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Installation Manual for Optical Cable System

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INSTALLATION MANUAL FIBER OPTIC CABLE SYSTEM

Installation Manual for Optical Cable System

Ver. 1.0

CONTENTS

1 GENERAL.............................................................................................................................3 2 DIRECT BURIED CABLE INSTALLATION STANDARD............................................3 3 DUCT BURIED CABLE INSTALLATION STANDARD................................................6 4 OPTICAL FIBER CABLE TERMINATION ....................................................................9 5 SPLICING OF OPTICAL FIBER CABLE......................................................................10 6 UNDERGROUND CLOSURE FOR REGIONAL AND METRO JUNCTION ...........11

Installation Manual for Optical Cable System

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1 General The installation standard consists of:

-Installation standard for optical fibre cable for direct buried applications; -Installation standard for optical fibre cable for duct applications.
2 Direct Buried Cable Installation Standards 2.1 Buried types of primary cables and secondary cables shall be installed on the footway away from the carriageway, unless it is too difficult and problematical to install the buried cables on the footway due to the already existence of other underground utilities and obstructions. 2.2 The excavation of trenches shall be carried out in such a manner as to minimize the interference with existing pipes, cables, trees or any other underground utilities. 2.3 A pilot excavation shall be required where congestion of the proposed buried cables and other underground utilities area foreseen or suspected. 2.4 Unless otherwise especially instructed by Local Government, Municipality, Public Works or other Authorities concerned, the width and depth of the cable trench, which shall be made on sidewalks of the road to place the direct buried types of cables, shall be as follows; Top width : Approximately 40 cm Bottom width : Approximately 30 cm Depth : not less than 110 cm (for OAN) Depth : not less than 130 cm (for Regional and Metro Junction) The depth is measured from the soil surface. 2.5 The bottom of the trench shall be well leveled off without sharp cutting stones or obstacles, which may damage the cable. Fine sand or equivalent shall be placed on the trench bottom and compacted well. The thickness of trench bottom and compacted well. The thickness of trench bed made by sand shall be at least five- (5) cm. The Partners shall install protective PVC pipes having 100 mm in nominal inside diameter and 5.5 mm in wall thickness for buried cables according to the number of cables and/or the cable size where the buried cables are placed across the roads, taking the space for cable replacement and/or for relief cable in future, into consideration. For OAN, the covering depth of the protective PVC pipes measured from the top of the pipes to surface of ground, road or pavement shall be at least one hundred ten (110) cm at the crossing of the carriageway, unless otherwise especially instructed by the Local Government, Municipality, Public Works or other Authorities concerned. For Regional and Metro Junction, the covering depth of the protective PVC pipes measured from the top of the pipes to surface of ground, road or pavement shall be at least one hundred twenty (120) cm at the crossing of the carriageway, unless otherwise especially instructed by the Local Government, Municipality, Public Works or other Authorities concerned.

2.6

2.7

Installation Manual for Optical Cable System


2.8

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Both ends of the protective PVC pipe shall be sealed adequately with sack cloth or equivalents. Buried types of secondary cables shall be placed on the bed so as to be directed from the cross-connection cabinet side to subscriber side. The buried cable shall be pulled in the trench within an allowable pulling tension and with constant speed, both of which are specified in the Partners standard installation practices. After the placing of cable, backfilling with fine sand or equivalent shall be carried out, and the cable trench shall be tamped well while adequately watering, until the top of the cable is covered with a layer of well compacted sand at least ten (10) cm in thickness. The cable trench over the sand layer with ten (10) cm in thickness shall be backfilling with the sieved soil or sand which has passed through a 38 mm-sieve in thirty (30) cm in thickness. The backfilling shall be carried out by layers not exceeding twenty- (20) cm in thickness. Each layers not twenty (20) cm in thickness shall be completed well while adequately watering, before the next layer or soil or sand is played. Backfilling for trench on asphalt carriageway or paved footway shall conform to the Specifications of the Local Government, Municipality, Public Works or other Authorities concerned. Trench shall be restored to original grade in accordance with the Specifications of the Local Government, Municipality, Public Works or other Authorities concerned. The concrete protective plate (capstone, length = 25 cm, width 10 cm, thickness 2.5 cm) shall be laid throughout the cable trenches, approximately ten (10) cm above the buried cable(s) or the protective PVC pipe(s), that is, just after completion of sand coverage. Splicing shall be carried out immediately after placement of the buried cables. If impracticable, the cable ends shall be sealed with suitable cable caps. The pit for splicing of the buried cables shall be dug out as follows: Length : Approximately 1.5 meters Width : Approximately 1.0 meters Depth : Approximately 1.2 meters (for OAN) Depth : Approximately 1.3 meters (for Regional and Metro Junction)

2.9

2.10

2.11

2.12

2.13

2.14

2.15

2.16

2.17

In the splicing point, the cable metallic shields shall be electrically continuos throughout an entire cable route. The splicing portions shall be protective by suitable concrete rectangles (length 60 cm, width = 30 cm, thickness = 5 cm) or equivalents. Marking posts shall be installed near the splicing point and at the location where the buried cable changes the direction. The electronic marking post shall be installed for every splicing point and placed on splicing closure The marking post shall be made by concrete, and the dimension shall be as follows: Height : 325 mm Top square : 100 mm x 100 mm, and marked with TEL and cable direction

2.18

2.19

2.20

Installation Manual for Optical Cable System


Bottom square : 250 mm x 250 mm 2.21

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Minimum clearance between buried cable and other underground utilities shall be given in Table 1-3-1. Table A-3-1 Minimum Clearance Underground Utilities between Buried Cable and

Utilities Underground Power Lines Water Mains Pipes Sewage Pipes

Parallel 45 cm (short span)

Crossing 45 cm

30 cm 30 cm

15 cm 15 cm

2.22

Where it is too much difficult to keep the minimum clearance as stated in Table A-3-1 of this section 2, the Partners shall consult with user or Construction Supervisor about the solution. Piles of backfilling materials, excavated soil or any other materials to have been used for placement of buried cables shall not be left at the site. The excess materials or soil shall be disposed immediately and that site shall be cleaning up before the shift to the next site.

2.23

Duct Buried Cable Installation Standard 3.1 General (1) A single mode optical fiber cable shall be applied in this Project. All the optical fiber cables have minimum 0.6-mm gauge of one (1)interstitial metallic pairs as specified in FOC [01] and FOC [02]. In the vicinity of and in the exchange building, the optical fiber termination cable with optical termination cords (for convenience, hereinafter abbreviated as optical fiber cable for indoor use) shall be used. The optical fiber cable (also for indoor use) shall replaced from CTF to manholes in the vicinity of the exchange buildings, in which the optical fiber cables for outdoor use and for indoor use shall be spliced.

(2)

3.2 Placement of Optical Fiber Cable into Duct (1) Duct assignment for the optical fiber cables shall be so carefully made as to avoid

Installation Manual for Optical Cable System

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crossing of cables among the duct entrance and cable racks and brackets, and blockage to future duct cables keeping easy access to vacant ducts. The uppermost and roadside duct will be assigned for optical cable installation in principle. (2) The main ducts having 100 mm in nominal inside diameter shall be rod by an acceptable method and cleaned. Then, three (3) smaller size sub-ducts, having 28 mm in nominal inside diameter, shall be placed at once into a main duct cleaned. The sub-duct shall not have joint in a main duct. If the sub-duct joint in the main duct is required, such a joint shall be so placed as to be staggered apart from the other two (2) sub-duct joints in the main duct, and shall never block nor damage the other two (2) sub-ducts and optical fiber cable to be placed. An anti-slip device shall be provided at the end of the sub-ducts of the main duct entrance, and a pulling wire shall be pulled throughout each sub-duct. An optical fiber cable shall be pulled in a sub-duct as longer as possible, usually to be longer than approximately 1,200 meters, between a joint of the optical fiber cables for outdoor use and the adjacent joint of the same or for indoor use. In case that the cable pulling into sub-duct with the standard lengths as above-mentioned in (4) of this section 3 is impossible according to the results of the Partner's detailed survey, then the cable pulling length longer than, or less than such a standard length may be allowed to the Partners If the existing sub-ducts are utilized, the Partners shall ascertain the situations of such existing sub-ducts by an adequate method before pulling the optical fiber cable, even where an existing pulling wire is already pulled through. Optical fiber cables shall be pulled with sufficiently friction free methods. The cable shall be pulled within an allowable pulling tension and constant speed, both of which are to be specified in the Partner's installation practice. Optical fiber cables and the sub-ducts shall be placed in such a manner that they do not block any vacant ducts nor restrict the working space in the manholes/handholes, etc. Optical fiber cables shall be so placed as to directed as indicated in the design/drawings. Usually those cables shall be placed to be directed from a host exchange side or a local tandem exchange side to a remote line concentrator (generally, called as Digital Line Unit and abbreviated as DLU in Indonesia) side or a local exchange side, respectively. Splicing shall be carried out immediately after placing of the optical fiber cables. The optical fiber cables shall be supported and fixed using suitable cable racks

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10) (11)

Installation Manual for Optical Cable System

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and brackets and binding ropes or equivalents in all the manholes and cable vault/trenches in exchange buildings. Should no suitable cable racks be available in existing manholes/handholes, the Partners shall provide the cables racks and brackets and/or hardware for fixing of the cable racks. (12) If required, the optical fiber cables shall be protected, using with helical coiled protectors or equivalents in manholes and cable vaults/trenches and/or in the exchange buildings. In every manhole, the cable name plates or tags shall be provided on each optical fiber cable. On the cable name plates or tags, the cable type, size and gauge, cable name, name of manufacturer and date of installation shall be indelibly inscribed as follows : a) In a manhole where optical fiber cables are spliced : Each one (1) of cable nameplate or tag shall be provided on the cable at both sides of splice enclosure. b) In case where optical fiber cables are pulled through without splicing in manhole : One (1) cable nameplate or tag shall be provided on the cable. (14) Upon completion of placing and setting up of optical fiber cables and the sub-ducts in exchange manholes in the vicinity of the exchanges and cable vault/trench in the exchanges, any gap and opening of ducts occupied with the optical fiber cables and sub-ducts shall be so sealed as to be watertight. Anti-creeping device shall be provided, where the creeping cable is detected or suspected. The Bidders shall state the details of the anti-creeping devices on his installation practices. In case of future development needed due to high demand or installation in branching manhole or in non-straight duct route, slack or spare cable is needed. Adequate length of ten (10) meters of slack cable should be provided which is consisted of at least 5 meters length cable in each splicing direction. This slack cable should be rolled and clamped in the proper place in manhole. The radius of the slack cable should be at least 40 D (where D is the optical cable outer diameter).

(13)

(15)

(16)

(17)

Optical Fiber Cable Termination For OAN: (1) The optical fiber cable shall be terminated on the optical fiber cable termination frame or box (CTF/BOX) in the equipment room, using the optical fiber termination cords which are connected to the optical fiber termination cable for indoor use and are usually prefabricated at a factory, or as an

Installation Manual for Optical Cable System alternative for this method, an exchange joint shall be made. (2)

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The optical fiber termination cable for indoor use shall be placed on the cable racks from the cable vault to CTF/BOX in the exchange building, where there are no suitable existing cable racks in the exchange building. Around and near CTF/BOX, the optical fiber cable and fiber ermination cords shall be suitable protected where those are exposed. The interstitial metallic pair shall be terminated on the CTF/BOX unless user instructs to the Partners to terminate those pairs to another place. For Regional and Metro Junction: (1) The optical fiber cable shall be terminated on the optical fiber cable distribution/termination frame or box (ODF/OTB) in the Transmission room, using the optical fiber termination cords, which are usually prefabricated at a factory, or as an alternative for this method, an exchange joint shall be made. (2) From MDF the exchange building, optical fiber cable (duct or direct buried type) shall be pulled up to point of termination cable plan (exchange joint). The cable shall place on the cable rack and coupling with ODF (Optical Distribution Frame) in transmission room. In case of the cable racks are not exist, Partners shall provided, which having racking structures approximately 350 mm in width, made by the 6 mm x 25 mm of steel frame. The optical fiber termination cable shall be placed on the cable racks from the exchange joint to ODF/OTB usually in transmission room. Around and near ODF/OTB, the optical fiber cable and fiber termination cords shall be suitable protected where those are exposed.

(3) (4)

(3)

(4)

Splicing of Optical Fiber Cable (1) All the splicing works, including the exchange joints, in any types of optical fiber cables shall be performed in conformity with the installation practices approved by user. (2) The Bidders shall state the full details of each type of the joint to be applied to the fiber core splicing and the installation methods of the splice enclosure in his installation practices. (3) The joint and splicing of optical fiber cores shall be performed in such a method that minimum splicing loss for the optical fiber is introduced. The Bidders shall state the maximum value of splicing loss in his installation practices. (4) Interstitial metallic pairs shall be spliced using with connectors. The Bidders shall state the splicing method of an interstitial metallic pair in his installation practices.

Installation Manual for Optical Cable System

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(5) Any coating materials on the fiber core must be easily removable without hazard to either the fiber or personnel when joint or splicing. (6) The splice enclosure shall be supported by suitable cable racks and brackets in all the manholes and cable vaults/trenches. (7) The splice enclosure shall be protected against accidental damage in a manhole when that manhole is opened. The Bidders shall state the details of the protection method in his installation practices.

6 Underground Closure for Regional and Metro Junction 6.1 Application (1) Place of set up closure There closures are to be used in a manhole a tuner and buried section (2) Cable Outer Diameter The closure should be usable for the following table 1. Table 1
Type of cable Optical fiber cable (3) Outer diameter

(4)

8.6 mm 25 mm

6.2 Raw Material Precondition (1) Material of Sleeve The sleeve is made from Polyethylene (PE) material with (2 ~ 3) % carbon black content or made from kind of plastic material with equality characteristics. The material of sleeve should have tensile strength 25 Mpa and still remains while the material sink to the chemical solvents as for 24 hours, such as : 0.65 N-H2SO4, 0.1 N-NaOH, 0.1 N-NaCI, 0.1 N-Na2SO4. (2) Component ability The metallic materials (excluding those of constituent items to be contained within the closure) should be those having corrosion resistance equivalent to or better than ISO-683/13 type 11 or better than (3) Isolating Component ability The isolating component as sealing should be made from rubber material or the other that prevent water infiltration and not be soluble in the chemical solvents as for 24 hours, such as: 0.65 N-H2SO4, 0.1 N-NaOH, 0.1 N-NaCI, 0.1 N-Na2SO4. 6.3 Construction (1) Construction The major constituent parts are the sleeve, the entry plate, the cable fixing component, the slack frame, the organizer and the gas valve.

Installation Manual for Optical Cable System (2) Sleeve

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a) Shall be able to protect the cable joint part from outside force by covering the cable joint part. b) Shall be able to keep the cable part airtight together the entry plate. c) Shall be able to open and close without having to touch the existing cable. (3) Entry Plate a) Shall be able to hold the cable in such proper position b) Shall be able to keep the cable part airtight together with the sleeve. c) Shall be able to do the installation work without having to touch the existing cable when the sleeve is opened for maintenance, repair or new cable installation. (4) Cable Fixing Component Shall be to hold firmly to protect the cable joint part from pulling force. (5) Slack Frame a) Shall be able to hold the tension to protect the optical fiber splice from pulling force. b) Shall be able to fix several splicing organizer.

(6) Organizer a) Shall be able to accommodate 6 or 12 fibers. b) Shall be able to storage 30 mm or more of the allowable bending radius of optical fiber. (7) Gas Valve The Sleeve should be provided with one gas valve as an air leakage test. (8) Assembling and dismantling Assembling and dismantling of the closures shall be done uninflammable. 6.4 Characteristics (1) Repeated usage After being dismantled and reassembled for 6 times there should be no bubbles detected due to gas-leakage when 40 Kpa of pressure is applied to the inside of the closure and it is immersed at room temperature for more than 30 minutes bellow the water surface. (2) Cable holding force test When 40 Kpa of pressure is applied to the inside of the closure and 784 N load is applied with 25 mm outer diameter of cable, there should be no abnormalities to occur, and neither should damages, such as cracks, fissures or disassembles, or falling cable. (3) Bending test After bending test for 4 times there should be no abnormalities occurred, and neither

Installation Manual for Optical Cable System

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should damages, such as cracks, fissures or disassembles, or falling cable, when 40 Kpa of pressure is applied to the inside of the closure and cable are bent to angle (+900) and (900) from normal condition each at 4 times. (4) Rotating test When 40 Kpa of pressure is applied to the inside of the closure, and the cable is twisted 4 times to angle of (+900-) and (-900) from normal condition at distance of 1 m from the closure at each branch, there should be no abnormalities occurred and neither should damages such as cracks, fissures or disassembles or falling cable. (5) Vibration test When 40 Kpa of pressure is applied to the inside of the closure, and it is vibrated for 2 hours at 10 Hz frequency and 5 mm amplitude at distance of 50 cm from the closure, there should be no abnormalities to occur and neither should damages such as cracks fissures or disassembles or falling cable. (6) Heat cycle test After the test no. 4.2 to 4.5 above and also having heat cycling test, under the condition 200 C ~ +600 C temperature with 3 cycle/day period and 21 cycles frequency, the gas pressure inside the closure should be equal to or more than 36 Kpa. (7) Hermetically test After having cycling test without gas pressure there should be no water seepage coming into the closure under such condition where water head length is equivalent to 2 m and of 7 days duration. (8) Pressure destruction test When such pressure is applied to the central part of the sleeve vertically accelerating at a rate of 10 mm/min the sample should not be getting destroyed at the load of 1940 N (for boried0 and 980N 9for duct). (9) Collision test When 40 Kpa of pressure is applied to the inside of the closure, it should be endured when it is struck at the center with 1 kg of load from 1 m height.

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