wrapping, clean core and fibres with methylated spirit. 3.1.3

Cut strength member at a point of 65 mm from the edge of the tension member by a bolt cutter or pliers combination no.1.

3.1.4

Remove plastic coating from strength member about 30 mm from the end of tension member by making a circular cut and scrape it with a knife.

3.1.5

Attaching air tight tape a) Determine length of rubber tape by applying closure scale around the cable b) Wrap around the cable sheath (which is first scuffed with sand paper) with one layer of sealing tape. c) Wrap around the sealing tape using rubber tape and cut the end of tape diagonally. See Figure 3. d) Check thickness of rubber tape around the cable using closure scale.

3.1.6

Attach cable clamp at the side of the air tight tape as shown in Figure 4.

3.1.7

Attach end plate on sealing tape with bolts as shown in Figure 5.

3.1.8

Fix fibre slack tray and cable clamps with bolts as in Figure 6.

3.1.9

Fix cable tension member to the tension member clamp as in Figure 7.

3.1.10

Splicing of optical fibre core. Refer to Section XI.

3.1.11

Fix fibre joint protector into the holder and the fibre slack tray as in Figure 8. This joint protector is used to strengthen and protect against moisture and damage to the joint.

3.1.12

Hold fibre slack-coiling in a fibre slack tray with more than 60mm diameter as shown in Figure 9.

3.1.13

a) Attach end plate and sleeve with seal tape. b) Attach sleeve with band and fasten screws with torque 70Kgf/cm.

3.2

Making a Y-joint for optical fibre cable


Page IX- 3


Y-joint for optical fibre cable requires at least three optical cables; two incoming and one outgoing cables or vice versa. The precautions and preparations are similar to para 3.1. However, additional care shall be taken for the following: a) Ensure the right (matching) fibre core of each incoming and outgoing cable are spliced together. b) Label spliced fibre cable with the route name for easy identification. 3.3

Making a double-Y joint for optical cable A double-Y joint for optical fibre cable requires at least two incoming and two outgoing cables. The method is similar to para 2 and 3.2 except that it depends on the selection of cable core chosen to be spliced for each route.


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SECTION IX A

INSTALLATION OF FIBRE OPTIC CLOSURE - RAYCHEM TYPE (FOSC-100 B/H)

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

MATERIALS AND TOOLS

1

3.

CABLE INSTALLATION IN OVAL OUTLET

2

4.

CABLE PREPARATION (SLOTTED CORE TYPE)

3

5.

SEALING OF OVAL OUTLET

4

6.

POSITIONING OF TRANSPORTATION TUBES

4

7.

SPLICING AND FIBRE STORAGE

4

8.

TRAY KIT

5

9.

DOME INSTALLATION

5

10.

RE-ENTRY AND RE-CLOSING

6

11.

CABLE INSTALLATION IN CIRCULAR OUTLET

6

12.

ADDITIONAL CABLE INSTALLATION

6

13.

MOUNTING KIT

7

14.

INTERTRAY JUMPERS

7

15.

TEMPORARY SEAL

7

16.

INSTALLATION OF JOINTING CLOSURE ON POLE

7



INSTALLATION OF FIBRE OPTIC CLOSURE - RAYCHEM TYPE (FOSC-100 B/H)

1.

GENERAL The specification describes the installation procedure of Raychem optical jointing closure. There are two sizes available for this purpose; namely a) b)

FOSL-100 B/H for 48 cores maximum. FOSL-100 B/H-B24 for 96 cores maximum.

These closures are of butt design where its base and dome are mechanically interconnected and locked by a ring (not reusable). It is applicable for manhole and aerial installation. The cable length required for jointing process to be done on ground level for aerial installation is approximately 8.7m. For manhole installation, see para 4.4.4a of Section V.

2.

MATERIALS AND TOOLS The materials list and tools required are as described below: 2.1

Materials FOSC-100 standard kit comprise of the following: a) b) c)

d) e) f)

Dome Locking Ring Base with strength member connections and one tray assembly kit; - 1 tray for 12 fusion splices - tray lid - tie-wraps - transportation tubes Velcro strip Tray support wedge Oval outlet cable seal kit consisting of: - Heat shrinkable sleeve - Branch-off clip - Aluminium cable protection tape - Abrasive strip - Cleaning tissues

Local Network Headquarters Page IX A - 1 Telekom Malaysia Berhad

Specification Lines WE FO 001 Issue April, 1995 g)

h) i) j) k) l)

m) n)

2.2

Tools: a) b) c) d) e)

3.

4.

Dome seal kit consisting of: - Heat shrinkable sleeve - Adhesive strip - Cleaning tissue - Abrasive strip - Silicagel Shield continuity wires Shield continuity connector Slack tray for uncut or extra length fibre Temporary seal kit for dome base seal Mounting kit consisting of: - For pole - For wall fixing in manhole Closure holder stand Fibre protection for slotted core cable consisting of: - Fibre distribution cap - Fibre distribution funnel - Transportation tubes - ‘O’ ring - Cleaning tissue - Abrasive strip - Heat shrinkable tube - Sealant strip

Hot air gun (1460 Watt) - Minimum hot air temperature : 350°c. Generator for hot air gun utilisation. Hacksaw Cable Cutter Pliers, Screw Drivers, Nippers, Markers etc.

CABLE INSTALLATION IN OVAL OUTLET a)

Cut the port at the ridge for cable entry by using a hacksaw. Smoothen the inner edge of the port opening with abrasive strip.

b)

Remove any contaminants from the cable sheath for approximately 2 meters with a clean cloth. Slide the oval cable seal over the cables. The non painted (black) edge of the sleeve should be pointed to the base of the closure.

c)

Slide the cables through the opened oval port. Prepare cables as described in section 4 (cable preparation). See Figure 1.

CABLE PREPARATION (SLOTTED CORE TYPE)


Page IX A - 2


a)

Remove the cable sheath 120cm from the end. Clean filling compound from fibre tubes.

b)

Remove the fibres out of the grooves. Degrease and clean the exposed fibres. Cut the slotted core to a length of 5.5cm and strength member 20cm from the cable jacket ring cut as shown in Figure 2. If a shield continuity is required, cut cable sheath axially for 25mm from cable ring cut. Crimp shield clip on cable sheath with pair of pliers.

c)

As shown in Figure 3, slide the distribution funnel over the fibres and the core till it butts against the cable jacket. Install the elastic ‘O’ ring at 1 cm from the end of slotted core. The ‘O’ ring will keep the fibres into the grooves.

d)

Assemble the transportation tubes into the holes of the fibre distribution cap according to the number of grooves of the core. Insert the fibres into the corresponding tubes and slide the distribution cap with transportation tubes over the strength member till it butts against the slotted core end. See Figure 4.

e)

Move the distribution funnel towards the cap and push it onto the cap. Remember not to rotate the distribution cap or funnel. Check the fibres are not rotated or squeezed in the grooves. Figure 5 shows this operation.

f)

Degrease with cleaning tissue the distribution funnel and cable sheath for about 10cm below the cable ring cut. Centre and wrap sealant strip around the cable and distribution funnel. Slide the heat shrinkable tube over the sealant strip and centre it as shown in Figure 6.

g)

Shrink the heat shrinkable tubing using hot air gun (1.5 Kw) till the sealant strip starts to flow. See Figure 7. Caution:

5.

1. Do not overheat the tubing. 2. Do not touch the tubing until it has cooled down to the ambient temperature.

h)

Align end of tubing with edge of base. Slide strength members into clamps and fix. Cut away the excessive length of strength member. Refer to Fig. 8.

i)

If required, connect shield continuity wire of both cables with shield continuity clip.

SEALING OF OVAL OUTLET


Page IX A - 3

Specification Lines WE FO 001 Issue April, 1995 a)

Clean oval port and cable sheath with a cleaning tissue 100mm from the edge of the port.

b)

Abrade oval port and cable sheath circumferentially on the cleaned area with the abrasive strip. Remove any abraded material with a clean cloth.

c)

Place oval seal kit over the oval part and cable. Mark the sleeve length onto the cable. Make second mark 5mm nearer the FOSC-base. Install aluminium cable protection tape around cable from the second mark.

d)

Slide the oval cable seal over the oval part. Install the branch-off clip. Ensure that the heat-shrinkable sleeve butts up against the FOSC-base and the branch clip is completely inserted.

e)

Shrink the oval cable seal on the base side with the recommended hot air gun device and reflector. Shrink sleeve until the green thermochromic paint is converted to black and the expansion lines on the sleeve are disappeared. (Make sure that the hot air temperature is at least 350oC. If CV 1981-1460W-220V is used, position on scale 10).

f)

Shrink down the end of the sleeve on the cable side. Heat until the sleeve shrinks down on the cables and take care that the green thermochromic paint is converted to black. Postheat the clip on both sides till the adhesive shows a proper flow on the clip between the two cables. See Figure 9. Caution:

6.

POSITION TRANSPORTATION TUBES AND FIBRES a)

7.

Wait until the sleeve is cool to the touch before moving the cables.

Mark on each tube at 15mm from tray edge. Cut the transportation tube at the mark and secure to splice tray with two tie wraps. Other tubes should be laid out of the way of the bottom tray. Alternatively, additional trays may be installed to store the fibres (refer para 8). Cut the transportation tubes in the tray. Always place transparent cover over tray.

SPLICING AND FIBRE STORAGE a)

For splicing of the optical cable, refer to Specification Lines WE FO 001, Section X.

b)

After each splice is made, keep the spliced fibre in the splice holder. Do not deform the splice protector during inserting. Coil the fibre slack into the tray. Install the


Page IX A - 4

Specification Lines WE FO 001 Issue April, 1995 clear protective cover on the tray. Secure cover by installing the Velcro strip around the trays and cover. Note:

8.

9.

For 12 fibre capacity (maximum) on a tray, two fusion protection sleeves should be installed on top of one another in one splice holder.

TRAY KIT a)

If additional trays are to be used, align the tray pins with the holes on base bracket. Squeeze tray pins and slip tray into bracket.

b)

Repeat the procedure from para 7 for splicing and fibre storage.

c)

Use tray wedge to keep the tray in upward position.

DOME INSTALLATION a)

Open the dome sealing kit and remove desiccant bag from the desiccant package. Place the bag on the tray and secure with vinyl tape.

b)

Carefully slide the closure dome onto the base. Align the white dot of the dome with the white dot on the base. Install the locking ring over the transition holding the dome and base together. The split ring should fit completely into the groove.

c)

Clean the sealing area with the cleaning tissue and abrade the base and dome circumferentially, till the moulding marks are removed. Remove any abraded material with a clean dry cloth.

d)

Remove the protective layer of the tape in the middle of the adhesive strip.

e)

Wrap adhesive strip around dome and base interconnection with tacky side towards base and dome as shown in Figure 10.

f)

Slide heat-shrinkable dome to base over the closure and position the sleeve over the dome/base transition.

g)

Using a recommended hot air gun device and reflector, shrink the sleeve till the edges of the sleeve have come down and the green thermochromic paint converted to black. The flow of red adhesive should be visible at the edges of the sleeve. (Ensure that the hot air temperature is at least 350oC. If CV 1981-1460W-220V is used, position on scale 10).

h)

Allow the heat-shrinkable sleeve to cool down before moving the closure. Mount the closure for storage.


Page IX A - 5


10.

RE-ENTRY AND RE-CLOSING a)

Heat the sleeve locally, cut gently the soft heat-shrinkable sleeve on the dome and base transition. Take care not to cut into the base or dome. Heat the cut line till the sleeve starts to open over its entire width. See Figure 11.

b)

Using a pair of pliers, peel the band from the dome and base transition. It is not necessary to remove any adhesive left from the original adhesive strip. The adhesive will melt and flow together with the adhesive from the new heat-shrinkable sleeve adhesive strip.

c)

Remove the plastic split locking ring and slide dome from base. Protect dome/base transition from dirt, moisture or other contamination. Remove the existing silicagel bag. Note:

d)

11.

12.

Do not re-use the split locking ring and silicagel bag.

Follow procedures as described in para 9, for re-installation of the dome.

CABLE INSTALLATION IN CIRCULAR OUTLET a)

Prepare the cable as outline in para 4.

b)

As described in para 5; "Sealing the Oval Outlet", follow the procedures to seal the circular outlet.

c)

Figure 12 shows the cable installation in circular outlet.

ADDITIONAL CABLE INSTALLATION a)

Open a new port with a hacksaw. Take care not to damage any existing cable. Smooth the rough edges of the port.

b)

Prepare and install the cable as described in para 4, 5 and 6. After the splicing process is completed, install cable seal and re-install dome and seal closure.


Page IX A - 6


14.

15.

16.

MOUNTING KIT a)

For pole mounting, position the two dome mounting bracket on the dome of closure. Clamp the brackets into the pole mounting brackets and secure it with the locking pin as described in Figure 13.

b)

For installation in manhole, fix it on a supporting plate as described for cables using Fujikura closure.

INTERTRAY JUMPERS a)

When it is necessary to splice fibres that are placed on different splice organiser trays an intertray jumper may be used to route one or more fibres to the desired tray.

b)

Secure one end of intertray transportation tube to the splice tray and secure with two tie-wraps.

c)

Mark the length of intertray jumpering tubes. Splice the fibres in the same way as described in Specification Lines WE FO 001, Section X.

d)

Route the fibres in the jumpering transportation tube.

e)

Carefully bend the intertray jumpering transportation tube to the appropriate tray and secure to the splice tray with two tie-wraps.

TEMPORARY SEAL a)

Slide the dome onto the base. Align the white dot of the dome with the white dot of the base. Install the metal locking ring over the transition holding the dome and base together. Fit the split ring into the groove.

b)

Slide the temporary rubber sealing ring over the dome/base interface.

c)

Install the temporary metallic clamp over the sealing ring and screw in place.

INSTALLATION OF JOINTING CLOSURE ON POLE When there is Raychem Closure being installed at a pole along a straight route, the pull through cable shall be installed on the opposite of the pole. a)

Install supporting brackets 600mm apart at the two 18mm diameter holes.


Page IX A - 7

Specification Lines WE FO 001 Issue April, 1995 b)

Bring the excess cable onto the pole and coil one side at a time within the supporting brackets. Ensure there is sufficient cable bending radius during this process.

c)

Fix securely the coiled cables using cable tie no.3 at six positions as shown in Figure 14.

d)

Adjust the position for mounting jointing closure on the pole at minimum height of 4000mm from ground level.


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SECTION X

SPLICING FIBRE ENDS

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

TOOLS AND MATERIALS

1

3.

SINGLE FIBRE

2

4.

RIBBON FIBRE

2



SPLICING FIBRE ENDS 1.

GENERAL The specification describes the procedure of splicing single (loose fibres) and ribbon type fibres using fusion splicing machine.

2.

TOOLS AND MATERIALS The following tools and materials (with their usage) are required for splicing a single or ribbon fibre cables:

2.1

Tools and devices

No.

Tools and Devices

Usage

b.

Hot Jacket Stripper.

2a.

Optical Fibre Cutter.

To remove the single fibre cables primary coating. To remove the ribbon fibre cables primary coating. To cut off the single fibre end.

b. 3.

High Precision Fibre Cleaver. Cotton Wools & Alcohol

To cut off the ribbon or single fibre end. For cleaning the fibre cables.

4.

V-Groove.

5.

Splicing Machine.

To hold the fibre cable on the splicing machine. For fibre cable splicing.

1a.

2.2 No. 1.

Optical Fibre Stripper.

Materials Materials Protection Tubes

Local Network Headquarters Page X - 1 Telekom Malaysia Berhad

Usage To protect the fibre cable splicing portion.


SINGLE FIBRE 3.1.

Stripping of nylon jacket Do not wind the fibre end around the finger when removing the nylon jacket using the jacket stripper because the bent fibre will cause misalignment of the fibre ends.

3.2.

Stripping of primary coating To remove primary coating, use the primary coat stripper or by wiping the fibre core with cotton wool soaked with alcohol towards the fibre end. Repeat this procedure for about 20 times to ensure the core is clean.

3.3.

Cutting off fibre end The fibre end must be cut by using a fibre cleaver. If you fail to cut off the fibre end properly, repeat the procedure from para 1.1.

3.4.

Protection of Spliced Portion Do not forget to place the protective tubing over both fibre ends to be spliced.

3.5.

Splicing fibre ends with fusion splicer Place the fibre ends on the V-groove of the splicer and operate the splicer to splice the ends.

4.

RIBBON FIBRE Perform splicing as for single fibre except use the specified tools as below for the ribbon fibre cables: a. b.

Hot Jacket Stripper. High Precaution Fibre Cleaver.

Refer to Fig. 1 and 2 for the related items used for optical fibre splicing.


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SECTION XI A

TERMINATION OF OPTICAL FIBRE CABLE USING FUJIKURA FIBRE TERMINATION BOX (FTB)

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

TOOLS AND MATERIALS

1

3.

TERMINATING OPTICAL FIBRE CABLE

2

4.

TERMINATION METHOD

2

5.

LABELING

3

6.

ARRANGEMENT OF FTB ON LADDER RACKING

3



TERMINATION OF OPTICAL FIBRE CABLE USING FUJIKURA FIBRE TERMINATION BOX (FTB) 1.

GENERAL The specification describes the termination of external optical fibre cable to the fibre cord cable (pigtail) in the Fibre Termination Box (FTB) at the MDF/SDF where the optical fibre equipment is to be located.

2.

TOOLS AND MATERIALS The main tools and materials included with their usage for installation of FTB are as follows: 2.1

Tools and devices No.

2.2

Tools and Devices

Usage

1.

Cable Cutter.

2.

Cable Stripper.

3.

Marker.

To cut off the fibre optic cables and their central strength members while working on installation of FTB. To strip off the outer sheath of the optical fibre cables. For marking the cutting or stripping position.

4.

Splicing Machine.

To splice the optical fibre cable.

5.

Screw Driver.

For fixing screw at the cable clamp, central strength member and FTB cover.

Materials No. 1.

Materials Alcohol and Cotton Gauze.

Local Network Headquarters Page XI A - 1 Telekom Malaysia Berhad

Usage For cleaning the optical fibre cable.


4.

TERMINATING OPTICAL FIBRE CABLE 3.1.

Optical fibre cord cable (one end connector terminated) for connection to the fibre distribution frame shall be suitably terminated and protected on the same Fibre Termination Box.

3.2.

The external optical fibre cable from the cable chamber shall be arranged neatly and tied with cable tie no. 1 along the horizontal racking and arrange in a loop approximately one meter (depending on the arrangement of the racking) and bring down along the ladder racking.

TERMINATION METHOD 4.1.

Fix terminal base with screws which are suitable for the hole of terminal base on the ladder racking.

4.2.

Vinyl chloride sheath wire (600 V) shall be used for earthing.

4.3.

Mark the cutting position of fibre cable with adhesive PVC tape, considering the location of Fibre Termination Box. Cut the outer sheath of the optical fibre cable by cable cutter and the tension member using a wire cutter.

4.4.

Strip the cable sheath 80 mm from the cable end. Before removing the cable sheath completely, the cable end shall be wrapped with suitable tape to hold each fibre together.

4.5.

Before cutting, fixing and protecting the tension member, the following procedures shall be taken. a) Remove the wrapping tape of cable b) After cutting the hardware of tension member 95 mm from the edge, clamp the tension member with tension member clamp. See Figure 1.

4.6.

Fix the cable and fibre cord by inserting the cable between cable clamps and tighten the clamp with screw. See Figure 2.

4.7.

Remove the sheath of fibre cords with primary coat stripper.

4.8.

Release the cover of cord clamp and loosen the screw of Kevlar holder. Fix the kevlar to the kevlar holder and fibre cord to the cord clamp. Refer to Figure 3.

4.9.

Splicing of the optical fibre is as described in Section X.

4.10.

Store the surplus length of spliced fibre cord into storing sheet.


Page XIA - 2

Specification Lines WE FO 001 Issue April, 1995 The surplus length shall be treated carefully with the following precautions : a) Minimum bending radius of optical fibre shall be more than 4 cm. b) After coiling each of the surplus length of fibre cable, store fibre in its respective sheets. 4.11.

5.

After completely storing the optical fibre, fix the termination case cover as in Figure 4.

LABELING 4.1.

Label the Fibre Termination Box with standard identification:a) b) c) d)

6.

Type, code and size of cable Route name Contract number Date of installation

ARRANGEMENT OF FTB ON LADDER RACKING The installation and arrangement of Fibre Termination Boxes is as shown in Figure 5.


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SECTION XI B

TERMINATION OF OPTICAL FIBRE CABLE USING HESFIBEL FIBRE TERMINATION BOX (FTB)

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

TOOLS AND MATERIALS

1

3.

INSTALLATION METHOD

1

PREPARATION OF FIBRE OPTIC CABLES FOR TERMINATION AND SPLICING

1

3.3

PREPARATION OF CORD CABLE FOR TERMINATION AND SPLICING INSTALLATION OF SPLICING CASSETTE

2 2

3.4

INSTALLATION OF FTB ON LADDER RACKING

3

3.1 3.2



TERMINATION OF OPTICAL FIBRE CABLE USING HESFIBEL FIBRE TERMINATION BOX (FTB) 1.

GENERAL The specification describes the installation of Fibre Termination Box (FTB) supplied by Hesfibel. It is used to terminate the external fibre cables to fibre cord cables. The Hesfibel FTB can accommodate 12 fibres per cassette where each FTB can have up to 6 cassettes with 72 terminations.

2.

TOOLS AND MATERIALS The main tools and materials for this installation is as described in Clause 2 of Section XI A.

3.

INSTALLATION METHOD 3.1

Preparation Of Fibre Optic Cables For Termination and Splicing a.

Mark the cutting position of fibre cable 2 meters from its end. Cut the outer sheath of the cable by using cable cutter.

b.

Cut off and discard polyester band, swelling tape and aramid yarn from optical cable.

c.

Insert cable slot, fibres and central strength member through the cable entry hole of FTB.

d.

Separate fibres from cable slots and clean them with alcohol or other cleaning agent and cotton gauze.

e.

Cut the slot and central strength member 8 cm from the end of outer polyethylene sheath (from the first point) by using a cable cutter. In the same manner, cut the slot on top of central strength member at a point 2 cm apart from the outer polyethylene sheath without damaging the strength member.

f.

Before fixing the fibres to the plastic adaptor cover, pass the fibres (80 cm long) through the transparent tubes. Make sure that plastic adaptor and cable's outer polyethylene are held closely together. Then, fix the cable with the cable clamp.


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3.2

3.3

g.

Fix the central strength member (with central strength member holder bolt) using a nut.

h.

Fix the plastic adaptor to the splicing cassette with two cable heads.

i.

Wind the fibres within the termination box carefully and number all the fibres accordingly.

Preparation Of Cord Cable For Termination And Splicing a.

Mark the fibre cable 2 meters from its end and strip off the outer sheath from this point.

b.

Mark 2cm from the first point and strip off the sheath of aramid yarns of cord cables.

c.

Cut off the central strength member and polyethylene 7 cm from the first point. Strip off the polyethylene part on top of central strength carefully. See Figure 1.

d.

Push fibre cord cable into FTB through cable entry and fix central strength member to its holder.

e.

Pass single fibre cord cables (135 cm long) through transparent tubes. Fix the tubes to the splicing cassette entry by using two cable heads.

f.

Wind fibre cord cable inside the cassette accordingly.

Installation Of Splicing Cassette a.

Arrange and place the transparent tubes neatly in the termination box by means of cable clips.

b.

Fix splicing cassettes with cassette holder.

c.

After steps 3.1, 3.2 and 3.3 have been done, the fibres are ready for splicing. See Section X for splicing procedure. In order to prevent unnecessary movement of protection tubes, cassette clamp is used. Fig.2 shows the termination box assembly drawing.


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3.4

d.

After each fibres are spliced, place the spliced protection tubes into the splicing cassettes and the cassette clamp will hold it from any unnecessary movement.

e.

After fibre cables and cord cables are neatly arranged in FTB, close and screw the FTB cover.

Installation Of FTB On Ladder Racking The arrangement of FTBs and its cabling is described and as shown in Clause 6 of Section XI A of this specification.


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SECTION XI C

TERMINATION OF OPTICAL FIBRE CABLE USING OPCOM FIBRE TERMINATION BOX (FTB)

NO. 1. 2.

CONTENTS GENERAL

PAGE 1

i. TOOLS AND MATERIALS

1

ii. INSTALLATION METHOD

1

iii. PREPARATION OF FIBRE CABLE AND CORD CABLE FOR TERMINATION AND SPLICING

1

iv. INSTALLATION OF SPLICING TRAYS

1

v. INSTALLATION OF FTB ON LADDER RACKING

1



TERMINATION OF OPTICAL FIBRE CABLE USING OPCOM FIBRE TERMINATION BOX (FTB) 1.

GENERAL This specification describes the installation practice for FTB supplied by OPCOM (contract K1092/93). The two types of FTB supplied under this contract are for 36 fibres and 96 fibres. The splicing trays are of slotted type which can be removed by lifting it without disturbing other trays for purpose of maintenance.

2.

The specification for Tools and Materials, Installation Method, Preparation of Fibre Cable and Cord Cable for Termination and Splicing, Installation of Splicing Trays and Arrangement of FTB on Ladder Racking of FTB are similar to Hesfibel type. Refer to Section XI B, clauses 2 to 3 for further details. Fig. 1 shows the Fibre Termination Box assembly drawing.

Local Network Headquarters Page XI C - 1 Telekom Malaysia Berhad



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SECTION XI D

TERMINATION OF OPTICAL FIBRE CABLE USING HESFIBEL FIBRE DISTRIBUTION PANEL (FDP)

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

TOOLS AND MATERIALS

1

3.

INSTALLATION METHOD

1

4.

SPLICING

2

5.

INSTALLATION OF FTB ON LADDER RACKING

3



TERMINATION OF OPTICAL FIBRE CABLE USING HESFIBEL FIBRE DISTRIBUTION PANEL (FDP)

1.

GENERAL The specification describes the installation of Fibre Distribution Panel (FDP) and its associated parts for termination of the external optical fibre cable to fibre cord cable. The two types of FDP supplied by Hesfibel are used for 12 and 24 core fibre terminations.

2.

TOOLS AND MATERIALS The main tools and materials for this installation is as described in Clause 2 of Section XI A.

3.

INSTALLATION METHOD 3.1

Preparation of fibre optic cable for termination a.

Mark, cut and strip off the outer polyethylene 2 meters from the end of the optical cable (using a cable cutter and stripper). Take off carefully the swelling tape, polyester tape and the thread to avoid any damage to the fibre. Insert the fibre cable into the splice box through the cable entry hole.

b.

Remove all the fibres from their slots and clean with a soft tissue paper and alcohol.

c.

Mark and cut the slotted core and strength member 15cm from the sheathing. Take off the slotted core (leave just the strength member) 4cm from the polyethylene. Refer to Figure 1.

d.

Pass the fibres and central strength member through the plastic adaptor. Insert the fibres (70cm long) through transparent tubes.

Local Network Headquarters Page XI D - 1 Telekom Malaysia Berhad

Specification Lines WE FO 001 Issue April, 1995 e.

Before fixing the fibre optic cable to the termination box using a cable clamp, fix the central strength member to the box using the central strength member holder.

f.

Hold the plastic adaptor together with the 2 cables in the splicing cassette and wound it in a uniform manner.

3.2.

Preparation Of Fibre Cords Cables For Termination a.

Insert the fibre cords into the distribution panel through the cable entrance and wind uniformly in the cassette.

b.

Fix the connectors at the end of the fibre cords to the adaptors.

c.

Remove the sheath and aramid yarn of the fibre cords up to the connector end. Then, wind this part (once or more depending on the length of the pigtail) around the cassette beginning from the connector adaptor point.

d.

Ensure correct the fibre cords to be spliced with the external fibre cables which are wound in the cassette. Note:

4.

Make sure that the length of the fibre cords to be wound inside the cassette are least 40cm. Otherwise splicing cannot be done due to short pigtail length.

SPLICING a.

After steps 3.1 and step 3.2 are completed, the fibre optic cable and the fibre cords are ready for splicing process.

b.

Splice the fibre in the cassette to the fibre cords in sequence using a fusion splicer. Ensure to slip the splice protector over fibres to be spliced. Then keep the spliced fibre in the cassette.

c.

Fix the splice cassettes with the bolts inside the distribution panel. Refer to Fig. 2 for the assembly drawing.


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5.

INSTALLATION OF FDP ON LADDER RACKING/WALL The arrangement of FDPs and its cabling is described as in the arrangement of FTBs in Clause 6 of Section XI A, of the specification. FDP can also be wall mounted when there is insufficient space at customers’ premises. However its installation and management shall follow the above procedure.


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SECTION XII

TESTING AND COMMISSIONING OPTICAL FIBRE SCHEME

NO.

CONTENTS

PAGE

1.

TESTING OPTICAL FIBRE CABLE

1

2.

TESTING FIBRE SUBSCRIBER ACCESS EQUIPMENT (FSAE) OLTM/DLC

2

3.

CHECKING SPARE MATERIALS

2

4.

COMMISSIONING

3



TESTING AND COMMISSIONING OPTICAL FIBRE SCHEME 1.

TESTING OPTICAL FIBRE CABLE The tests to be conducted shall be as follows:

1.1

Cable End to end Loss Maximum allowable loss between sending and receiving stations = aL + bN + C Where,

a

= Cable Loss dB/km, which is 0.40 for 1300 nm region and 0.25 for 1550 nm region. b = Average Loss per splice, which is 0.20dB for RT and 0.1dB for FOKUS and trunk lines. C = Constant of 1 for Connector Loss (i.e. 0.5dB per connector). L = Cable Length (Km). N = Number of splices.

1.2

When measured using the light source/power meter method, the loss measured shall be less than that stipulated formula.

1.3

Splice Loss The maximum loss allowed shall be less than or equal to 0.20dB. This value shall be average value (measured from both sides of the link using an OTDR).

1.4

The measured value at 1550nm region shall not exceed that measured at 1300nm region by 0.15dB. The rationale of this requirement is to ensure that the macro-bending and micro-bending losses at 1550nm is not excessive as a result of poor installation practices at a jointing closures. Any splices failing to meet the above criteria shall be respliced. The acceptance test format used is as shown in App.1.

1.5

Core Reversal Test This test is to ensure that the correct fibre cores are spliced together. It is to be tested at both sides of the optical fibre link specifically at the FDF by using Fibre Identifier.

Local Network Headquarters Page XII - 1 Telekom Malaysia Berhad


a) Testing Method.

1.6

i.

Light source is sent from upper station and lower station.

ii.

Detect light signal in fibre cores starting from the centre fibres using Fibre Identifier. This is to ensure fibre core numbers are matched and spliced together at both ends of the link.

iii.

If fibre core reversal is not detected, repeat the same process (i and ii) at first joint (FTB joint of upper station) and last joint (FTB joint of lower station) until signal is detected at both FDFs.

iv.

If signal is detected at the different core numbers from FDF in the above procedure, this shows that there could be a core reversal at any joint along the link. Repeat the above process at all the joints until the error at the joint is rectified.

Checking cable routing and connection The Superintendance Officer (S.O) shall ensure that the cables installed below are carefully inspected and checked for acceptance and commissioning of optical fibre links:

2.

i.

On poles.

ii.

In manholes, in cable chamber, in MDF room, is on cable tray up to FDF.

iii.

Fibre cords are neatly arranged from FTB to FDF.

iv.

Collets are tagged onto fibre cables with complete identification of link.

TESTING FIBRE SUBSCRIBER ACCESS EQUIPMENT (FSAE) - OLTM/DLC Testing procedures and test formats for FSAE equipment are as shown in App. II and shall conform to the specification of each contract. (Not applicable for JKH contract)

3.

CHECKING SPARE MATERIALS All unused cables and materials ordered and supplied for a particular scheme shall be promptly returned to a centralised location for subsequent re-allocation to other projects or maintenance purposes. This will ensure the most efficient use of resources and minimise costs.


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4.

COMMISSIONING After testing have been successfully completed in the presence of Superitendant Officer (S.O) or his appointed representative, test results shall be certified by both contractor and TM's S.O.


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SECTION XIII-A

INSTALLATION OF PLINTH FOR MARCONI CABINET 480

NO.

CONTENTS

1.

GENERAL

1

2.

DIMENSION

1

3.

MATERIALS

1

4.

VARIABLE PLINTH HEIGHT

1

5.

CONDUIT AND MANHOLE

2


PAGE


SECTION XIII-A

INSTALLATION OF PLINTH FOR MARCONI CABINET 480

1.

GENERAL This specification is used in conjunction with Specification Lines WE 303 Issue August 1993 for the construction of plinth cabinet and Specification Lines WE 304 Construction of manholes, jointboxes and laying of ducts for its quality of construction materials with respect to its plans and structural drawings shown in Appendices 1 and 2.

2.

DIMENSION The dimension of plinth for Marconi type cabinet is 1400 x 800 x 1250

3.

(LxWxH).

MATERIALS The list of materials required is as follows:a)

UPVC bend pipe 76.5 mm radius (152 mm diameter)

b)

PVC pipe 50 mm diameter (for power cabling/earthing)

c)

Cement concrete 1:2.4 (Grade 20)

d)

60 mm screw and nut

e)

Steel template 1347 x 730 mm (LxW). Refer to Appendix 1.

f)

Reinforcement bar. Refer to Appendix 2.

g)

PVC duct 152 mm when necessary for connection between plinth to last manhole.

Local Network Headquarters XIII A - 1 Telekom Malaysia Berhad

Page

Specification Lines WE FO 001 Issue April, 1995 4. VARIABLE PLINTH HEIGHT In flood prone areas, a variable height plinth is constructed according to the height required in addition to the existing plinth. The drawings and dimensions are as shown in Appendix 3. The material specification and processes shall be as described in para 1.

5. CONDUIT AND MANHOLE The connection of cabinet plinth to the nearest manhole shall be installed via a 152 mm PVC duct bend. To avoid the usage of extra length of the 152 mm PVC duct the cabinet plinth shall be placed within 233.45 mm from the manhole wall. If the situation at site forbids, install PVC ducts accordingly. The ends of PVC duct bend or pipe installed at both the plinth and manhole duct entry shall be firmly plastered with cement to prevent any entry of soil or water at the manhole walls. The PVC bends/pipes may or may not be encased in concrete depending on the nature of soil.


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SECTION XIII-B

INSTALLATION OF PLINTH FOR ERICSSON CABINET 480

NO.

CONTENTS

PAGE

1.

GENERAL

1

2.

DIMENSION

1

3. 4. 5.

MATERIALS VARIABLE PLINTH HEIGHT CONDUIT AND MANHOLE


1 1 2


SECTION XIII-B

INSTALLATION OF PLINTH FOR ERICSSON CABINET 480

1.

GENERAL This specification is used in conjunction with Specification Lines WE 303 Issue August 1993 for the construction of cabinet plinth and Specification Lines 304 - Construction of manholes, jointboxes and laying of ducts for its quality of construction materials with respect to its plans and structural drawings shown in Appendices 1 and 2.

2.

DIMENSION The dimension of plinth for Ericsson cabinet is 1600 x 1000 x 1400 mm (LxWxH).

3.

MATERIALS The list of materials required is as follows:a)

UPVC duct bend 76.5 mm radius (152 mm diameter)

b)

PVC pipe 50 mm diameter (for power cabling/earthing)

c)

Cement concrete 1:2:4 (Grade 20)

d)

M16 rag bolts

e)

Plinth structure. Refer to Appendix 2.

f)

12 mm diameter bolt. Refer to Appendix 3.

g)

PVC duct 152 mm when necessary for connection between plinth to last manhole.


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VARIABLE PLINTH HEIGHT In flood prone areas, a variable height plinth is constructed according to the height required in addition to the existing plinth. The drawings and dimensions are as shown in Appendix 4. The material specification and processes shall be as described in para 1.

5.

C0NDUIT AND MANHOLE The connection of cabinet plinth to the nearest manhole shall be installed via a 152 mm PVC duct bend. The cabinet plinth shall be installed approximately 400 mm to the manhole to avoid the usage of extra length of the 152 mm PVC duct . If the situation at site forbids, install PVC ducts accordingly. The ends of PVC duct bend or pipe installed at both the plinth and manhole duct entry shall be firmly plastered with cement to prevent any entry of soil or water at the manhole walls. The PVC bends/pipes may or may not be encased in concrete depending on the nature of soil.


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Telekom Handbook for Cabling Works

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