PROCEDURE FOR FIBER OPTIC INSTALLATION AND TESTING

PROCEDURE FOR FIBER OPTIC INSTALLATION AND TESTING

TOOLS AND EQUIPMENT FOR FIBER OPTIC INSTALLATION AND TESTING

Tools and equipment needed should be in good condition and must be checked by Supervisor prior to usage in the construction area.  These includes, but not limited to:

1. Set of Hand Tools
2. Fiber Optic Cable Termination/Splicing Tool Kit
3. Splicing Machine Fujikura FMS 40S/SOS/Sumitomo Microcore Type 39
4. AT&Y Connectorization Kit
5. Fiber Optic Cable Stripper.
6. Cleaver
7. Cable Rollers, Stand and Jacks
8. Digital Multimeter
9. Optical Time Domain Reflectometer
10. Set of nylon ropes
11. Electric Power Tools (i.e. drill, etc.)
12. Boom Truck
13. Power Meter
14. Power Source
15. Talk Set
16. Launch Cable
17. Fiber Tracer
18. Fiber View Scope
19. For additional splicing tools, refer to SAES-T-624 sec. 4.7.4
20. Laser Pointer
21. Splicing Tray/Organizer
22. Heat Gun
23. Cleaving Tool
24. Polishing Tool
25. Buffer Stripper

All tools utilized in a classified area should be safe and suitable for hazardous areas.

GENERAL REQUIREMENTS

1. Special tools and testing tools shall bear valid calibration certificates traceable to a national standard indicating calibration validity and periodically (at least 12 months) checked by a third party laboratory testing facility as per Schedule Q, Attachment 4, Para. 7.1
2. Manpower, equipment, tools and other logistics shall be ready and prepared for installation.
3. Fiber optic cable shall be withdrawn after determining inspection report as accepted with material receiving inspection report form.
4. Unless otherwise stated, all tests shall be conducted by the Communication site Engineer and witnessed by the Communication QC Inspector. The test shall be recorded as defined herein.
5. Cable reels shall be shipped and handled on the edges of flanges only. Reel shall be shocked during shipping to prevent damage from load shifting.
6. Splicing procedures shall be done as per available fiber optic cable (FOC) splicing instructions or with this procedure.

FIBRE OPTIC CABLE ROUTING

1. The fiber optic cables (FOC) route for all new cables shall be approved by Saudi Aramco prior to the trenching and cables works.
2. All buried and unburied cable route shall be marked in accordance with the Saudi Aramco standard drawing Following.           
3. For direct buried fiber optic cables, it is recommended that, route be ripped, so that obstacles can be identified and removed and the placing operation precautions during installation and back filling shall be in accordance with the requirements of SAES-T-628 and SAES-T-629.
4. Verify that cable reel storage condition and protection is as per manufacturer’s recommendation. For outdoor storage, verify that cable reel is supported off the ground and provided with a weatherproof (i.e., rain and dust-tight) cover per the manufacturer recommendations.
5. EMS Markers shall be provided on all fiber optic cables (FOC).

CABLE BENDING RADIUS FOR FIBER OPTICS

Bending radius specified by the cable manufacturer shall be obtained where available or as per SAES-T-624 Para. 4.1.10

1. 10 times the cable diameter, when the cable is not under tension.
2. 20 times the cable diameter, when the cable is under tension.

Pulling tension on fiber optic cables shall not exceed 600 pounds.

Cable should be pulled in a straight line and never be bent or wrapped around the hand or any other object.

Use Pulling tension measuring device a dynamometer (1,000 pounds).

CABLE FIBER OPTIC INSTALLATION

1. Prior to shift the cable supports to the site, the supports frame, stand and/or brackets shall be inspected and checked against the issued for construction or standard drawing.
2. Pay attention to the existing point for correct sizing and orientation.
3. Check to ensure that rough edges are removed and the assemblies are primed, and painted in accordance with project specifications and international applicable engineering standards.
4. Check to ensure that the installation does not obstruct access ways, exits or passage to the equipment.
5. Ensure that adequate access area have been maintained and available to do the maintenance work as required from time to time.
6. Installed supports shall be verified and inspected to ensure that, it is leveled, vertical and the whole assembly is rigid.
7. Check the elevation of the installed instruments to ensure it position.
8. Supports that are installed on precast foundation it shall be checked to ensure that they are tight and secured.
9. Supports shall not be fixed to the hand railing or similar, less than entirely rigid structures.
10. RGS/RGS PVC coated conduits and fittings shall be used for fiber optic cable.
11. Sub-ducts shall be installed, if required per issued for construction drawings or as per SAES-T-624, Sec. 4.3.
12. Cable trays and cable tray supports shall be verified and inspected prior to cable pulling.
13. For cable pulling operation refer to method statement no.
14. A pulling swivel with a (maximum7/8-inch diameter) shall be use.

FIBER OPTIC CABLES SPLICING PROCEDURES

• • • Prior to fiber optic cable (FOC) splicing, check the Cable Schedule and location plan to confirm it is of the correct cable tag number, type, size and location (to and from).

• • Check that the equipment/fiber splice boxes and fiber optic patch panel are already available.  Put PVC cap on the connector patch panels when not in use ensuring them it is covered to keep them clean.
  • Ensure that the splicing shall be done in controlled environment and the work area is clean and away from source of dust.  Use lint-free wipes (not cotton swaps or rags) to clean every fiber end before splicing or testing.
  • Whenever connectors are not terminated they should be covered with PVC cap to protect the end of the ferrule from dirt.  One should never touch the end of the ferrule, since the oils on one’s skin causes the fiber to attract dirt.
  • Prepare the fiber optic cable by removing the outer jacket of the cable to expose the cable strength, which usually Kevlar, using separator scissors and cut the Kevlar leaving 6mm to 8mm sticking out of the out jacket.  Hold the cable to prevent the buffered fiber from being pulled out of the outer jacket before stripping.
  • Remove the buffer with modified no-nik tools arrow pointing in the direction of the stripping.  Remove at least 16mm of the fiber’s buffer into 3 bites of no-nik tools.
  • After removing the buffer, wipe the fiber with lint-free cloth dampened with alcohol or alcohol pad.  Make sure that no buffer residue or dirt on the fiber by holding it light and inspect the fiber for smooth and shiny surface.
  • After cleaning all the fiber with alcohol, inspect and hold the connectors up to a light to ensure that the capillary hole of the ceramics ferrule is clean.  If the hole is obstructed, blow it clear with compressed air or use a piece of stainless wire to clean the hole.
  • Fiber cable is now ready for splicing and termination.  Before beginning the splicing operation, secure the cable in an optical Fiber Splicer tray/organizer.  Splice the fiber optic cable to the factory made fiber optic pigtail.
  • Turn on the splicer machine and then select the splice mode.
  • Prepare the fiber ends.  After removing the coating, clean the cladding surface.  Then, cleave the fiber precisely by using optical fiber cleaver.
  • Set the fiber on the V-groove and close the sheath clamp and the fiber clamp carefully.  As the fiber position depends on it’s cleave length, set the fiber correctly by referring to the label inside the wind protector.  Then set the other fiber to the opposite V-groove by the same procedure above.  Finally, close the wind protector.
  • Start the splice by pressing the “SET” key to proceed.  At first, the fiber move toward each other.  During the forward movement, a short arc occurs the fiber surface.  The splice stops the forward movement when the gap between the fiber ends is proper.  After the initial gap setting, the splicer measures and display the cleave angle, then cladding and/or core alignment is performed.  Then the splicer reduces the gap (a final gap setting) and generates a high voltage discharge for the arc fusion along with stuffing the left side fiber into the right side fiber.  Finally the microprocessor calculates and indicates the estimated loss on the screen.
  • In a case that the estimated loss is higher than expectation, press the “ARC” key to generate the re-arc.  After the additional arc discharge, the splicer estimates and displays the loss again.
  • By operating the wind protector, the splicer stores the splice data result that includes the splice mode, date, estimated loss and so on.  Also a proof test is automatically performed when the proof test function is “ON” in the menu commands.
  • Reinforce the fiber with the tube heater.  Then finally remove the fiber from the heater.  At that time, do not touch the protector (let it cool before storing the splice in the splice tray) and ceramic heater element because of the high temperature.  After final inspection of all fiber connectors, start to organized the fiber into connector coupler (ensure that the coupler are free of dust and with dust cover on the other side).
  • Prepare and make labels for fiber cables at both ends.
  • All fibers shall meet acceptance test requirements listed in Table 4 prior to establishing service. Refer to SAES-T-634 para. 5.3.4
  • After splicing is completed, it is now ready for QC inspection and testing.  Result will be filed and recorded on applicable forms as per approved SATIP.

FIBRE OPTIC CABLE TESTING PROCEDURE

1. All optical fibers shall be 100% attenuation tested by-directionally A to B and B to A. Attenuation/Power Test shall be 1310 nm and 1550 nm. The fiber optic cable will be tested at 1550 nm for Single Mode as per Project Specification VE-539014 Para-7.5.1.5 and SAES-T-634.
2. Before the start of testing, connect the launch cable to the power source and power meter to calibrate the power output from 0 dB-0 dB for quick reference.
3. Always clean the connections and launch cable with lint-free cloth or alcohol pads.
4. Testing sequence should be from one point to the point and vice versa, and then record all the test data in applicable forms as per approved SATIP.
5. FOC should be tested by both OTDR and Power meter as per Aramco standard.
6. The difference power is supposed to represent the amount of power launched by the source and should be measured directly by a power meter.
7. These are two methods that are used to measured loss. Single ended loss uses only the launch cable while double ended loss uses a received cable attached to the meter.
8. Single ended loss is measured by mating the cable you want to test to the reference launch cable and measuring the power out the far end with meter. When doing this measure the loss of connection mated to the launch cable.  The loss of any fiber splices or other connections in the cable are tested.
9. For double ended loss test attach the cable to test between two reference cables, attached to the source and one to the meter. This way you are measuring the connector losses, one on each end, plus the loss of the cable.
10. Always remember that the launch power reference is set the same way for all measurement to minimize confusion.
11. After the installation and testing, the maximum power loss should not exceed the calculated “Budget Loss” and test shall be acceptable to the various equipment vendors (i.e., Yokogawa, ATI’s, Vista Net, etc.). Splice acceptance test: Individual splice insertion loss shall be 0.05 dB average link splice loss with no single splice loss above 0.1 dB for fusion splices, and 0.1 dB average link splice loss with no single splice loss above 0.2 dB for mechanical splices; connectors shall have insertion losses of 0.5 dB or less. End to End testing shall be as per SAES-T-634 Table-4.
12. Test result shall be filed and recorded on applicable forms as per approved SATIP.
13. Polarization Mode Dispersion and Chromatic Mode Dispersion tests will be conducted on all G.652D fiber as mentioned.

SAFETY PRECAUTION FIBER OPTIC CABLES

1. Obtain the approval of the work permit from the concerned Company Representative before starting any work.
2. Fire Watcher with Fire Extinguisher shall be at work are whenever there is hot work.
3. All electrical tools shall be checked and color coded.
4. Continuous monitoring and inspection shall be implemented to detect and correct unsafe practices while performing the work activities.
5. Provide warning sign and sufficient barricade on work area and only assigned personnel will be allowed in the area.
6. Safety Supervisor shall monitor the work activities to help and protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipment (PPE’s) are supplied and used that comply with Saudi ARAMCO applicable standards.
7. Fiber Optic Cable (FOC) cut pieces/waste shall be kept in separate container and dispose it properly in a trash bin. Housekeeping shall be maintained and working area shall be kept in a clean and tidy manner.
8. Hazard Identification Plan (HIP) of this procedure shall be disseminated and explained to workers for safety awareness.