ANNEXURES TECHNICAL SPECIFICATIONS - JDA

JOHANNESBURG DEVELOPMENT AGENCY (JDA) Contract No. JDA-WP 15N-02 Part T1: Technical Specification

ANNEXURES – TECHNICAL SPECIFICATIONS

TURNKEY IMPLEMENTATION OF THE ITS REDUNDANCY LOOP

REA VAYA BUS RAPID TRANSPORT SYSTEM

PHASE 1C

PLANNING, DESIGN, BUILDING, MONITORING AND INFRASTRUCTURE

SECURITY OF THE OPTICAL FIBRE NETWORK

WORK PACKAGE: 15N

City of Johannesburg Johannesburg Development Agency

No 3 President Street The Bus Factory Newtown Johannesburg, 2000

PO Box 61877 Tel +27(0) 11 688 7851 (O) Marshalltown Fax +27(0) 11 688 7899/63 2107 e-mail: [email protected]

www.jda.org.za www.joburg.org.za

mailto:[email protected]

http://www.jda.org.za/

http://www.joburg.org.za/


JOHANNESBURG DEVELOPMENT AGENCY (JDA) TURNKEY IMPLEMENTATION OF THE ITS REDUNDANCY LOOP

REA VAYA BUS RAPID TRANSPORT SYSTEM PHASE 1C

PLANNING, DESIGN, BUILDING, MONITORING AND INFRASTRUCTURE

SECURITY OF THE OPTICAL FIBRE NETWORK WORK PACKAGE: 15N

CONTRACT No: JDA-WP 15N-02

Contents

A. 110mm HDPE Sleeves and Warning Tape ......................................... 3 B. 7 way (12/10) micro duct ..................................................................... 4 C. Splice Closures ................................................................................... 7 D. Post Installation Duct Integrity Test (DIT) procedure ....................... 8 E. Optical Fibre Cable Drum Handling and Pre-Installation

Test Procedure .................................................................................. 19 F. Optical Fibre Cable Post-Installation Test Procedure ..................... 27 G. Optical Fibre Conformance Test Procedure .................................... 32 H. 72 core G652.D cable to be installed in 12/10 micro duct :

Technical Specifications for Micro Duct Optical Fibre Cables ....... 42


A. 110mm HDPE Sleeves and Warning Tape

1. 110mm HDPE sleeves

110mm sleeves shall be manufactured from HDPE material manufactured to SANS IEC

61386-24:2005 (Type N 450) “Conduit systems for cable management Part 24: Particular

requirements – Conduit systems buried underground”.

Double wall corrugated construction provides high ring stiffness.

Smooth bore ensures easy draw-in of cables.

The pipes shall carry the SABS certification mark in respect of specification.

Push fit couplings shall include rubber sealing ring.

2. Warning tape

Warning tape shall be installed during the backfill process. The warning tape shall be

installed a minimum of 300mm above the ducts. The warning tape shall be of yellow colour

and 150mm wide x 200 micron thick. The warning tape shall have the following wording in

thick black lettering:

“WARNING FIBRE OPTIC CABLE – PHONE JDA (“number to be confirmed”)”

3


6

B. 7 way (12/10) micro duct[GS1]

1. General

The following ducts shall be supplied:

7-way duct consisting of 7 x 12/10 mm HDPE micro duct with a minimum 2mm thick

HDPE outer jacket to renderer the duct suitable for direct burial;

End caps for the respective size ducts and micro ducts;

Ducts to be supplied on steel reels (preferred) or on wooden drums. Should ducts be

supplied on wooden drums then all the ducts and sub-ducts shall be tested in factory

and on delivery for deformation by blowing a ball bearing of 85% of the internal

diameter of the duct.

The minimum length of any duct type ordered will depend on the proven manufacture

capacity of the Manufacturer.

2. Material properties

The duct and micro duct must have the following material characteristics:

Construction: Outer layer HDPE; Inner layer silicone layer co-extruded;

Extruded from 100% prime grade virgin PE (Polyethylene) in accordance with

ISO1872-1 (ISO1872-2) Class N;

Working life: 20 years;

UV stability: 1-year outdoor storage; and

Chemical resistance: Pass ISO/TR10358.

The following are indicative values for the HDPE – the supplier must provide the minimum

specifications:

Melt index (190oC/2.16kg): 0.33g/10 minutes

Density: 0.950g/cm3

Tensile strength at yield point: 26 Mpa

Elongation at break: > 500%

Flexural stress 3.5% deflection: 22 Mpa

Charpy notched impact strength:23kJ/m2 at 23oC

Charpy notched impact strength:20kJ/m2 at -30oC

Shore hardness D: 62

Vicat softening point: 80oC using load of 5kg


7

3. Physical characteristics

The 12/10 micro duct shall have the following physical characteristics:

Manufactured to ISO 9001 certification

Outer Diameter: 12.0mm with +/- variance of 0.1mm

Wall thickness: 1.0mm with +0.0mm to -0.1mm variance

Ovality: <5%

Air pressure rating: 10 bar for 5 minutes

Minimum tensile force at yield: 445N

Reversion ISO 2505 < 3%

Coefficient of friction: <0.1

Ball testing: 85% of internal diameter ball passes freely

4. Colour coding:

Ducts and micro ducts shall be colour coded in different colours to ensure ease of

identification.

Outer sheath shall be Yellow according to the TIA/EIA 598 colour code

Micro ducts: 7-way: Blue, Orange, Green, Brown, Slate, White, Red

5. Packaging for transport:

The ducts must be supplied on steel reels. A rebate price must be provided for all steel reels

returned to supplier in an acceptable condition.

The individual reels shall carry the following markings:

JDA

Manufacturer’s Name

Reel Number / Duct Identification Number

Duct Length in meters

Type of Duct

Gross weight in kgs

Arrow of Rotation

6. Compression couplings and end caps:

Compression couplings – Plasson or similar approved for different size ducts and micro

ducts

Minimum pressure rating of 16 Bar

End caps as approved for different size ducts and micro ducts


8

7. Factory acceptance tests:

The supplier shall provide facilities for factory acceptance tests and shall state the process to

be carried out for factory acceptance testing.

The cost shall be included in the per meter rate for the duct.

JDA reserves the right to witness the factory acceptance tests.


C. Splice Closures

1. INTRODUCTION

There are many splice closures available for different applications and for different cable

configurations. It is important that when selecting a splice closure, the product should be

versatile and well-constructed closure. The dimensions and configurations of the various closure

types will vary but the basic principles of the preparation and the splicing will be very similar.

2. GENERIC CHARACTERISCTICS

The Optical Fibre Splice Closure should be an environmentally sealed enclosure for the fibre

management system that provides the function of splicing in the external network.

The Optical Fibre Splice Closure needs to provide for all cable terminations and sealing

requirements.

The closure would typically be a single ended design made of a thermoplastic material. The base

and dome are sealed with a clamp and pre-installed Gel-O-ring system.

The closure should typically allow a total of six (6) cables, with a diameter of minimum 9mm and

maximum 25mm, to be terminated.

The closure can be opened and closed repeatedly without the need to replace the sealant.

The closure can be used in both underground or in overhead network designs.


8

D. Post Installation Duct Integrity Test (DIT) procedure

1. SCOPE

This document describes the complete procedure of the post-installation Duct Integrity Tests

(DIT) that must be performed on all newly laid cable ducts.

In cases where ducts were installed on previous projects it is recommended that the ducts be

subjected to a second DIT prior to a new cable installation.

2. PURPOSE OF DIT TESTS

The purpose of the duct integrity tests is to ensure and to certify that all the installed ducts

are;

Continuous,

Connected according to the correct color codes and are not crossed,

Leak free,

Free from deformities and,

Free from dirt particles and water.

Only after this status has been obtained and certified may cables be installed into the ducts.

3. REFERENCE DOCUMENTATION

CBI Electric – Optical Fibre Cable Installation, Splicing & Testing.

HDPE Duct Specification – CBI Electric.

Duct Integrity Test Procedure Prior to Installation – Fibre Optic Telecoms (FOT).

4. DEFINITIONS, ABBREVIATIONS AND ACRONYMS

DIT – Duct Integrity Test

CFM – cubic feet per minute

5. EQUIPMENT REQUIREMENTS

Compressor

An air compressor that can handle a minimum of 10.5 bar of output pressure with a

100 CFM rating must be used when performing the tests.

Air Filters shall be fitted at all times in order to remove moisture.

Air after-coolers must be provided when compressors are not fitted with built-in after-

coolers.

Compressors must be fitted with air intake filters. The filters will reduce the intake of

dirt and contaminants.

A 10.5 bar air dispenser with air flow meter is to be connected to the compressor

when performing the tests.


9

Mandrel specification (for checking deformities)

The mandrel to be used shall be made of Nylon or Teflon with rounded off ends.

The mandrel diameter must be 85% of the inside diameter of the duct to be tested.

This equates to 8.5mm for 12/10mm ducts and,

For the 32/26mm ducts it must be 22mm.

The mandrel length must be approximately five (6) times the inside diameter of the duct. Rounded off

figures will equate to:

±60mm long for 12/10mm ducts and

±150mm long for 32/26mm ducts.

Mandrel sizes for other duct sizes must be calculated in the same manner.

Sponges (for cleaning and drying)

The sponge will have a diameter twice the inner diameter of the duct and a length of 5

times the inner diameter of the duct.

The sponge must be high density of at least 28 grams /cft

Pressure gauge and connector manifold

There are various configurations of manifolds that are used for connecting the air

supplies to the ducts to be tested.

The most practical is to have a manifold fitted with a number of gauges and valves so

that the tests can be done on several ducts simultaneously.

An example of a typical manifold is shown below for reference (Figure 1).

FIGURE 1: MANIFOLD WITH GAUGES, VALVES AND DUCT CONNECTORS

6. TESTS TO BE PERFORMED

The following tests must be performed on all newly laid ducts. It is extremely important that

the sequence of these tests be strictly adhered to:

Air-Pass test (continuity and blockage test).


10

Sponge blowing test (cleaning).

Mandrel test (check for deformities).

Pressure test (test for air leakages).

7. AIR-PASS TEST

Principle

The Air-Pass test is performed on every duct and the individual micro-ducts of a multi

way duct to confirm end-to-end continuity between the two access points.

Air is introduced from one end of the duct and the resultant flow is observed at the far

end of the duct.

If the air escapes from the far end of the duct then it is established that the duct is

continuous.

If a reduced volume of air or no air emerges at the far end it must be considered that

a blockage could have occurred.

The fault has to be identified, localized and rectified before proceeding with any

further testing.

Procedure

Prepare (open-up) the duct ends to prepare for the DIT.

The Air-Pass test is performed on each individual duct and micro-duct to confirm end-

to-end continuity between the two access points.

The individual ducts from the Manhole or Jointing Pit must be connected to the duct

calibrating equipment.

The other end of the duct calibrating equipment must be coupled to the outlet of the

air compressor by means of a flexible air-hose.

On the downstream end, the micro duct is secured in a suitable mesh wired flexible

grip (cable pulling sock) to avoid any accidents in the event of a pebble or solid

particle already present inside the micro-duct before the start of Air-Pass testing

procedure.

When the set-up is ready, open the air discharge valve from the compressor slowly.

The air starts flowing in a controlled fashion via the regulator on the duct calibrating

equipment into the micro duct. Pressure stabilization in the micro-duct will take

approximately 20 seconds. The standard multi-duct length which can be put to test is

1000m.

Normal Air discharge: If the air discharged at the far-end is sufficient, then the micro-

duct length under test is deemed to have passed the Air-Pass test.

Low Pressure Discharge: If the observed pressure at the downstream end is less than

the norm, there may be a possibility of air leakage from a loose coupler, micro-duct

puncture, partial blockage or cuts on the multi-duct etc. in between the points of

testing. If this test fails, the joints at the marked coupler points in the section must be

opened to locate and repair possible loose or un-secured couplings.


11

Back Pressure: If the pressure observed on the regulator pressure dial is more than

the set pressure, then there may be possibility of a blockage due to several causes –

e.g. deformity in the micro-duct, severe kinks, crush, bends, severe indentations, etc.

giving rise to back pressure. If the back-pressure test fails, a Crush & Deformity test

must be carried out.

Details of faults found must be noted on the DIT certificate and a supporting site

instruction must be handed to the relevant contractor for immediate remedial action.

Possible causes of the failure can be:

Missing ducts,

Ducts not connected through,

Damaged ducts or,

Wrong connection on duct colors.

Warning: During the whole operation, no one should be allowed to stand directly in

front of the multi-duct end whether in the trench or the Jointing Pit/Manhole.

8. SPONGE TEST

Principle

The purpose of this test is to clear the duct of any dirt, objects or water that may have

entered the duct during the installation process.

Any small obstacles or water in the ducts could cause the mandrel to get stuck in the

ducts and could lead to damage of the low friction lining on the inside of the duct.

Procedure

Release the connecting tube between the test assembly and the duct after all air has

been released.

Insert a high-density sponge of the correct size as described above into the duct to be

tested and reconnect test assembly to the duct.

Inform all personnel at far end to stand clear and open the air gradually. The air

pressure must not exceed 10 bar during this operation.

The sponge should arrive at the far end of the duct within a minute.

If there are any signs of water or dirt the process must be repeated with a clean

sponge of the same diameter to ensure that the duct is clear of all debris. If required,

this step must be repeated until the sponge is clear of all debris and water.

Once the test is successful, close the air and move to mandrel test.

The sponge can be left in the safety catching device to reduce the impact of the

mandrel when it exits the duct.

If the sponge does not appear at the far end of the duct, or within a reasonable

amount of time, the suspected fault must be recorded on the DIT test report and handed to

the relevant contractor on a site instruction for immediate attention.

Possible causes for a sponge in getting stuck in a duct are:


12

The duct could be badly kinked,

The presence of dirt or water in the duct or;

Faulty or wrongly fitted duct connectors.

9. MANDREL TEST

Principle

The purpose of the test is to verify that the inside diameter of the duct is constant

throughout at 85% of the specified inside diameter.

Deformities and bends in the duct can cause friction on the cable and will adversely

affect installation distances.

Procedure

Disconnect the connecting tube between the test assembly and the duct after all air is

released.

Insert the correct size mandrel as described above and reconnect the test assembly

to duct.

Inform personnel at the far end of the duct length to stand clear and gradually

increase the airflow to a maximum of 5 bar pressure. On an elevated terrain, the

pressure may be increased to 8 bar.

If the ducts are clear and connected properly the mandrel should take approximately

one minute to travel a distance of 1000m.

If the test is successful, close the air and move to the pressure test and take note of

the mandrel condition. If grooves are present on the mandrel it is possibly from

indentations in the duct.

If the mandrel does not appear at the far end, record the fault and hand it to the

installation contractor for immediate attention.

Possible causes for the mandrel to get stuck are:

Reduction in inside diameter of the duct,

Excessive pressure on the duct due to incorrect bedding and padding,

Kinks in the cable caused during installation,

Deformities in the duct or

Faulty connectors.

10. PRESSURE TEST

Principle

Cable installation by means of jetting can only be carried out successfully under a

pressure of 10 bar. Before any cable installation is attempted it is necessary to verify

that the duct can hold this pressure.

The test criterion is set to maintain a pressure of 10 bar for 5 minutes with a tolerance

of 0.5 bar pressure drop


13

Procedure

Connect the near end of the duct to be tested to the air-feed from the compressor via

the duct calibrating equipment and seal off the far-end of the duct using the correct

end-plug.

Feed the air from the compressor into the duct and raise the pressure to equalize at

10 bar. Close the air inlet valve.

Observe the pressure reading for 5 minutes. A pressure drop of 0.5 bar is

permissible.

If the pressure does not drop below 9.5 bar within 5 minutes, the pressure test is

considered as passed.

If the pressure test drops below 9.5 bar, the pressure test has failed. The probable

causes could be either a coupler leakage or a puncture in the duct under test.

In the case of the duct failing this test, the suspected fault must be recorded on the

DIT Report and a supporting site instruction must be handed to the relevant contractor for

immediate remedial action.

11. CORRECT SEQUENCE AND PURPOSE OF THE VARIOUS TESTS

# Test Specification Purpose

1 Air Full discharge from compressor Check for duct continuity

2 Pressure 10 bar for 5 min. Permissible drop 0.5 bar Check for coupler leakage, puncture

3 Sponge Diameter = twice the duct ID.

Length = 5 times the ID of the duct.

Sponge Density = Min. 28 gram/cubic foot

Cleaning of the duct

4

Mandrel

Diameter 85% of the duct ID and the lengths

are 60 mm for the 12/10 inner ducts, 100mm

for the 18/15 inner ducts and 150 mm for the

32/28 ducts

Check for bends and twist in duct

12. SAFETY

Do not go inside the manhole or hand hole while the DIT is being performed.

Wear safety glasses outside the manhole or hand hole.

Do not stand in front of the ducts when air/shuttle/sponge/transmitter is blown.

Do not open couplers before air is released completely.

Use warning tape and proper barricading wherever manholes or hand holes are opened.

Use warning cones and tape around the compressor for proper identification by approaching

traffic from a distance.


14

13. CABLE FLOATING PLAN

The Cable Floating plan consists of vital documents and line diagrams to assist a blowing

team to pre-plan floating activities. It must give a clear picture of the quality of the duct

sections from a floating point of view. With the help of the DIT documentation the blowing

team should be in a position to foresee any problems that may be encountered during

blowing and it can plan to tackle those problems in advance. Apart from this the DIT

documentation should also give a good indication of the quality of duct laying done by the

contractor.

With these objectives in mind a comprehensive and objective cable floating plan with the

following information must be supplied:

Line Diagram: Indicates the coupler points along the sections, as well as all

crossings.

DIT information: Indicates the shuttle pass time, sponge time and result of the

pressure test.

Faults/ Failures: Indicates type of faults encountered in a given section.

Rectification: Gives the details of rectification carried out in a given section.

14. DUCT TEST AND ACCEPTANCE SHEET

The Duct Test and Acceptance Sheet is designed in such a manner to capture all the

relevant important information and specifications at the same time, to obviate time wastage.

Provision is made on the certificate to record the position of three adjacent manholes with

their two intermediate duct sections (Manholes “A”, “B” and “C”).

The DIT testing must be done in both directions from the middle manhole on the certificate

(Manhole “B”).

The testing is firstly done from Manhole “B” to “A” and on completion, the tests are repeated

between Manhole “B” to “C”.

The four individual test results must be recorded for both sections in the provided columns.

Provision is made at the bottom of the form for the three witnessing parties to sign, certifying

the results obtained.

All signatories must be present and have witnessed the test procedure when signing the

certificate.


15

Contractor Test Date

Compresso Make: Model CFM

Site A – Manhole Site B – Manhole

Item Description Ti ck or note val ue

Air Pass Test (Para. 7)

1 Micro Duct 1 - Blue

Duct failures must be reported to Company

PASS FAIL

Micro Duct 2 - Orange PASS FAIL

Micro Duct 3 – Green

Micro Duct 4 - Brown PASS FAIL

Micro Duct 5 – Slate PASS FAIL

Micro Duct 6 – White PASS FAIL

Micro Duct 7 - Red PASS FAIL

Pressure Test (Para 10)

2

The ducts must retain a pressure of 10 bar for 5 minutes with a maximum allowable drop of 0.5 bar

Micro Duct 1 - Blue

Duct failures must be

reported to Company

PASS FAIL

Micro Duct 2 - Orange PASS FAIL

Micro Duct 3 – Green PASS FAIL

Micro Duct 4 - Brown PASS FAIL

Micro Duct 5 – Slate PASS FAIL

Micro Duct 6 – White

Micro Duct 7 - Red PASS FAIL

Sponge Test (Para. 8)

3

Sponge dia. 2 x ID of duct and length 5 x ID of duct

Micro Duct 1 - Blue Sponge Dia. : Length: 130mm. PASS FAIL

Micro Duct 2 - Orange Sponge Dia. : Length: 130mm. PASS FAIL

Micro Duct 3 – Green Sponge Dia. : Length: 50mm. PASS FAIL

Micro Duct 4 - Brown Sponge Dia. : Length: 50mm. PASS FAIL

Micro Duct 5 – Slate Sponge Dia. : Length: 50mm. PASS FAIL

Micro Duct 6 – White Sponge Dia. : Length: 50mm. PASS FAIL

Micro Duct 7 - Red

Control Sheet


16

Mandrel Test (Para. 9)

Micro Duct 1 - Blue Mandrel Size: Dia. : 8mm. Length: 75mm. PASS FAIL

Micro Duct 2 - Orange Mandrel Size: Dia. : 8mm. Length: 75mm. PASS FAIL

Micro Duct 3 – Green Mandrel Size: Dia. : 8mm Length: 75mm. PASS FAIL

Micro Duct 4 - Brown Mandrel Size: Dia. : 8mm Length: 75mm. PASS FAIL

Micro Duct 5 – Slate Mandrel Size: Dia. : 8mm Length: 75mm. PASS FAIL

Micro Duct 6 – White Mandrel Size: Dia. : 8mm Length: 75mm.

Micro Duct 7 - Red Mandrel Size: Dia. : Length: 75mm. PASS FAIL

Duct Connectivity and Labelling

Ducts Plugged & Labelled YES NO

All Ducts coupled through YES NO

Site A – Manhole # Site B – Manhole #

Acceptance Signatures

Contractor

Name Signatur Date

Representative

Name Signatur Date

S.M.E.

Name Signatur Date


17

15. CLEANING AND PROVING PROCEDURE FOR 110MM OUTER DUCTS (HDPE)

Generally, the ducts (pipes) must be placed in the trench, a length at a time and must be

jointed on the floor of the trench with the plastic couplings provided (pre-fitted on one side of

each length). See Figures 2 & 3 below.

FIGURE 2 & 3: 110MM SLEEVES AND COUPLINGS

As the ducts are laid and jointed they must be kept free from internal obstructions and the

ingress of dirt/moisture, by plugging/sealing the ducts and on completion of the laying of the

pipes, insert duct end caps in the manholes and pits. See Figures 4 & 5 below.

FIGURE 4 & 5: DUCT END CAPS

On completion of the laying and backfilling the ducts must be cleaned and proved by pulling

through a cylindrical cleaning brush followed by a wooden or Teflon mandrel ± 400mm long

and 5mm less in diameter than the bore of the duct. The brush should be pulled through the

duct twice and then followed by the mandrel. See Figure 6 below.


18

FIGURE 6: CYLINDRICAL CLEANING BRUSH FOR 110MM SLEEVES

On successful completion of these actions the duct end caps must be replaced on all of the

open ducts.


19

E. Optical Fibre Cable Drum Handling and Pre-Installation Test Procedure

1. INTRODUCTION

This document details the test procedure that must be performed on all optical fibre cables

after delivery form the cable supplier and before installation. This test is also known as a “On

the drum Test”.

The document will also refer to relevant topics such as the safe handling of cable drums and

safety aspects specifically pertaining to optic fibres.

Although there are various cable types and sizes available and a wide range of optic fibre

splicing machines and test equipment, this document will describe the processes in a

generalised manner so that it can easily be adapted to meet all requirements.

Order of description

Purpose;

Handling and storage of cable drums;

Test Procedure; and

Safety.

2. PURPOSE

All fibre strands in all optical fibre cables delivered on site must be inspected and tested by

the installer/contractor on the drum prior to installation. This is to ensure that the cable was

not damaged during shipment from the manufacturer to the job site. Since the cost of cable

installation is usually high it is important that a faulty cable is not installed. The test will

confirm the length of the cable as provided by the manufacturer, the continuity of all fibres,

and the attenuation loss of all the fibres.

3. OPTICAL FIBRE CABLE DRUM HANDLING AND STORAGE

This section provides information for the safe handling and storage of optical fibre cables and

drums at various places – from receiving from the manufacturer to delivery on site. Optical

fibre cables are sensitive to damage during handling and installation. Such damage can

degrade cable performance to the extent that replacement is necessary. In order to obviate

this risk, the following precautions should be taken.

Cable unloading

Whilst unloading drums of cable from a truck it is important that the drums may not be

pushed from the truck to land on tyres or any such cushioning objects to “soften” the

impact. The weight of the drum and cable could cause damage to the flanges of the drum

which in turn could flatten the cable on the drum.

The drum must be rolled from the truck onto a receiving platform which is the same height

as that of the tailgate of the transporting vehicle.

A forklift or crane with suitable rigging chains may be used to offload the cable drums. The

necessary safety precautions whilst using these mechanical aids must be strictly adhered

to.


20

If inclined ramps are used to offload cable drums, this must be done with adequate restraint

and control of the drums. The drums may not be allowed to roll off freely.

Roll each drum away from the bottom of the ramp before handling the next drum.

Cable drum protection battens

Cable drums are fitted with wooden battens for protection of the cable. The purpose of the

battens is to protect the cable from damage by minor impacts resulting from rolling the

drums on rough surfaces.

Drums must always be rolled in the direction of the arrow on the drum flanges. Rolling the

drum in the opposite direction will result in slack accumulating on the drum which could

cause kinking and tangling of the cable.

Do not remove the battens from the drum until the drum is ready to be tested in preparation

for installation.

Cable drum storage

Cable drums must always be stored in an upright position and resting on the drum flanges.

Storage of drums in any other position can lead to winding defects and result in damage to

the fibres (see Figure 2 below).

FIGURE 2: POSITIONING OF DRUM ON FLANGE EDGE AND SIDE

If storage place is limited and it becomes necessary to stack the drums they must be

stacked in the upright position (see Figure 3 below).


If the wooden battens are removed from the cable drums, their rolling edge should be lined

up in rows with the flanges touching each other so that the flanges do not overlap and

damage the cable (see Figure 4 below).


21


Cable storage environment

Optical fibre cables are supplied on wooden drums. Due to this reason in house storage is

advised.

If drums are outside, the drums must be placed on a solid hard surface and drum must not

come into contact with moist soil. This will result in the degradation of the wooden drum.

During rainy seasons the drum must be covered with tarpaulins or polythene to avoid the

drum becoming water logged.

Cable inspection

On receipt of a cable drum on site the documentation and the stencilled markings on the

drum must be compared and verified. This will include:

Manufacturer;

Drum number;

Cable length; and

Cable type.

Check the condition of the protective battens and drum flanges. If there is any damage

inform the supplier immediately.

If there is no visible damage it can be accepted that no damage occurred during transit and

the cable can be tested.

Upon receipt of the cable on site the contractor takes full responsibility for the safekeeping

and protection of the cable against damage and theft. The contractor shall take necessary

precautions to ensure the safety of the cable.

Opening the cable drum

The wooden protection battens are nailed to the drum flanges. These can be carefully

removed with a hammer or nail removing tool.

Once the battens have been removed make a visual inspection for any damage or

flattening of the cable.

Locate and take out the inner and outer ends of the cable and confirm the embossed cable

length and drum number with that on the dispatch documents.

Fig 3. a) open drums stored by touching flanges b) wrong storage


22

4. FIBRE STRAND TEST PROCEDURE

The following important notes must be kept in mind when arranging delivery and scheduling

the testing of cables:

The delivery of cables to site must be scheduled as close as possible to the installation date to

avoid the possibility of damage or theft whilst being stored on site.

The fibre testing must be done within 48 hours after delivery of the cable on site.

The Project Owner’s representative must be advised at least 48 hours in advance of when the

testing will take place.

After the removal of the battens from the drum, locate the outer end of the cable and carefully

unwind an adequate length of cable to reach the area where the testing will take place. This is

usually in a sheltered area or vehicle.

Cut and remove 1m of the cable sheath with a cable slitter.

Tape the butt-end of the cable with PVC tape for a distance of 10mm to support the loose

tubes.

Remove the cellophane wrappings and all filling and protection material up to the butt-end of

the cable.

Clean the loose tubes with isopropyl alcohol to remove petroleum jelly.

Cut the first tube to be tested with a tube cutter. Care must be taken not to cut through the

tube into the fibres. Remove the cut tube by pulling it forward to the end of the fibres.

Clean the exposed fibres with pre-packed cleaning tissues.

Position and switch on the OTDR.

Set the OTDR to the 1550nm setting.

Connect a test lead to the OTDR and prepare the other end to be spliced to the first fibre to be

tested. This entails stripping the primary coating from the fibre and then cleaning the fibre with

isopropyl alcohol and a lint free cloth.

Cleave the fibre to be tested and the test lead and complete the first splice. If a splicing

machine is not available a mechanical splice can be used to connect the test lead of the

OTDR to the fibres to be tested.

Ensure that the far end, the end on the inner side of the drum, is insulated and protected.

Perform the OTDR test of the fibre and save the results under an appropriate label on the

OTDR.

Now repeat this process for all the fibre strands in the cable (see Annexure A for the cable

colour coding and strand numbering schedule).

A soft copy of the OTDR test results must be made available to the Project Owner’s

representative.

The test results must also be recorded on a Pre-Installation Record Form (see Annexure B).

The maximum allowable attenuation loss is 0,25dB per km and any readings greater than this

must be regarded as a failure in the fibre.


23

In addition to the cable loss, fibres with any points or steps of discontinuity, referred to as

events, greater than 0,04dB shall be regarded as a failed fibre.

On completion of the above tests the cable must be resealed and rewound onto the cable

drum.

5. SAFETY

In addition to the regular standard safety precautions there are additional precautions to be

taken when working with optical fibre cables that are extremely important to adhere to. All

staff working or assisting with any form of optical fibre activities must be sensitized in this

regard.

Laser protection

Laser beams used in optical communication are invisible and can seriously damage the

eye. Viewing it directly does not cause any pain and the iris of the eye does not close

automatically as it does whilst viewing bright light. This can cause severe damage to the

retina of the eye.

Never look into a fibre that has a laser coupled to it.

If your eye has accidentally been exposed to a laser beam, immediately seek medical

assistance.

Optical fibre handling precaution

Broken ends of fibres created during termination and splicing are extremely sharp and

dangerous and can easily penetrate the skin. They invariably break off and due to being

transparent and very thin it is extremely difficult to see and remove these pieces once they

have penetrated a person’s skin. A delay in removing these pieces could lead to infection.

Be careful whilst handling fibres.

Avoid the penetration of these pieces into your skin.

Do not drop pieces on the floor where they will stick to your shoes and be carried

elsewhere.

Pieces of fibre that have dropped to the floor can be picked up with a tweezers or with

sticky tape.

Dispose of off cut pieces of fibre by placing them in a sealable container.

Do not eat or drink near the installation area where fibres are being handled.

Material handling

Fibre optic splicing and termination processes require various chemical cleaners and

adhesives. The safety instructions defined for these substances must be followed. When

working with these materials remember the following instructions:

Always work in well ventilated areas.

Avoid skin contact with the materials as much as possible.

Avoid using materials that cause allergic reactions.


24

Even simple items such as isopropyl alcohol used as a cleaner is flammable and should be

handled carefully.

Safety summary

5.1.4.1.1 Keep all food and beverages out of the work area to avoid fibre particles being

ingested.

5.1.4.1.2 Wear safety glasses with side shields and handle the fibre optic splinters similar to

glass splinters.

5.1.4.1.3 Never look directly through the end of fibres or connectors until you are sure that there

is no light source at the other end.

5.1.4.1.4 Only work in well ventilated areas.

5.1.4.1.5 Do not touch your eyes whilst working with fibres until your hands have been

thoroughly washed.

5.1.4.1.6 Keep all combustible materials away from the curing ovens and splicing machine.

5.1.4.1.7 Dispose the fibre scraps properly in sealed containers.

5.1.4.1.8 Thoroughly clean the work area after completion of the installation or tests.

5.1.4.1.9 Do not smoke whilst working with fibre optic systems.


25

ANNEXURE A: LOOSE TUBE AND FIBRE COLOUR CODING TABLE


26

ANNEXURE B: PRE-INSTALLATION RECORD FORM

This form must be completed and signed by the contractor prior to the installation of the cable. This

completed form and a soft copy of the OTDR results must be handed to the Project Owner’s representative

for record purposes.

Project Name and Link Description Date

Cable Manufacturer Drum No.

Testing Contractor Cable Length

Make and Model of Test Equipment

No of Fibres

Fibre No

Test results (dB)

Tube1 Tube2 Tube3 Tube4 Tube5 Tube6 Tube7 Tube8 Tube9 Tube10 Tube11 Tube12

1

2

3

4

5

6

7

8

9

10

11

12

I hereby confirm that the optical fibre cable has been received by me in good working order.

Site Engineer / Subcontractor

Name Signature Date

Witnessed / Accepted by

Name Signature Date


27

F. Optical Fibre Cable Post-Installation Test Procedure

1. INTRODUCTION

Scope

This document describes the test procedure that must be performed on all optic fibre cables

after installation and prior to splicing.

The document will also refer to safety aspects specifically pertaining to optic fibre cable

handling.

Although there are various cable types and sizes available and a wide range of optic fibre test

equipment, this document will describe the processes in a generalised manner so that it can

easily be adapted to meet the various configurations.

Order of Description

Purpose;

Test Procedure; and

Safety.

2. PURPOSE

All fibre strands in all optic fibre cables delivered on site should be inspected and tested by

the installer/contractor, on the drum, prior to installation. This is to ensure that the cable was

sound and all of the fibres faultless prior to the cable installation process.

This post installation test is to ensure and confirm that no damage was done to the cable

during the installation activity. The test will confirm the length of the installed cable, the

continuity of all fibres, and the attenuation loss of all of the fibres.

3. FIBRE STRAND TEST PROCEDURE

The following important notes must be kept in mind when arranging the time for the post

installation tests to be done:

The tests must be scheduled as close as possible after the cable installation date.

The Project Owner representative must be advised at least 48 hours in advance of when the

testing will take place.

Carefully unwind the cable slack from the manhole and take the cable end to the area where

the fibre testing will take place. This is usually in a sheltered area or in a vehicle.

Ensure that enough slack was left in the manhole for the required slack coil and the joint to be

made. (15N-02 slack + 2m for jointing + 1m for post installation testing)

Cut and remove 1 meter of the cable sheath with a cable slitter.

Tape the butt-end of the cable with PVC tape for a distance of 10mm to support the loose

tubes.

Remove the cellophane wrappings and all filling and protection material up to the butt-end of

the cable.


28

Clean the loose tubes with isopropyl alcohol to remove the petroleum jelly.

Cut the first tube to be tested with a tube cutter. Care must be taken not to cut through the

tube into the fibres. Remove the cut tube by pulling it forward to the end of the fibres.

Clean the exposed fibres with pre-packed cleaning tissues.

Position and switch on the OTDR.

Set the OTDR to the 1550nm setting.

Connect a test lead to the OTDR and prepare the other end to be spliced to the first fibre to be

tested. This entails stripping the primary coating from the fibre and then cleaning the fibre with

isopropyl alcohol and a lint free cloth.

Cleave the fibre to be tested and the test lead and complete the first splice. If a splicing

machine is not available a mechanical splice can be used to connect the test lead of the

OTDR to the fibres to be tested.

Ensure that the far end of the cable is insulated and protected.

Perform the OTDR test of the fibre and save the results under an appropriate label on the

OTDR.

Now repeat this process for all the fibre strands in the cable. (See Annexure A for the cable

colour coding and strand numbering schedule)

A soft copy of the test results from the OTDR must be made available to the Project Owner

representative.

The test results must also be recorded on a Pre-Installation Record form. (See Annexure B)

The maximum allowable attenuation loss is 0,25dB. per Km and any readings greater than this

must be regarded as a failure in the fibre.

In addition to the cable loss, fibres with any points or steps of discontinuity, referred to as

events, greater than 0,04dB shall be regarded as a failed fibre.

On completion of the above tests the cable must be resealed and rewound and secured on the

cable supports inside the manhole.

4. SAFETY

In addition to the standard safety procedures there are additional precautions to be taken

when working with optical fibre cables that are extremely important to adhere to. All staff

working or assisting with any form of optical fibre activities must be sensitized in this regard.

Laser Precaution

Laser beams used in optical communication are invisible and can seriously damage the eyes.

Viewing it directly does not cause any pain and the iris of the eye does not close automatically

as it does whilst viewing bright light. This can cause serious damage to the retina of the eye.

Therefore,

Never look into a fibre that has a laser coupled to it; and

If your eyes have accidentally been exposed to a laser beam, immediately seek medical

assistance.


29

Optical fibre Handling Precaution

Broken ends of fibres created during termination and splicing are extremely sharp and

dangerous and can easily penetrate the skin. They invariably break off and due to being

transparent and very thin it is extremely difficult to see and remove these pieces once they

have penetrated a person’s skin. A delay in removing these pieces could lead to infection.

Hence,

Be careful whilst handling fibres;

Avoid the penetration of these pieces into your skin;

Do not drop pieces on the floor where they will stick to your shoes and be carried

elsewhere;

Pieces of fibre that has dropped to the floor can be picked up with a tweezers or with sticky

tape;

Dispose of off cut pieces of fibre by placing them in a sealable container; and

Do not eat or drink near the installation area where fibres are being handled.

Material Handling

Fibre optic splicing and termination processes require various chemical cleaners and

adhesives. The safety instructions defined for these substances must be followed. When

working with these materials remember the following instructions:

Always work in well ventilated areas;

Avoid skin contact with the materials as much as possible;

Avoid using materials that causes allergic reactions; and

Even simple items such as isopropyl alcohol used as a cleaner, is flammable and should be

handled carefully.

Safety Summary

Keep all food and beverages out of the work area to avoid fibre particles being ingested.

Wear safety glasses with side shields and handle the fibre optic splinters similarly to glass

splinters.

Never look directly through the end of fibres or connectors till you ensure there is no light

source on the fibres at the other end.

Only work in well ventilated areas.

Do not touch your eyes while working with fibres until your hands have been thoroughly

washed.

Keep all combustible materials away from the curing ovens and splicing machine.

Dispose of the fibre scraps by placing them in containers and sealing them.

Thoroughly clean the work area after completion of the installation or tests.

Do not smoke whilst working with fibre optic cables or fibre optic systems.


30

ANNEXURE A: LOOSE TUBE AND FIBRE COLOUR CODING TABLE


31

Project Name and Link Description

Manhole # End A Manhole # End B

Drum No. Cable Length

No of Fibres Make and Model of Test Equipment

Project Name and Link Description

ANNEXURE B: ATTENUATION TESTING OF FIBRE OPTIC CABLE POST INSTALLATION

This form must be completed and signed by the contractor post installation and prior to splicing the cable. This completed form and a soft copy of the OTDR results must be handed to the Fibreco representative for record purposes.

Manhole # End A Manhole # End B

Drum No. Cable Length

No of Fibres Make and Model of Test Equipment

Test results (dB)

Fibr e No

Tube 1

Tub e2

Tub e3

Tube 4

Tube 5

Tube 6

Tube 7

Tube 8

Tube 9

Tube 10

Tube 11

Tube 12

1

2

3

4

5

6

7

8

9

10

11

12

I hereby confirm that I have tested the fibre optic cable

Site Engineer / Subcontractor

Name Signature Date

Witnessed / Accepted by

Name Signature Date


32

G. Optical Fibre Conformance Test Procedure

1. SCOPE

The content of the document provides the guidelines, standards, procedures and pass/fail

criteria to be used with the qualification of installed fibre cable and related infrastructure.

Section 2 contains an overview of tests required.

The following fibre cable qualification tests are described in the document:

Visual Connector Inspection;

Optical Return Loss (ORL) and Reflectance;

Optical Link Loss Measurement;

Optical Time Domain Reflectometry (OTDR) measurements;

Polarization Mode Dispersion (PMD); and

Chromatic Dispersion (CD).

2. QUALIFICATION REQUIREMENT SUMMARY

Cable Acceptance tests will be done from an ODF to an ODF.

The following tests will be required for cable acceptance tests:

Optical Link Loss (or Insertion Loss) at wavelengths of 1550nm and 1625nm (in both

directions);

Optical Return Loss at wavelengths of 1550nm and 1625nm (in both directions) (tested

with ILM test set);

Reflectance at wavelengths of 1310nm and 1625nm (from both ends);

Bidirectional OTDR at wavelengths of 1550nm and 1625nm;

Chromatic Dispersion over C band, 1530nm and 1565nm to be recorded on

characterization report; and

Polarization Mode Dispersion over C band, 1530nm and 1565nm to be recorded on

characterization report.

If an additional Inter-facility cable test is required as part of the link, the following should be

performed:

Optical Link Loss after installation (in both directions); and

Reflectance at wavelengths of 1310nm and 1625nm from the patch closest to the

transmission equipment towards the outside cable.

3. REFERENCE DOCUMENTATION

Optic Fibre Cable Pre-Installation Test Procedure.

Optic Fibre Cable Post-Installation Test Procedure.

Relevant Naming conventions.


33

“Corning SMF28e+ Low Loss” and “Corning LEAF Optical Fibre” datasheets.

Samsung ITU-T G.656 compliant fibre specification.

All relevant Testing Equipment Manuals & Safety Procedures.

4. GENERAL

For acceptance, the Contractor will materially perform all tests, provide documentation, and

meet the standards identified in this procedure. On completion of all testing, the test reports

shall be signed off by the Project Owner’s nominated representative.

The Project Owner shall have the right to witness all tests.

All fibre cables that conform to the tests standards as set out in this document shall be clearly

marked as per the relevant naming and numbering convention.

The electronic results shall be numbered according to the naming convention.

Electronically fibres shall be numbered with a Fibre and the number, padded to two

digits, i.e.: Fibre01, Fibre02, Fibre03 … Fibre72 etc.

Any test that yield results outside the expected values as specified in this document shall be

deemed to be not conformant and corrective action shall be scheduled to repair any fault

identified.

A summary fibre conformance report shall be completed and submitted per cable.

The objective for each splice is a splice loss value as indicated in Table 3 when bi-directionally

measured with an OTDR. If the Constructing party is not able to meet or exceed the

requirements after three (3) attempts to correct a fault, then 0.2 dB or less bi-directionally shall

be accepted.

Fibre splices with a splice loss greater than the requirements in Table 3 will be identified

as Outside of Specification and indicated as such in the summary report.

Documentation of the three attempts shall be provided as part of the acceptance

documentation.

The following considerations should be taken into account for all tests:

Measurement shall be made after the route has been closed (e.g. trenches, manholes).

It is the contractor’s responsibility to ensure the continuity/connectivity of all tubes and

fibres in the cable under test is correct as per the color coding of the cable/fibre and

positions on the ODFs.

All test equipment used shall be calibrated by a reputable calibration facility and the

associated photo copy of a valid calibration certification attached to the test reports.

All optical connectors in the optical span (ODF/Optical patch panels closest to Tx

equipment/test equipment) shall be cleaned before the commencement of any testing.

An Optical talk set shall be used whilst testing, to ensure voice communication between the

testers at either end of the fibres under test.

All results shall be recorded, saved and presented to the Project Owner:

Drum test (continuity) certificate;


34

After installation (continuity) certificate. This test can be excluded by the contractor, at

his own risk; and

Full qualification certificate, including all raw test data.

5. TEST EQUIPMENT

The following test equipment is required to perform the tests in this procedure:

Optical Talk Set at either end of the fibres under test;

Optical Fibre Video Microscope (optional, but preferred for fault finding);

Optical Power and Return Loss Meter;

Optical Time Domain Reflectometer (OTDR);

Chromatic Dispersion Tester; and

Polarization Mode Dispersion Tester.

6. TESTING METHODOLOGY

Cleaning and Inspecting connectors

The quality and cleanliness of mechanical connections is a primary contributor to loss

and reflectance in a fibre optic network.

To qualify fibre optic links, a visual inspection for physical defects and dirt is

recommended on connector ends. An optical fibre scope probe can be used for this

purpose.

For safety reasons, before inspecting connector ends, an optical power meter should be

used to ensure there is no light in the fibre. Failure to comply with this procedure may

result in injury and/or loss of sight.

Cleaning a connector:

Wipe with a dry fibre connector cleaner. Re-inspect after cleaning.

If the connector is still dirty, use Alcohol and Optical wipes followed up with a

dry fibre connector cleaner. Re-inspect and replace if necessary.

Cleaning a connector on the ODF:

Clean the connector with an optical swab and/or compressed air.

If the connector is still dirty, it may be necessary to remove the connector from

the patch panel for more thorough cleaning or replacement.

Do not leave optical connectors exposed. Connect patch cords to ODF directly after cleaning

or protect with a dust cap.

Optical Return Loss (ORL)

ORL is a measurement of the intensity of light being reflected towards a laser source.

The value for ORL is positive – the higher the value the better.

ORL measurements shall be performed:


35

Using a calibrated Optical Power and Return Loss Measurement test set (dual

ended test set).

At wavelengths of:

6.2.2.2.1 1310nm (only applicable for link lengths less than 30km);

6.2.2.2.2 1550nm; and

6.2.2.2.3 1625nm.

In both directions on the link

The guidelines for the expected values of measured results are shown in Table 1.

Reflectance

Reflectance refers to a single event, typically a connector where there is a change or break in

the optical path. The value for reflectance is negative – the more negative the value is, the

better the connectors or optical paths are joined.

Reflectance measurement shall be performed:

Using an OTDR (Short pulse length: 5ns / 10ns, Range: 100m, Time: 15/30

seconds);

With a launch reel;

At wavelengths of: 1310nm and 1625nm; and

From both ends of the link (to assess both connectors).


TABLE 1: EXPECTED ORL AND REFLECTANCE MEASUREMENTS

Measurement Expected value

ORL > 30dB

Reflectance (PC/UPC connectors) < -45dB per event

Reflectance (APC connectors) < -60dB per event

Optical Link Loss Measurement

Optical Link Loss test measures the end-to-end attenuation in the optical fibre link path.

Optical Link Loss measurements shall be performed using a calibrated Optical Source

and Power Meter.

Optical Link Loss shall be measured in both directions of the fibre cable being tested.

Optical Link loss measurements shall be performed at the following wavelengths:

1310nm (only applicable for link lengths less than 30km);

1550nm; and

1625nm.

Before any tests are performed, the manufacturer’s recommended referencing (or

zeroing) procedure shall be performed.



36

TABLE 2: EXPECTED LINK LOSS LEVELS

Wavelength Fibre Attenuation values (dB/km)

G.652D G.655D G.656

1310nm ≤ 0.35 N/A N/A

1550nm ≤ 0.19 ≤ 0.20 < 0.20

1625nm ≤ 0.21 ≤ 0.22 < 0.21

Record and save the measured link loss at the measured wavelengths.

Bi-Directional OTDR Traces

An OTDR allows the approximate measurement of a range of physical

properties that influences the overall performance of an optical fibre link, such

as:

Bad or dirty connectors;

Fibre bends;

Bad splices; and

Mismatched mode-field diameters.

All measurements shall be performed using a calibrated OTDR tester.

Bi-directional OTDR traces shall be taken using a patch cord (3m to 10m) which shall

have the exact same characteristics as the pigtail being used i.e. G656 and/or G655D

and/or G652D.

OTDR measurements shall be performed with the connectors terminated on the optical

distribution frame or patch panel.

OTDR measurements shall be performed in both directions of the fibre cable which is

being tested.

Measurements for both directions shall be recorded. These values shall then be

averaged using the averaging software of the test units.

OTDR measurements shall be performed at the following wavelengths:

1310nm (only applicable for link lengths less than 30km);

1550nm; and

1625nm.

All OTDR traces shall be measured with the following acquisition parameters and

process:

All acquisition parameters shall be identical for the two directions in which the

bidirectional traces are being measured;

Distance range to be set to the shortest range that covers the entire link

distance including the pigtails and patch cords;


37

The smallest pulse width setting to be used;

Averaging time to be set to 60 seconds;

If the noise level is not acceptable with these settings, increase the averaging

time and repeat the measurements;

After adjusting the average time, and the averaging time exceeds 120 seconds

while the noise level is still not acceptable, reduce the averaging time back to

60 seconds and increase the pulse width. Repeat the measurements; and

Save all results once measurements are complete.

The guidelines for the expected Splice/Connector Loss values of measured results are shown

in Table 3.

Expected Reflectance values are shown in Table 1.

Expected Link Loss/Attenuation values are shown in Table 2.

TABLE 3: EXPECTED SPLICE / CONNECTOR LOSS VALUES

Measurement Expected value

Splice Loss @ 1550nm < 0.15dB

Splice Loss @ 1625nm < 0.13dB

Connector Loss < 0.5dB

Average splice loss over a section (ODF-to-ODF, for any section >20km)

< 0.08dB

If any splice value exceeds the value in Table 3, the rectification process would be:

The splice should be re-spliced up to three times to attempt to bring it within

specification.

If after three (3) re-splice attempts the value still exceeds the expected value,

the incident must be recorded on an Out of Specification report. The report

must be signed by the Project Owner’s witness. Only include the 1550nm out of

specification splices.

Record and save test results at measured wavelengths.

The traces are to be saved electronically and the virgin (un-manipulated) trace must be

provided:

in Bellcore format (GR-196-CORE / SR-4731);

via USB flash drive at time of witness testing (USB flash drive to be provided by

witness); and

Appropriately named and submitted (zip file preferred) with an electronic copy of

the final summary test report as part of the final test documentation.

The IOR should be considered when setting up the OTDR for the fibre under test as shown in

Table 4.


38

TABLE 4: INDEX OF REFRACTION VALUES

Wavelength OTDR Index of Refraction (IOR) Value

G.652D G.655D G.656

N @ 1310 nm 1.4676 N/A tbc

N @ 1550 nm 1.4682 1.468 tbc

N @ 1625 nm 1.4680 1.469 tbc

Chromatic Dispersion Testing

Chromatic Dispersion (CD) is caused by the wavelength dependence of the Index of

Refraction (IOR) in optical fibre. This causes the different frequencies that comprise an

optical pulse to separate and widen during propagation, which leads to inter-symbol

interference. CD tests are necessary for spans greater than 50km in length and

considered for 10 Gbps and higher signals.

All measurements shall be performed using a calibrated Chromatic Dispersion test set.

Unidirectional Chromatic Dispersion measurements shall be taken without a launch reel.

All measurements shall be made after the splice hand holes and manholes have been

closed.

Always ensure that the connectors on the optical distribution frame or fibre patch panel

are cleaned properly.

Chromatic Dispersion measurements shall be taken uni-directionally with a testing step ≤

2nm from 1530nm to 1625nm for complete and accurate analysis of all fibre spans

throughout the C+L Bands.

Always perform all referencing and calibration tests as recommended by the test

equipment supplier.

All Chromatic Dispersion measurements shall be performed with the following

acquisition parameters and process:

Fibre length to be set to the distance as measured during the bidirectional

OTDR test;

Fibre type to be set according to fibre type deployed;

Wavelength range to be set to include both the C- and L-band of wavelengths;

and

Guidelines for acceptable averaging times and step sizes are shown in Table 5.

TABLE 5: GUIDELINES FOR OTDR AVERAGING TIMES

Distance Step size Averaging Time

< 10km 5nm – 10nm 1 s

20km – 50km 2nm 1 s

50km – 100km 1nm 2 s

> 200km 0.5nm 2 s – 5 s


39


TABLE 6: EXPECTED CHROMATIC DISPERSION (CD) VALUES

Wavelength Expected CD (ps/(nm.km)

G.652D G.655D G.656

1530nm 15 to 17 2 to 5 6 to 10

1565nm 17 to 19 4 to 8 8 to 14

Record and save all test results measured.

Polarization Mode Dispersion

Polarization Mode Dispersion (PMD) is caused by the birefringence of optical fibre.

Birefringence causes the different polarization modes of an optical pulse to travel along

the fibre at slightly different speeds, causing the pulse to broaden.

PMD is the average Differential Group Delay (DGD) measured. PMD values are to be

taken uni-directionally at 1550nm and analyzed via a Route Mean Square (RMS)

algorithm for optical spans made up of more than one all-optical and separately tested

section.

High PMD increases the bit error rate, which limits bandwidth. This imposes limitation to

transmitting information at higher speeds and/or over longer distances.

All measurements shall be performed using a calibrated PMD test set.

PMD tests must be performed in factory and after installation.

ISO 9001 factory acceptance test certificates shall accompany all fibre cables

utilized in the project.

The Project Owner reserves the right to witness any or all factory tests.

Unidirectional Polarization Mode Dispersion measurements shall be taken without a

launch reel.

Polarization Mode Dispersion measurements shall be taken with the connectors

terminated on the optical distribution frame or patch panel.

Always perform all referencing and calibration tests as recommended by the test

equipment supplier.

All Polarization Mode Dispersion measurements shall be performed with the following

acquisition parameters and process:

Fibre length to be set to the distance as measured during the bidirectional

OTDR test;

Fibre type to be set according to fibre type deployed; and

Wavelength range to be set to include both the C- and L-band of wavelengths.

The PMD coefficient (measured in ps/√km) indicates the rate at which the pulse broadens

along the fibre length.

The guidelines for the expected cabled PMD values are shown in Table 7.


40

TABLE 7: EXPECTED CABLED PMD VALUES

Fibre installation type Expected PMD Value

New Fibre Installation (G.652D & G.655D & G656)

≤ 0.1 ps/√km

Existing Fibre Installation ≤ 0.2 ps/√km

Testing of Installed cables/fibres that have not been terminated onto frames/ equipment. Instances will arise where cables have been installed and jointed end to end but may not be terminated onto frames or equipment pending the readiness of the buildings or equipment. In such cases the cables/fibres must be subjected to the following tests as an interim acceptance.

Pre-installation testing of all fibres prior to hauling (On the drum test)

Post-installation testing of all fibres before jointing.

Bi-directional testing of all fibres on completion of splicing in accordance with section 6.5

above

End to end verification of correctness of splicing by using an OTDR with a light source at

the far end. This will confirm straight splicing with no cross overs or swapping of tubes

7. TEST RESULTS

All test results and files shall follow the specified naming convention.

Naming of Fibre Numbers.

A “Witness Test Report” will be filled in on the day of witness testing.

The person witnesses the testing should make an electronic copy of the raw data and trace

files.

The Final Test Report shall include:

The “Section ODF to ODF Acceptance” sheet;

Cable Summary Report in electronic and printed format;

All raw result files, appropriately named and zipped together in electronic format; and

Scanned calibration certificates.

As a minimum, the cable summary report shall contain the following information in the header:

Contractor.

Date testing was performed.

Name of the testing Technician.

Near End and Far End locations.

Location, Rack, Panel, and port of the Optical Distribution Frame or patch panel.

Type of test equipment used.

Calibration certificate number and date for test equipment used.

Project details.

Fibre link details.

Fibre type.


41

Tests performed.

Summarized measured results of tests performed. and

References to all detailed measured stored test results and traces.

An example header below:

All final test results shall be provided in the following formats:

One printed copy

Witness Test Report, with the following data: Point A, Point B, Total Length,

Operator A (being witnessed), Far-end Operator, Date of testing, Contractor;

Out of Specification Report;

Fibre Characterization, with the following data: Summary of OLTS, OTDR, CD,

PMD, Reflectance;

Splice Register; and

7.7.1.4.1 Acceptance certificate to be signed, with the following info.

7.7.1.4.2 Point A, Point B, Total Length, maximum allowed length, Number of

splices, Date of Testing, Subcontractor, Testing Operator, Far-end

operator.

Electronically (CD / USB)

Electronic report to be provided in Excel format

7.7.2.1.1 Fibre Characterization;

7.7.2.1.2 Bidirectional Splice Loss Report; and

7.7.2.1.3 Splice register: should contain the MH name, Coordinates and splice

closure.

Electronic reports to be provided in PDF format

7.7.2.2.1 Bidirectional Trace views; and

7.7.2.2.2 CD/PMD Trace view.

Other PDF reports (typically scanned)

7.7.2.3.1 Witness Test Report;

7.7.2.3.2 Calibration Certificates;

7.7.2.3.3 Floating Register; and

7.7.2.3.4 Fibre Factory test results (or in Excel).

Raw data to be provided (all data in the following folders and zipped in a single

zip file, named according to the section name):

7.7.2.4.1 OTDR_BIDIR: Bidirectional OTDR traces (.bdr files);

7.7.2.4.2 OTDR: Unidirectional Traces;

7.7.2.4.3 OLTS: Single OLTS result file (. olts); and

7.7.2.4.4 CDPMD: CD/PMD results, either PMD files (.pmdB) and CD files


42

(.exfoCD) -OR- Combined files (.cdpmd files).


43

H. 72 core G652.D cable to be installed in 12/10 micro duct : Technical Specifications for Micro Duct Optical Fibre Cables

1. SCOPE

Micro Fibre Optic Cable should be versatile cabling solution suitable for micro duct deployment

of cables using blowing techniques. The cables should be able to blow inside the ducts. These

cables shall be produced using Dry Core Technology and thus providing benefits in terms of

weight, Mid-span Access of the cable and easier installation at site.

2. DESCRIPTION

The cable offered should be based on the multi-tube micro cable design. Cable shall consist of

a multi loose tube manufactured from PBT (Polybutylene terephthalate). In order to aid

identification during installation, the individual optical fibres are color coded in accordance with

specific color coding. To protect the fibres in the loose tube against water ingress and vibration,

the loose tube should be filled with a thixotropic jelly.

Loose Tubes shall be stranded around central strength member made of Fibre Reinforced

Plastic (FRP). The CSM shall provide anti-buckling properties, bend resistance and mechanical

strength as specified in this specification. S-Z stranded, loose tube design along CSM shall

isolate fibres from installation and environmental rigor & facilitates mid span access

Rip Cords shall be applied longitudinally before application of the sheath, to enable easy

stripping of the cable during testing & end preparation.

A Black High-Density Poly-Ethylene, UV resistant, Sheath shall be applied over the preceding

structure of core. The sheath shall be evenly formed around the cable core and shall be free

from blisters and pin holes.

3. GENERAL CABLE CONSTRUCTION

The construction of the cable shall be in accordance with details as given below –

No of fibres Up to 72

No of fibres per tube 12

Buffer tube material PBT (Polybutylene Terephthalate)

Buffer tube diameter Nom 1.6 mm

Filler Black Polyethylene Rod

Central Strength Member Material FRP (Fibreglass Reinforced Plastic)

Core Wrapping Water swellable Tape/Yarns - Dry core technology

Jacket material Black UV resistant HDPE

Jacket thickness Nominal: 0.5 mm, Min 0.4 mm

4. FIBRE AND LOOSE BUFFER TUBE IDENTIFICATION SCHEME:

The fibres in buffer tube shall be coloured in a clearly identifiable manner using the following

colours:


44

Fibre 1 Fibre 2 Fibre 3 Fibre 4 Fibre 5 Fibre 6 Fibre 7 Fibre 8 Fibre 9 Fibre 10 Fibre 11 Fibre 12

Blue Orange Green Brown Slate White Red Black Yellow Violet Pink Aqua

Buffer Tubes in each layer shall be color coded and stranded in a sequence as given below –

Tube 1 Tube 2 Tube 3 Tube 4 Tube 5 Tube 6

Blue Orange Green Brown Slate White

Tube 7 Tube 8 Tube 9 Tube 10 Tube 11 Tube 12

Red Black Yellow Violet Pink Aqua

5. MECHANICAL & ENVIRONMENTAL CABLE CHARACTERISTIC

Test Description Acceptance Criteria

Cable Tensile Strength

Mandrel Dia. > 20 D, Time – 10 Minutes.

Maximum Load Installation: 600 N

Test Method – IEC 60794-1-2 Method E 1

Fibre strain < 0.25%

Attenuation change < 0.1 dB @ 1550 nm

(before & after completion of test)

No jacket cracking and fibre break

Crush performance

Plates – 100 x 100 mm, Time – 10 Minutes, at one Point.

Load Applied – 1000 N


Attenuation change < 0.1 dB@ 1550 nm



Micromum Bending Radius

Dynamic – 20 D, 1 turn – 1 Cycle

Static- 15 D, 1 turn – 1 Cycle

Where D is diameter of cable.


No Attenuation change (< 0.05 dB@ 1550 nm)


No jacket or cable elements damages


45

Temperature Cycling

Cable Length > 1000 meters, Soak Time – 24 hours.

Temp. Cycling: -20 ºC + 70 ºC

No of Cycles: 2 (Duration > 12 hrs for each cycle)

Test Method – IEC 60794-1-2 Method F1

Attenuation change < 0.1 dB/Km @ 1550 nm



Water Penetration

Sample Length – 3 meters,

Test time – 24 hours

Height of water – 1 meter

Test Method – IEC 60794-1-2 Method F5B

No water leakage throughout the open cable end

Drip Test

Sample Length – 300 mm,

Temperature: 70 ºC

Test time – 1 hours

No filling compound shall drip from sample

Operating Temperature Range: -20ºC to +60ºC

Installation Temperature Range: -20ºC to +60ºC

Storage Temperature Range : -30ºC to +70ºC

No jacket or cable elements damages

6. CABLE MARKING

To externally identify the cable, the following printing shall be marked at 1-meter intervals, in

white with hot foil embossing.

“JDA ABC MM/YYYY MC 72 G652D XXXXX MMMM”

With:

Employer: JDA

Supplier Name: ABC

Month/ Year of manufacture: MM/ YYYY

Micro Cable: MC


46

Standard Code (Fibre Count, Fibre Type): 72 G652D

Cable Identification No.: XXXXX

Sequential Length Marking in meters: MMMM

The accuracy of marking shall be ± 0.5%. Occasional loss of printing & remarking shall

be as per Bell core GR 20 and this super cedes the earlier markings. (Other markings

are available on request)

7. PACKAGING

The cables shall be shipped on treated wooden drums, battened around the circumference for

protections.

Inner and outer ends of the cable will be accessible for testing and each end will be end capped

with thermal shrinkable caps.

A direction of rotation arrow is marked on the drum together with the markings detailed below.

Standard lengths of cable shall be 4000 meters with tolerance ± 100 meters

8. DRUM MARKINGS

The individual cable drums shall carry the following markings –

JDA

Manufacturer’s Name

Drum Number / Cable Identification Number

Cable Length in km

Type of Fibre

Gross weight in kgs

Arrow of Rotation

9. QUALITY SYSTEMS

*Quality System

The cable manufacturer shall be TL 9001-R 4.0, ISO 14001:2004, ISO 18001:2007

certified facilities and all these ISO shall be integrated through Integrated Management

System. Cable facilities shall be certified 10002:2004 for complaints handling

procedures. Certifications shall be provided along with the Bid Submission

Test facilities

The cable manufacturer shall have test facilities to proof that cables comply with this

specification. Factory Acceptance Test shall be witnessed by JDA authorised

representatives.


47

10. SINGLE MODE DISPERSION UN-SHIFTED OPTICAL FIBRE CHARACTERISTICS IN CABLE ACCORDING TO ITU-T G.652.D and IEC 60793-2-50

Fibre Geometry

Mode field diameter at 1310 nm [m] 9.2 ± 0.3

Mode field diameter at 1550 nm [m] 10.5 ± 1.0

Cladding diameter [m] 125.0 ± 1.0

Core-Clad Concentricity Error [m] < 0.5

Cladding Non Circularity [%] < 0.8

Coating diameter ( Uncoloured) [m] 245 10

Coating diameter (Coloured) [m] 250 10

Mechanical Characteristics

Proof Test Kpsi ( Gpa) ≥ 100 (0.7)

Coating Strip Force N ≥ 1.3

Fibre Curl m ≥ 4

Macro Bend Loss -1 turns- 16mm radius @ 1550 nm dB < 0.5



Average Attenuation Coefficients of Cabled Fibre

Attenuation at 1310 nm [dB/km] ≤ 0.33



Attenuation at 1625nm [dB/km] ≤ 0.21

Dispersion Coefficients

Chromatic Dispersion in the range 1285 to 1330 nm [ps/(nmkm)] ≤ 3.5

Chromatic Dispersion at 1550 nm [ps/(nmkm)] ≤ 17.0

Chromatic Dispersion at 1625 nm [ps/(nmkm)] ≤ 22.0

Zero Dispersion wave length

Nm

1300 ~ 1324

Zero Dispersion Slope ps/(nm2.km) < 0.092

Cable Cutoff Wavelength (cc) [nm] ≤ 1260

PMD Link Design Value Ps/√km < 0.1


48

11. CABLE DIMENSIONS:

Fibre Count

Fibre Type

Fibres Per

Tube

Tubes

Passive

Fillers

Diameter of Cable

(+5%)

G652D Numbers Numbers Number mm

72 72 12 6 0 6.0

Documents

ANNEXURES TECHNICAL SPECIFICATIONS - JDA