NOTICE TO TENDERERS - SA-Tenders.co.za

BID ADVERTISEMENT FORM

NOTICE TO TENDERERS

Bid number: DBN/CAP (RTPC) 771

Bid invited for: INSTALLATION OF FIBRE CABLE & SPLICING AT WEST SIDE AREA FOR METRORAIL KZN

With effect from 09 JULY 2018 to 16 JULY 2018, the Bid document (CD) may be collected at: Address: Metrorail Regional Office

65 Masabalala Yengwa Avenue Durban Station

Office hours: Mondays to Fridays 08:00 to 15:30 (ONLY)

where CD’s can also be obtained on payment of an amount of R 1 000.00 per disc which is not refundable. No cash or cheques will be accepted at PRASA offices – (Bank Deposit or Electronic Payments - allow for 1-day delay). Clearly indicate the Tender Number on the Deposit Slip or EFT document as reference. BANKING DETAILS:-

Metrorail KZN, Standard Bank, Windermere, Branch Code: 042726, Account No.: 050832948

Confirmation of EFT payment must be e-mailed to the Senior Buyer PRIOR to collecting the CD or attending the Briefing Session. Failing to do so will result in you not being granted access to the Briefing Session.

Bidders must arrange own transport and parking.

Bidders failing to attend the compulsory Bid briefing session will be disqualified.

PRASA reserves the right to only allow Bidders in possession of a valid Bid document at the briefing.

A maximum of two representatives per company will be allowed to attend the briefing.

THE ONUS IS ON THE TENDERER TO PRINT THE DOCUMENT FROM THE CD DISC AND SUBMIT PRINTED TENDER DOCUMENTS WHEN SUBMITTING THEIR TENDERS.

NB: IT IS MANDATORY REQUIREMENT FOR PROSPECTIVE SUPPLIERS TO BE REGISTERED ON THE CSD IN ALL REQUESTS FOR PROCUREMENT OF GOODS AND / OR SERVICES.


TECHNICAL EVALUATION MATRIX

No EVALUATION CRITERIA TOTAL POINTS

1

Previous Experience: (Installation of Optic Fibre)

a) Letter of reference from previous client. (similar work to fibre installation)

(20) b) Submit proof of registration with FOA (fibre optic association) (20)

40

2

Capacity: Resources available for project.

Submit staff certificates:

2 x Flagmen

1 x Track master with C-Green

Installer responsible for climbing mast pole must possess a C-Green certificate

20

3

Quality: Submit the following:

Method Statement: minimum requirements;

Working Practice

Machinery, equipment and tools

Precautions

Storage

Program of works.

10

TOTAL 70

Minimum 80% must be attained to qualify to the next evaluation stage of Price

and BBBEE

Price 80

BEE 20

Total 100


SPECIFICATION

SPECIFICATIONS FOR TRENCHING OF OPTIC FIBRE AND FOR THE ERECTION OF AERIAL OPTICAL FIBRE CABLE ON TRACTION MASTS, OPTICAL FIBRE ACCESSORIES FOR INSTALLATIONS

IN THE METRORAIL KZN ENVIRONMENT.

NON-DISCLOSURE OF INFORMATION

Information contained in this document is proprietary in nature and/or protected by copyright. Please obtain written permission from the Author prior to reproducing this document, in whole or in part.


TABLE OF CONTENTS PART A: ERECTION OF AERIAL OPTICAL FIBRE CABLE ON TRACTION MASTS.

I Abbreviations, Acronyms and Definitions

II Relevant Documentation Applicable

1 Scope and Purpose

2 Specifications and Drawings

3 Design and Approval

4 Survey

5 Installation

6 Tensioning

7 Cable Slack

8 Intermediate Poles

9 Safety Precautions

10 Splicing, Termination and Testing

11 Final Acceptance

12 ANNEXURE 1 – Sample of “As Built” Drawings

13 ANNEXURE 2 – Sample of “Equipment”

A Blocks

B Pulling Grips and Devices

C Blocks, Chutes and Brackets

D Lashers, Pullers, Positioners and Guides

E Lifting Tools and Brakes

F Fibre Preparation and Splicing

14 ANNEXURE 3 – Drawings and Photos


PART B: OPTICAL FIBRE ACCESSORIES USED IN THE METRORAIL KZN ENVIRONMENT.

I Document Abbreviations, Acronyms and Definitions

1 Scope

2 Introduction

3 Optical Fibres

4 Outer Sheaths

5 Pigtails and Patch – Lead Identification

6 Dust Caps

7 Mid-Couples (Bulkhead)

8 Connectors

9 Optical Distribution Frames and Racks

9.1 ODF’s Must be Available in Three Different Types

9.2 Wall Mount Unit

9.3 19inch Stackable ODF Sub Rack

9.4 Specialized Main ODF Rack or Cabinet

10 Splice Protectors

10.1 Heat Crimping Type

10.2 Mechanical Crimping Type

11 Joint Closure with Splice Organiser

12 Manufacturing

13 Extent of Testing

14 Inspection

15 Samples

16 Packaging

17 APPENDIX A – Optical Performance of Connectors

18 APPENDIX B – Testing of Assemblies

19 APPENDIX C – Mechanical Performance of Ruggedized Assemblies

(Un-Ruggedized Pigtails Are Excluded From These Tests)


PART C: TRENCHING OF OPTIC FIBRE CABLE

1 Introduction

2 Scope

3 Technical Requirements

3.1 Trenching and Laying of Cables

3.1.1 Trenching Dimensions

3.1.2 Bedding and Padding

3.1.3 Back-Fill

3.1.4 Re-instatement

3.1.5 T-Off Points From Main Route

4 Acceptance of Work

5 Contamination of Ballast

6 Duration

7 Occupation

8 Warranty

9 Guarantee

10 Penalties

11 Work Program

12 Protection

13 Material Supplied

14 BOQ

15 Evaluation Matrix


I ABBREVIATIONS, ACRONYMS AND DEFINITIONS

ABBREVIATIONS AND ACRONYMS

DESCRIPTION

AC Alternating Current

"As-Build" Drawings Final drawings of a site and/or route installation of transmission infrastructure as presented to the customer at handover.

BS British Standard

DC Direct Current

GPS Global Positioning Satellite (a system whereby the latitude and longitude co-ordinates of any site on earth can be determined via a GPS receiver)

HDPE High Density Polyethylene

Kv Kilo-volt

Nm Newton Meters

OFC Optical Fibre Cable

OHTE Overhead Traction Equipment

OTDR Optical Time Domain Reflecto meter

QAD Quality Assurance Department

SOP Standard Operating Procedure

METRORAIL KZN Passenger Rail Agency of South Africa

UV Ultra Violet

GIS Geographical Information System


II RELEVANT DOCUMENTATION APPLICABLE

SPC-00029 Trenching, Laying and Hauling in of Communication Cables

SPC-00033 Optical Fibre Testing Equipment

SPC-00575 Planning and Erection of Aerial Optical Fibre Cable on Traction Masts

SPC-00583 Optical Fibre Accessories

SPC-00588 Optical Fibre Cable Ducts

PRC-00106 Post installation Test for Optical Fibre Cables

PRC-00107 Pre-testing of Optical Fibre Cables on Drums

PRC-00112 Written Safe Working Procedures for Erection of ADSS OFC on AC OHTE

E7/1 Works on, over, under or adjacent to railway lines and near high voltage equipment

E.4E Compliance with the Occupational Health and Safety Act (Act 85 of 1993)

SOP-0H00 Safe Work Procedure for working in confined spaces


1. SCOPE AND PURPOSE

THE SCOPE OF WORK

1.1 INTRODUCTION

1.1.1 METRORAIL KZN requires the installation and commissioning of Optic Fibres OFC in various railway

corridors. Details of spurs and terminations, specific to each section, will be provided. 1.1.2 Emphasis is placed on safety and safe working procedures and Respondents shall adhere to all

instructions and procedures issued with this tender enquiry, especially the Written Safe Working Procedure PRC-00112 and all its associated documents as well as provisional SOP 0H00 for working in confined spaces. If Respondents intend climbing masts, strict adherence to minimum safe clearances must be maintained.

1.1.3 The new Optic fibre OFC must be installed in parallel with an existing working fibre cable, carrying high bandwidth services, and no interference with this cable will be allowed. The intention is to install the new cable above the existing cable. Spare cables are required as indicated in the BOQ.

1.1.4 The work must be planned to ensure minimal interruption to normal train services. Underground track crossings must be executed by means of the “directional drilling” method specified.

1.1.5 Respondents must note that many of the underground track crossing works may have to be conducted at off peak hours to reduce disruptions to train services. They must allow for significant overtime and weekend working.

1.1.6 Maximum benefit must be gained from normal electrical and track occupations requested by other departments. It is therefore imperative that the Metrorail KZN regional personnel attend the regular “occupation” meetings arranged by Train Operations.

1.1.7 Respondents must take specific note of the safety aspects as depicted in Written Safe Work Procedure PRC-00112 as well as the safety arrangements and instructions attached thereto and procedural compliance with the Occupational Health and Safety Act; Act 85 of 1993 and regulations. A full Statement of Compliance must be submitted for WSWP PRC-00112, and this compliance document must be included in the Respondent’s Site Safety File.

1.1.8 An Occupational Health and Safety Plan and Risk Assessment must be outlined in the tender document and submitted to the Project Manager by the successful Respondent before work commences. The Risk Assessment and Safety Plan must also be placed on the Respondent’s Site Safety File.

1.1.9 Safety induction by Metrorail KZN electrical officers is required before commencement of work. Minimum safety clearances from live electrical conductors and Safety Instructions and Guidelines will be taught and must be observed and exercised at all times.

1.1.10 Certificated employees (Technicians working on installation of optic fibre) to work on OHTE structures must be in the Respondent employment during construction works. Employee must have “C” certificates, level 2-first aid and ladder working rules certificate.

1.1.11 The Respondent must be equipped with all the required plant, tools, safety equipment and PPE (Personal Protective Equipment) to effectively and safely carry out the Works.

1.1.12 Where electrical and track occupations are required, these must be arranged by the Respondent with the METRORAIL KZN Supervisor and Electrical Officer.

1.1.13 Respondents must note that METRORAIL KZN will utilize one METRORAIL KZN (Telecoms) supervisor / Project manager/inspector at any time during the contract period to inspect the progress and quality of the Respondent's work. This person is not available on a full time basis (on site) and will make scheduled and random site visits.

1.1.14 The successful Respondent must appoint a Site Supervisor for the duration of the contract. The Site Supervisor must be “in charge” on site for the full duration of the contract.

1.1.15 The Respondent's site supervisor must be issued with a site diary and METRORAIL KZN will provide a site instruction book. These books must be kept updated at all times and copies handed over to the Metrorail KZN Project Manager at progress meetings.

1.1.16 Respondents must take note that METRORAIL KZN Perway or OHTE Departments must approve and supervise all underground and overhead (boom or other) rail (track) crossings.

1.1.17 This specification covers the trenching of optic fibre cable and erection of aerial optical fibre cable on 3 kV DC, 25 kV and 50 kV AC overhead high tension electrification (OHTE) masts for Metrorail KZN.

1.1.17.1 Construction will mostly take place under live traction power conditions and with the normal operation of train services. 1.1.17.2 Specific attention shall be paid to section 12 of this specification, which covers safety precautions during construction. 1.1.18 The objective is to install the major component of the cable Underground. Overhead sections should be


kept to a minimum. Pipe and chamber systems may be constructed or utilized where these exist. 1.1.19 The same optical fibre cable must be utilized for aerial and buried sections. 1.1.20 A clause-by-clause statement of compliance to this specification is required. This should be done by the

contractor on the route surveillance and all points of non-compliance must be detailed and discussed with the Metrorail KZN Project Manager and singed off before any deviations will be allowed.

1.1.21 Should a tenderer method of construction and cable erection differs from this specification, full details thereof must be provided for possible prior approval by the Metrorail KZN Project Manager. KZN CORRIDORS SUPPLY & INSTALL NEW 96 SM FIBRE OPTIC

NO. STATIONS OVERHEAD

FIBRE UNDERGROUND

FIBRE TOTAL

WEST LINE

ROSSBURGH TO JACOBS 3 5KM 5KM

JACOBS TO FYNNLAND 4 7KM 7KM

TOTALS 7 12 KM 12 KM

1.2.1 The successful Contractor is required to survey the railway section(s) awarded to him / her, the

contractor is not allowed to revise the original bill of quantities. 1.2.2 The Contractor will test the fibres in the delivered cable drums and send these results to METRORAIL

KZN Project manager, alerting him if any traces differ from the supplier’s records. 1.2.3 The Contractor must install the OFC according to Metrorail KZN specifications and Written Safe Working

Procedures. 1.2.4 The Contractor must test all the fibres of the OFC from ODF to ODF and submit the fibre traces to

METRORAIL KZN Project Manager/Telecom department. 1.3 THE TECHNICAL REQUIREMENTS 1.3.1 The installation works and materials offered must comply with the following specifications As per

Annexure 3. Any deviations from these specifications must be clearly stated in a clause by clause statement of compliance to each specification. Failure to do so will result in automatic disqualification.

2. SPECIFICATIONS AND DRAWINGS 2.1 This specification sets the standards for the materials and techniques to be used in underground optical fibre cable installation and aerial optical fibre cable installations, and may not be deviated from without the permission of the Metrorail KZN Project Manager at all times. 2.2 Where reference is made to approved materials or techniques, this approval must be obtained from the Metrorail KZN Project Manager, who must co-ordinate any necessary interfacing with the relevant authorities. 2.3 This specification shall be read in conjunction with the Main Specification describing the project requirements. Should discrepancies arise between the Main Specification and this specification the requirements of the Main Specification shall prevail? 2.4 The following documentation should be read in conjunction with this specification : 2.4.1 Specification for works on, over, under or adjacent to railway lines and near high voltage equipment. (SPK7/1) 2.4.2 E.4E: Safety arrangements and procedural compliance with the occupational health and safety Act; Act 85 of 1983 and regulations. 2.4.3 Guideline for approval of OFC Suspensions on OHTE Masts. 2.4.4 SPK7: Protection of construction workers on or near railway lines. 3. DESIGN AND APPROVAL 3.1 Installation shall consist of a bracket clamped to the traction mast supporting a cable suspension fitting and the cable. No drilling or welding will be allowed on traction masts for the fixture of support brackets of any kind. 3.2 The design of the suspension hook shall be such as to prevent the cable touching or chafing against the suspension bracket or other infrastructure under the various load conditions that the OFC will be subjected to. 3.3 All fittings and brackets installed must be galvanized in accordance with SABS specification 763 or manufactured from approved corrosion resistant materials. Where the installation is within 30 kilometers from the coast, fittings and brackets must be stainless steel 304 as per BS (British standard) 1449/2. Tenderers


must comment on the likelihood of galvanic corrosion between the stainless steel bracket and the galvanized mast and propose measures to avoid this possibility. 3.4 An approved range of fittings and brackets, strain grips; suspenders etc. must be used (Approval by METRORAIL KZN Project Manager).Should alternative brackets and fittings be offered then the tenderer must submit a drawing and sample of each type of bracket and fitting for approval. Design specifications of the brackets and fittings are required. 3.5 The design of each bracket and fitting must be sufficient to support one span of cable load under installation and worst load conditions. 3.6 Tenderers must note that Metrorail KZN reserves the right to free issue all or part of the necessary fittings and brackets as well as other materials including cable should this option be exercised. 3.7 At termination points (dead ends) the cable tension shall be aligned with the mast to avoid bending moments that cantilever fittings would cause. The tension on any mast, in any direction and under maximum load condition, must not exceed 2000 Newton’s. 3.8 On an A frame structure, only one suspension arm must be fitted on one leg of the A frame. 3.9 Installation of the optical fibre cable must comply with the Guideline for Approval of OFC Suspensions on OHTE Masts (as per Spoornet's letter reference S.PL&T/I/CAO/13/3/1/6). The location of the OFC cable must not obstruct access to the OHTE conductors for maintenance purposes at any point. 3.10 NOTE: Where this specification refers to HDPE conduit it must comply with SABS specification 533 Part 2/1982. 3.11 Where a signal gantry structure is utilized to cross the tracks, the optical fibre cable must be installed in 50 mm diameter HDPE conduit or galvanized trunking secured to the channeling of the handrail. The HDPE conduit or trunking must be properly secured to prevent sagging. 3.12 Where a boom structure is utilized to cross the tracks, the optical fibre cable must be installed in 50 mm diameter HDPE or galvanized trunking secured in the web of the boom. or in the channel of the I beam so that overhead personnel can walk on top of the beam The HDPE conduit or trunking must be properly secured to prevent sagging. When galvanized trunking is used, an electrical occupation must be arranged with the relevant operational department to cross tracks. 3.13 Alternative methods or material such as fibre glass, PVC or poly carbon may be used to cross the tracks where a boom structure is utilized, but will require prior approval from the Metrorail KZN Project Manager. 3.14 No suspension must be made on masts carrying track switches, transmission line switches, make-off arrangements (except on A-frame structures) and transformers. The installer will use alternative structures. Optical fibre cable deviating onto such alternative structures must clear this equipment by 2 meters in the horizontal. This alternative structure must either be a galvanized pole, treated wooden pole or a concrete telephone pole of the right height and thickness to support the cable approved by the Metrorail KZN Project Manager. 3.15. The height of the cable must be so that it will not interfere with the normal day to day activities of the maintenance personnel and their vehicles and ladders. This height to the bottom of the cable should be in excess of 5 meters minimum. 3.16 Where existing optical fibre is suspended on traction infrastructure, new installations must be positioned as close as possible to the existing cable, in order to minimize possible obstruction, or be installed on the opposite side of the rails in compliance with the revised requirements which will be approved by METRORAIL KZN rail and the Metrorail KZN Project Manager. 3.17 The design must be such that at any point the bending radius of the cable must not be less than 20 times the outside diameter of the cable. 3.18 At anchor and intermediate positions, there shall be no slippage of the cable under any condition. 3.19 No fitting or clamp shall exert a crushing force on the cable of more than 1 000 N. 3.20 The cable shall be tensioned so that under normal conditions, i.e. when no wind is blowing, a cable temperature of 25 °C, the maximum sag per 70 meter span length must be 500 mm. Under the worst conditions, i.e. when the wind is blowing cross-sectional at a speed of 100 km/hour, at a cable temperature of 65°C, the maximum sideways deviation (sag) shall not exceed 2 meters. 3.21 The cable parameters will be provided in the Main Specification as supplied by the cable manufacturer. 3.22 To avoid Point Loads being applied to the cable, the following guidelines in this regard shall apply : 3.22. 0 — 15° deviation from the straight run - standard suspension method, preformed fibre optic suspension type unit or other approved fitting. 3.22.2 15° and greater deviation from straight run - false termination or similar method. 3.23 Excessive lengths of non-terminated cable shall be avoided. On straight runs, false terminations must be installed at intervals not exceeding 500 meters. 3.24 The position and types of brackets to be mounted on bridges and tunnels must be clearly indicated on the bridge plans. The OFC position must be selected to protect the cable against objects protruding from train wagons and wind lashing. The cable may also be protected by means of an approved conduit. The METRORAIL KZN Project Manager, together with the relevant authorities, must then approve these fittings and plans.


3.25 Clearance must be obtained from the Metrorail KZN Project Manager and other departments for each bridge, tunnel and retaining wall where brackets must be mounted. These brackets must be fixed against the wall by means of a stainless steel stud grouted into a hole and sealed. Rawl bolts are acceptable if the sheath is made with an aluminum bronze finish. Chemical fixers are also acceptable. Unsuccessful holes must be closed in an approved manner. 3.26 Optic Fibre Aerial Cable Pulley or Sling : 3.26.1 A specially designed pulley or sling for the erection of optical fibre aerial cable should be obtained for the installation and regulation of the cable. 3.26.2 The pulley/sling shall be of a suitable size to accommodate the minimum-bending radius of the cable, of low friction and should be able to accommodate an installation tension in all four directions (i.e. down, up, left and right). 3.26.3 The design of the installation pulley shall be such as to prevent touching or chafing against any infrastructure under the various load conditions that the pulley and OFC will be subjected to during installation. 3.26.4 After regulation it should be possible to remove the cable from the pulley or sling and attach the cable to the suspension fitting. 3.26.5 A sufficient number of pulleys shall be available to install a cable length of 2 000 - 4 000 meters at every suspension point. 3.26.6 The Metrorail KZN Project Manager must approve the design of the pulley or sling. NOTE: Photo 1 indicates an approved stringing pulley for fibre optic installation. Alternative designs will be considered, but full technical details and a sample shall be provided for evaluation and approval. 4. SURVEY 4.1 Aerial optical fibre cable should normally be ordered in lengths of 2 000 or 4 000 meters. Shorter lengths can be provided on request. It is however advisable not to exceed 4 000 meters due to excessive drag under installation conditions. 4.2 When a route is to be measured for the purpose of erecting an aerial optic fibre cable, a measuring wheel should be used for accuracy. It should therefore be determined in advance on which mast a joint/splice will be required. 4.3 Specific lengths should be determined as follows : 4.3.1 Start measuring at the termination cabinet up to the 2 000 / 4 000 meter mark. At the 2 000 / 4 000 meter mark, a suitable mast should be selected at which a joint could be made without any obstructions. The selected mast must be situated in a position where it accessible for splicing. A standard length of slack on either end must be allowed for termination and splicing of the fibers at ground level.


4.3.2 Add at least 35meters to every length of cable to allow for splicing and add additional for the sag of the cable per span. 4.4 False terminations must be placed at intervals of less than 500 meters. 4.5 The mast must also be identified for the construction team exactly where the first length of cable ends and the second length starts. These masts are to be indicated on the survey sheets. The whole route must be measured and marked in this way. Masts where joints are to be made must not have any other traction equipment on it. 4.6 It should be noted that no additional splices, without the approval of the Project Manager would be allowed. That means that the cable shall be fed through any obstacle that may occur. 4.7 Care should also be taken, when measuring, to avoid short lengths of cable at the end of the routes, thus eliminating extra splices in the cable. Transmission losses must be reduced to a minimum. 4.8 The final route selected must avoid an excessive number of track crossings. It is important that the correct side of the track be selected beforehand. This should normally be where the service road runs, for ease of access and added fire protection. 4.9 Care must be taken at platforms, bridges and footbridges to keep the cable clear from pedestrians in order to avoid tampering and malicious damage to the cable. 4.10 The positioning of the optical fibre cable on 3 kV DC, 25 kV and 50 kV AC electrified structures must be selected to avoid placing the cable in strong electric fields. Surveyors must specifically adhere to the minimum clearances required. 4.11 Possible damage by grass and bush fires, e.g. on the embankments of cuttings, must be taken into account during the survey. All potential grass and bush fire hazards must be indicated on the survey. An alternative route must be indicated on the survey on how to avoid these potential fire hazards. 4.12 All positions where intermediate poles are required must be indicated on the survey drawings. 4.13 A complete set of survey sheets must be submitted before installation commences. These survey sheets must indicate the start and finish of cable sections, types of brackets and fittings, joints, track crossings, obstacles, etc. The cable route must be distinguished by the international symbol for optic fibre cable. 4.14 The survey sheets must be A4 pages in portrait, and each page shall cover 1 km. The start of the cable shall be on the top of the first page, and each page will follow in logical order. Refer to Annexure 1. 4.15 The contractor will survey the route of optical fibre cable and will provide drawings and positions for the suspension on each mast to the Project Manager for approval by the Regional METRORAIL KZN rail Maintenance Manager at each Infrastructure Depot or local authorities. 4.16 On completion of the work, "As Build" route drawings must be submitted, as per the survey sheets and as stipulated in the Main Specification, which must indicate the following : 4.16.1 Requirements as per sub clause 4.12. 4.16.2 Joint numbers and traction mast numbers. 4.16.3 Amount of cable slack at joints, underground deviations and at other intermediate points. 4.16.4 All cable and drum numbers must be recorded on the survey sheets. 4.17 The co-ordinates of all joints, terminations and significant changes in direction must be recorded via GPS. These co-ordinates must be shown on the "As Built" drawings, and must be provided in electronic format (Auto Cad or Micro stations) in order for it to be loaded into Metrorail KZN G.I.S Database. 5. INSTALLATION 5.1 On receipt of the cable, the following steps must be taken : 5.1.1 Ensure that the cable delivered is of the correct type and fibre count e.g. anti-tracking cable for AC electrified sections. 5.1.2 Ensure that the cable or drums are not damaged. 5.1.3 Record drum numbers and lengths, and verify cable lengths. 5.1.4 Arrange drums according to the survey to ensure that the relative lengths are erected in the correct order.


5.2 Ensure that all pre–testing has been completed and approved. 5.3 Preparation must be carried out on the route on which the cable is to be erected. Trees, bushes and grass must be cut so that work can be carried out without any obstacles by the contractor. The aerial route must be at least 3 meters clear of bush and trees within the METRORAIL KZN rail reserve. Where excessive trees or bush, which could become a fire hazard are encountered, an alternative route must be chosen in accordance with the METRORAIL KZN Project Manager’s approval and the availability of alternative land within the METRORAIL KZN rail reserve. Tree branches overhanging the cable must be removed. 5.4 It is recommended that a 7 mm nylon ski-rope of ±2 000 meters shall be obtained to haul the cable through the special manufactured pulleys. 5.5 The rope must be fed through the pulleys before hauling commences. Equipment such as a mechanical fuse and swivel must be inserted between the end of the cable and the hauling rope to prevent the cable from twisting during installation. A grip on or Kellems Grip must be used to pull the fibre optic cable. The correct size grip for the particular cable must be used. If aramid yarn is a part of the cable structure, it must be tied to the grip to further distribute the pulling force between the hauling rope and the cable. 5.5 The mechanical fuse must be examined after every few hauls. If the fuse has worn more than half way it must be replaced with special copper fuse wire. 5.6 Erection of Cable on AC/DC Traction Masts : 5.6.1 Fit the universal multipurpose bracket at ±1, 5 meters above ground level. 5.6.2 Fit a pulley or sling on every suspension bracket for a distance equivalent to the length of the cable to be hauled in. 5.6.3 Feed the hauling rope through the pulleys or slings. Two hauling ropes may be used to expedite the hauling i.e. while the one is used for hauling, the other can be fed through the pulleys of the next section. 5.6.4 Place the drum with cable at least one span length of 70 meters away from the mast where the cable will pass through the first pulley. This would prevent the cable from bending too much while being hauled. Under no circumstances should the cable be bent excessively. This drum should be placed on cable jacks with an axle. The rate of the hauling should be controlled from this point. 5.6.5 The cable must be fed off the drum according to the speed with which the cable is hauled. Care must be taken that the cable is not tightening between the drum and the first pulley. A constant tension must be maintained on the cable by braking of the cable drum when necessary. Tension must be maintained to avoid contact with trains. Hauling should be avoided on very windy days. 5.6.6 The hauling team must haul the cable evenly and slowly to prevent the cable from jerking which can result in broken fibers. 5.6.7 Good communication between persons at the drum, alongside the cable end and the hauling team, is absolutely essential and must be available at all times. If the communication breaks down, the hauling must be stopped immediately until such time that communication had been re-established. 5.6.8 When hauling the cable, a person with a two-way radio must walk alongside the cable-end to ensure that the cable is not twisting with the rope, especially at angle-masts where the possibility of twisting is great. When the cable starts twisting, hauling must be stopped immediately. The cause of the problem must then be pinpointed and rectified. 5.6.9 The person walking at the hauling end must ensure the best route for the cable, avoiding the cable chafing against stays or other obstacles. 5.6.10 Tensioning shall be as per sub clause 5.7. 5.6.11. Less cable slack is required for AC-type installations but sufficient slack must be left for splicing purposes. 5.6.12. Once tensioning and splicing of the cable is completed, the suspension bracket shall be moved up the mast in at least three steps with various lengths of installation tools to the correct position on the mast. Note that approved non-conductive tools must be used and installation teams must avoid touching any high voltage carrying infrastructure at all times. 5.6.13. The splicing team must strive to keep-up with the hauling team. If this is not the case, additional labor will be required to lower and raise the cable for splicing purposes.


6 TENSIONING The pulling tension for the particular type of cable used is specified in kg/N. 6.1 A termination bracket and fitting (dead end) must be installed at the beginning of each length. Where only false terminations occur in a cable section the cable must be tensioned sequentially for every false termination section. 6. 2 The cable sag and tension under normal installation conditions may vary around bends. Special care must be taken when the cable is removed from the pulley and placed onto the termination fitting so that the cable does not exceed the prescribed tension. 6. 3 The cable shall be tensioned by means of an approved device and the tension shall be continually monitored not to exceed the parameters provided by the cable manufacturer. 6. 4 On sections with a number of angle masts, it may be required to tension the cable over shorter distances. In this case care should be taken not to damage the cable at the intermediate tensioning points. 6.5 Sufficient time shall be allowed for the tensioned cable to settle. This time is when there is no longer a movement on the tensioning scale. When the correct tension has been achieved, the suspension and termination fittings shall be fitted. 6.6 The cable must be marked at all anchor points in an approved manner to indicate possible slippage. 6.7 The site supervisor must record the final stringing tensions and terminated span lengths on a control sheet. The site supervisor must submit these sheets with the site diaries for scrutiny and retention. NEVER EXCEED THE MAXIMUM PULLING TENSION! Excessive pulling force will cause the cable to permanently elongate. Elongation may cause the optical fibre to fail by fracturing. Good construction techniques and proper tension monitoring equipment are essential. 7 CABLE SLACK 7.1 At positions where it may be required to accumulate cable slack due to the nature of the route, this slack must always be coiled in a figure of eight to avoid twisting of the cable. In muddy conditions the figure of eight must be done on a ground sheet to avoid soiling of the cable. 7.2 After the hauling process, sufficient slack must be left for splicing purposes. The cable must reach ground level plus 15 meters plus another 15 meters on the hauling end, which must be cut off by the installation team. The installer must ensure that this length is cut off during the installation process. 7.3 The slack shall be coiled in two separate coils of minimum 500 mm diameter, tied with UV stabilized cable ties at four positions and secured at the top of the mast. 7.4 If slack boxes are specified in the main specification, these must be of sufficient size to accommodate the cable minimum bending radius. The contractor will supply these items according to the project specifications and the approval of the Metrorail KZN Project Manager. 7.5 Care shall be taken not to twist the cable when coiling the cable slack. 7.6 A small amount of slack, between 250 and 300 mm (sag) must be allowed at false terminations. 7.7 In order to avoid sharp angles in the vertical plane when going over or under bridges a gradual increase or decrease of the route shall be obtained by adjusting the suspension brackets upwards or downwards on the masts. 8. INTERMEDIATE POLES 8. 1 Intermediate poles (where required) must be installed where span lengths exceed 70 meters or where the cable veers away from the track for any reason. Intermediate poles must be of the wooden, steel or concrete telephone type. The ground clearance of the suspended cable must not be less than 7, 0 meters. Where the intermediate wooden pole is in the danger of burning, a 2 meter high galvanized metal sleeve must be fitted around the base of the pole. 8.2 The Project Manager will obtain approval for the erection of intermediate wooden, steel or concrete poles in the vicinity of electrified tracks. 8.3 Similar cable support fittings must be utilized for the suspension of the cable on poles as that used for the electrification masts.


8.4 The contractor will supply intermediate poles. These poles will be approved by the Metrorail KZN Project Manager. 8.5 Stays or struts must be fitted as required or as directed by the Project Manager. Critical poles must be concreted in position. 8.6 To make the poles more visible at night, a reflective band of UV resistant material must be fixed to the pole next to service or other roads at a height of 1, 5 meters above ground level. 9. SAFETY PRECAUTIONS 9.1 Due to the proximity of live wires the installer must ensure that his employees installing the cable on the masts obtain a Category C certificate from the Metrorail KZN Metrorail KZN Project Manager in conjunction with Esselen Park training center or any Metrorail KZN accredited institute before any work can be carried out on the masts. 9.2 The contractor's employees must be trained for competence and understanding of the basic electrical safety requirements. The certificate obtained will not be transferable. The cost of the training will be borne by the Installer or as stipulated in the contract document. 9.3 The installer and his employees installing the cable must be fully conversant with the Electrical Safety Instructions and the Transnet specification E.7/1 and E.4E. 9.4 No work within 900 mm from live. DC equipment and transmission lines, and 1200 mm from 11 kV AC live equipment. Preferably this clearance should be as great as possible. 9.5 In all instances where the safety of workmen is jeopardized, electrical and/or track occupations must be requested. The METRORAIL KZN rail representative in accordance with the METRORAIL KZN Project Manager will arrange these occupations. Notification is however required Twelve (12) weeks in advance. 9.6 Under bridges where live cross span wires are involved, at make off masts and where the live conductors approach the optical fibre cable very closely, a standard warning board must be fitted. Electrical personnel must be approached to arrange for a work permit to fit the cable and warning boards. 9.7 No attempt must be made to install the cable in windy conditions, especially when the sag (before tensioning) is blown in the direction of the track. Supervisors must use their discretion in this regard. 9.8 Tenderers must note that no metal ladders will be allowed but only wooden or fiberglass ladders. 9.9 Tenderers must note that the AC bracket installation tool (stick) may not be used in wet or rainy conditions. 9.10 Hard hats, protective clothing and safety belts must be worn whilst working on masts and other structures. 9.11 Optical fibers are extremely thin and can easily penetrate skin and eyes. Any off cuts or bare pieces of fibre must be properly disposed of. Optical fibers are categorized as hazardous materials and require special disposal measures. 9.12 Care must be taken when testing as the laser in test equipment produces an invisible light, which can cause permanent eye damage. All fibers should be treated as "live". 9.13 All personnel involved in the installation and testing must be made aware of the above safety aspects. 9.14 A Health and Safety Agreement shall be entered into between Metrorail KZN and the successful tenderer. The contractor will also comply with the METRORAIL KZN rail regions Health and Safety standards and will be represented on the METRORAIL KZN rail regions Health and Safety meeting. 9.15 The contractor must comply with the "Standard Safety Work Procedures for the Installation of Optical Fibre Cable" SANS 10340 (latest version). This document must also be attached to the Health and Safety Agreement. 9.16 The Contractor must comply with the "Protection of Construction Workers on or near Railway Lines". This document must be read in conjunction with this specification.(SPK7/1) 10. SPLICING, TERMINATION AND TESTING 10.1 Splicing can commence after approval is obtained from the Metrorail KZN Project Manager. 10.2 All splicing and testing must be done inside a vehicle or a dust free shelter. Cleanliness is absolutely essential to make satisfactory splices. 10.3 A competent team using an optical fibre fusion splicer in compliance with the manufacturer of the said device (with the stipulated software) must carry out fusion splicing and terminations. Tenderers must state the competence and experience of the personnel envisaged to do the fusion splicing. Splicing must be carried out in accordance with procedures and instructions as stipulated by the cable and splice housing manufacturers.


10.4 The splicing team must be suitably equipped with all the necessary materials, accessories and equipment to carry out the fusion splicing. The splice losses expected during installation must be similar to those obtained during the drum tests which should be recorded on a spreadsheet for reference purposes. This spreadsheet should be attached to the test certificate when handed to the Project Manager. 10.5 Splicing must comply with the splice housing manufacturer's specifications i.e. securing of the strength member and Kevlar, slack inside the splice closure and protection of the individual splices. 10.6 The individual fibers must be numbered or easily identified inside the splice organizer. The up and down ends of the cable and loose tubes must be identified. 10.7 On completion of the individual splices the organizer must be placed in approved hermetically sealed splice housing. The contractor will supply these splice housings with an approved manufacturer as specified in the main specification. And with the approval of the Metrorail KZN Project Manager. 10.8 The splicer must ensure that the silica-gel packet, supplied with the dome closure, be opened and inserted in the dome closure before closure of the dome. 10.9 The splice housing must be fixed to the mast and numbered in an approved manner with sufficient cable slack as specified in sub clause 7.11.7. 10.10 Termination of the fibers must be carried out on approved connector’s pigtails and termination cabinets as specified in the Main Specification. The contractor will supply these items with an approved manufacturer specified in the main specification. And with the approval of the Metrorail KZN Project Manager. 10.11 After the complete installation each individual fibre must be tested from both fibre ends Testing must be carried out in conjunction with Projects personnel from Metrorail KZN. The test to be conducted shall be : 10.11.1 Fibre continuity. 10.11.2 Overall attenuation (loss) - tested by means of optical power source and power meter. 10.11.3 Splice Loss - for each individual splice. 10.11.4 Attenuation profile - tested by means of OTDR. 10.11.5 The Project Manager reserves the right to carry out individual tests should this be required on any length of installed fibre during any phase of the construction. The installer shall be required to witness these tests. 10.11.6 Graphic print outs or software files must be submitted to the Project Manager for his scrutiny and forwarded for approval by the Chief Signal Engineer. 10.11.7a. When a splice is completed and fitted into a joint enclosure, the cable slack (30 meters in total) must be coiled into a suitable slack box, which is fitted to an arm on the pole or coiled around suitable brackets fitted on the pole. 10.11.7b. When coiling the slack after the joint has been completed; it must be coiled before the joint is secured to the pole/arm. Start coiling by rolling the slack with the joint as the leading end (roll cable like a wheel). This will ensure that no twists are put in the cable which will result in the fibers being damaged. 10.11.7c. When completed place the coil into the slack box and secure the joint closure at a suitable position on the arm/pole. 11. FINAL ACCEPTANCE 11.1 Each fibre must be tested before it is introduced as directed in clause 7.11and with the approval of the METRORAIL KZN Project Manager. The purpose of these tests is to ensure that the fibers are acceptable for use in the METRORAIL KZN network. 11.2 An approved OPTICAL TIME DOMAIN REFLECTOMETER (OTDR) in compliance with the cable manufacturer with the stipulated software must be used for the testing and measuring of the fibers. Records of all the results must be kept for reference purposes. 11.3 Tests must be carried out at both 1310 nm and 1550 nm wavelengths. These test results must be forwarded to The Metrorail KZN Project Manager for scrutiny and approval.


ANNEXURE 1: SAMPLE OF "AS BUILT" DRAWINGS


ANNEXURE 2 A Equipment: Blocks

Multiple Cable Block Used for supporting multiple cables in independent rollers. Multiple cable blocks make a cable positioner unnecessary when lashing multiple cables.

Single Roller Block Typically used to support a single cable prior to lashing and may be used when cables are lashed directly to strand or in over-lash applications. In new strand situations, single roller blocks may be locked onto the strand. In over-lash applications, this block should not be pushed in front of the lasher.

Economy Block Used to support a single cable prior to lashing and, depending on the actual block, may be used when cables are lashed directly to Strand or in over-lash applications.

Pole Mount Cable Block Used to install self-support cable and is attached to the pole hardware to support the cable as it is pulled out.

Take care that cable slack does not exceed the minimum bend radius over blocks.

B Equipment: Pulling Grips and Devices

Kellems® Grip This reusable grip is woven from strands of stainless steel, acts like ‘Chinese finger cuffs’ and compresses upon being relaxed. It provides an evenly distributed hold on the jacket of the cable.


Dynamometer Used in monitoring the pulling tension applied to Fibre optic cables

Breakaway Swivel Used for preventing excessive pulling tension. It is designed to break should it exceed a pre-set tension limit.

C Equipment > Blocks, Chutes and Brackets

90° Corner Block Used to route cables through inside or outside corners up to 90°. It minimizes drag on the cable in corners and ensures that the minimum bending radius of the cable is not exceeded. It requires specialized mounting hardware depending on the specific use of the equipment

45° Corner Block Used to route cables through inside or outside corner up To 45° it minimizes drag on the cable in corners and Ensures that the minimum bending radius of the cable is Not exceeded.45° corner blocks may be used as a set- Up chute to guide Cables from the cable trailer or a reel stand. It

requires specialized mounting hardware depending on the specific usage of the equipment

Set-Up Chute

A set-up chute is used to guide cables from the cable trailer or reel stand. This equipment requires specialized mounting hardware depending on the specific use of the equipment.

Set-Up Bracket This bracket is used to support 45° and 90° corner blocks or set-up chutes at mid-s


D Equipment > Lashers, Pullers, Positioner’s and Guides

Cable Positioned (or Magic Box) This is pushed in front of a lasher by a cable block pusher to uniformly position multiple cables that are being lashed. Cable Guide

Used for guiding the cable into the lasher in drive-off applications. It

can be used for new strand or over-lash applications. The guide may be pushed in front of the lasher with a cable block pusher, pulled in front of the lasher or physically attached to the lasher, dependent on the cable guide type.

Cable Lasher Used for lashing cable directly to installed strand or cable bundles. Lashers are somewhat specific to cable and strand size – improper lasher size or adjustment may damage cables.


Multiple Cable Pullers This allows for multiple cables to be pulled into place when lashing cables directly to the strand. It’s equipped with a strand brake to prevent sagging of cables as the pulling tension is released. Allows pulled cables to independently swivel.

Over-lash Cable Puller This allows multiple cables to be pulled into place in over-lash applications. Allows pulled cables to independently swivel.

Cable Block Pusher (Shotgun / Shuttle) Used for pushing equipment ahead of a pulled lasher.


E Equipment: Lifting Tools and Brakes

Lay-Up Stick A fibreglass stick used to lift cable blocks and cables into place utilizing appropriate lay-up stick heads. Cable Lifter (or Lay-up Stick Head) This is used in conjunction with a lay-up stick to lift cables into place. The lifter ensures that the cables being lifted are not damaged by exceeding the minimum bending radius. Cable Block Lifter Used in conjunction with a lay-up stick to place assorted cable blocks mid-span. Wire Raising Tool This is used in conjunction with a lay-up stick to lift cable blocks and strand. Strand Brake This device is selectively placed at pole hardware locations to prevent dangerous strand sag while strand is being installed. The strand brake allows the strand that is being pulled into place to move in only one direction, which is the direction of the strand pull. Use of strand brakes in conjunction with reel brakes effectively limits the amounts of strand sag between poles during strand installation.

F Equipment > Fibre Preparation and Splicing

Buffer Tube Cutter These are used to score drop armoured, central tube and stranded loose tube buffers to facilitate exposing the fibbers. Coating Stripper This device mechanically strips fibre coating using precision blades and preset openings in much the same way as a wire stripper takes insulation off a copper wire. After the coating has been stripped, the fibre is cleaned with a solution of 95% or higher isopropyl alcohol. Fibre Cleaver (Hand Held) Fibre cleavers score and then trim the fibre. Price and complexity of cleavers vary widely - generally, the more you spend, the greater the consistency of cleave. The beaver tail cleaver shown is a lower cost model.


Fibre Cleaver (Free Standing) This is a larger and more expensive version of a cleaver. Its main advantage is that it performs accurate cleaves more consistently than the hand-held models. Fusion Splicer Most low-loss splices are made with fusion splices, which use an electric arc to fuse together the cleaved ends of fibbers. Splicers vary widely in complexity, features and price. Some automate the entire splicing process. An applicable splicer for fibre optic cables would have:

1. A fusion heat source, usually an electric arc 2. V-groove clamps for holding the fibbers 3. A way of positioning the fibbers for optimum splicing 4. A way of viewing the fibbers (microscope, display screen) So they can be accurately positioned. 5. LID (Local Injection and Detection) and/or PAS (Profile 6. Alignment System) to aid with fibre alignment


ANNEXURE 3. Drawings and photos

Photo 1 Cable pulley

Photo 2


Photo 3 Termination bracket

Drawing 1


Drawing 2

Drawing 3


Drawing 4

Drawing 5


Drawing 6

Metrorail KZN

Dark Fibre 48-Core Splice Layout - Links 1 - 4 of 13

Splicing Layout Diagram 1

Rossburgh Rossburgh Booth Clairwood Jacobs wentworth kingsrest fynlands fynlands

Relay Room

3kV Sub 3kV Sub Sub

B002266 B002036

B002049

Ticket Office Ticket Office

12 CORES TO BE

SPLICES

12 CORES TO BE

SPLICES

SLACK TO BE

PROVIDED

SLACK TO BE

PROVIDED48-P

OR

T L

C

PA

TC

H P

AN

EL

48-P

OR

T L

C

PA

TC

H P

AN

EL


As Built Diagram 2



OTDR Report Diagram 3


Photo 4. 24 Dome joint 4

END- PART A


PART B: Optical fibre accessories used in the METRORAIL KZN environment Abbreviations, Acronyms and Definitions’

ABBREVIATION AND ACRONYMS DESCRIPTION

PVC Polyvinyl Chloride

ODF Optic Distribution Frame

LSZH Low Smoke Zero Halogen

PABX Private Automatic Branch Exchange

DEFINITION DESCRIPTION

Assembly Consist of a terminated cable in a pigtail or patch-lead configuration

Pigtail - Unruggedised Secondary coated fibre connectorised at one end (of specified length)

Pigtail - Ruggedised Secondary coated fibre with aramid polymer fibers in a 1,6mm PVC sheath connectorised at one end (of specified length)

Patch lead - Ruggedised Secondary coated fibre with aramid polymer fibers in a 1,6mm PVC sheath connectorised at both ends (of specified length)

Duplex Patch lead - Ruggedised Two of secondary coated fibre with aramid polymer fibers in a figure 8 PVC sheath with nominal thickness of 1,6mm each (of specified length)

Overall Ruggedised Two of secondary coated fibre with aramid polymer fibers in a figure 8 (zip cord)PVC sheath with nominal thickness of 1,6mm each (of specified length) with an additional overall protective sleeve

Connector Coupling device attached to pigtail or patch – lead (of specified type)

Mid – Coupler Receptacle to fit in a cabinet to join two connectors together, also known as a middle alignment sleeve.

Flat twin cable Two simplex cables (see Duplex Patch- Lead Ruggedised) with a PVC outer protective sheath.

Strain relief boot Mechanical device that ensures that additional strain on the cable will not be transferred to the ferrule or fibre.

Organizer A unit that can accommodate fibre slack coils and splice protectors

1. SCOPE

1.1 This specification covers the supply of optical fibre accessories to supplement single mode optical fibre

cables.

2. INTRODUCTION 2.1 This specification covers the requirements for the supply of the following optical fibre accessories and

services to Metrorail KZN: 2.1.1 Pigtails (ruggedized and unruggedised). 2.1.2 Mid-Coupler (Mid alignment sleeves). 2.1.3 Patch cords with Connectors. 2.1.4 ODF's (Optical distribution sub racks) 2.1.5 ODF's (Optical distribution Main Frames) 2.1.6 Splice protectors. 2.1.7 Joint closures with splice organizers. 2.1.8 Training on installation practices. 2.2 This specification also covers the quality requirements and testing of the completed

patch-leads and pigtails as per Appendixes A, B and C.


2.3 The tenderer must indicate, clause-by-clause, in a separate statement of compliance whether optical fibre accessories offered comply or do not comply with this specification.

2.4 If the tenderer submit ANY alternative offer, all deviations from this specification must be clearly stated and explained. The alternative will have a test sheet and must be approved by the METRORAIL KZN project manager.

2.5 The Tenderer must note that the standard connector requirement is the E-2000 APC type. 2.6 Various combinations of connectors may be a requirement in specific cases. 2.7 All units must be able to accommodate and organize cable, fibre and patch-lead slack. 2.8 Tenderers will be required to demonstrate all units offered when requested. 2.9 All ODF's must be manufactured from durable materials suitable for use in coastal areas. 2.10 All units must be completely dust proof. Tenderers are requested to specifically comment on this

requirement. 3. OPTICAL FIBRES

3.1 Only 9/125/250 pm coated optical fibers must be used to ITU G.652.D recommendations. 3.2 The fibre types used must be easily strippable and comply with customer specifications for single mode

optical fibre.

4. OUTER SHEATH 4.1 The outer jacket material must be uniformly sheathed with PVC Type TM1 or alternatively with LSZH

(when specified). 4.2 The sheath must have a minimum thickness of 0; 5 mm and the overall diameter must be 1, 6 mm +0, 2 mm. 4.3 The sheath must be yellow for single mode (SM) and orange for multi-mode (MM). The sheath must

be easily strippable from the cable.

5. PIGTAIL AND PATCH-LEAD IDENTIFICATION 5.1 A unique serial number must be printed on a permanent affixed label and attached to each unit between

10 -20 cm from the boot of each connector. This label can also serve as proof of testing/QA. 5.2 Labelling must be done at both ends in the case of a duplex patch-lead. 5.3 The following information must accompany each assembly:

5.1.1 Insertion loss @ 13 10 nm and 1550 nm (Single mode). 5.1.2 Return loss @ 13 10 nm and 1550 nm (Single mode). 5.1.3 Unique serial number. 5.1.4 Product description. 5.1.5 Order number. 5.1.6 Date tested. 5.1.7 Length of tail or patch-lead. 5.1.8 Type of connector. 5.1.9 Type of fibre (e.g. 13101 1550 nm single modes).

5.4 The rubber boot of the connector can be blue for 0" flush-polished connectors and green for 8" angle

polished connectors. 5.5 A unique identification mark (color or number) must be applied to either end of patched-leads to assist

with identification of patched-leads in densely populated ODF's or termination cabinet. 5.6 The A and B leg of Duplex Patch lead must be identified.


6. DUST CAPS

6.1 This specification also covers the quality requirements and testing of the completed patch-leads and pigtails as per Appendixes A, B and C.

6.2 Each E-2000 (or otherwise specified) connector or mid-coupler supplied must be fitted with an integrated dust cap to protect the end face from dust and scratches.

6.3 The E-2000 (or otherwise specified) dust cap must be spring loaded to ensure positive closure when not mated and constructed of a material to protect users from laser radiation.

6.4 Dust caps for other connectors and mid-couplers must comply with the requirements of this specification.

6.5 Dust caps must be color coded to differentiate between single mode and multi- mode units as well as angle and flush polished (refer to sub clause 8.3).

7. MID-COUPLER (BULKHEAD)

7.1 Dust caps must be color coded to differentiate between single mode and multi- mode units as well as

Single mode mid-couplers must have a ceramic alignment sleeve with a yellow insert for identification purposes. Mid-coupler offered must have a self-secured clip that can easily connect onto the coupling plate supplied by the optical distribution frame or rack.

7.2 The color coding must be blue for 0" flush polished and green for 8" angle polished mid-couplers.

8. CONNECTORS

8.1 This specification also covers the quality requirements and testing of the completed

patch-leads and pigtails as per Appendixes A, B and C. 8.2 This specification also covers the quality requirements and testing of the completed This specification

generally specifies the (angle polished connector) APC E2000 connectors unless otherwise specified. 8.3 Other types of connector’s angle or flush polished may be required and the minimum requirement is

conformance to this specification. 8.4 All connectors must consist of a ceramic ferrule and strain relief boot. Other materials will be

considered but comprehensive technical information and test results will be required. 8.5 All connectors must withstand the mechanical tests covered in this specification. 8.6 A heat-cured epoxy must be used on all connectors. 8.7 Isopropyl alcohol together with lint free tissue will be used for cleaning connectors. Assemblies must be

inert to cleaning with this fluid. 8.8 The customer reserves the right to request specialized connector materials. 8.9 The optical performance of the required connector is specified in Appendix A of this specification. 8.10 The colour coding must be in accordance with Heading 8. MID-COUPLER (BULKHEAD) sentence 3 9. OPTICAL DISTRIBUTION FRAMES AND RACKS 9.1. ODF's must be available in three different types 9.1.1. A wall mount unit for small communication or PABX rooms. 9.1.2. A 19 - inch stackable ODF rack for terminating and patching fibers for small to large communications

room. 9.1.3. Specialized ODF (Main frame) for large distribution site. 9.2. Wall Mount Unit 9.2.1. The wall mount unit must have a minimum capacity for the termination of 48 Fibre. 9.2.2. The unit must be easily accessible and easy to terminate and patch fibers. 9.2.3. The unit must be supplied with a removable panel to accommodate different types of

connectors and mid-couplers. 9.2.4. The unit must be tamper proof and lockable. Two separated areas will be required:

(I) Cable entry and termination of fibers; and (II) Distribution and patching of fibers.

9.2.5. The unit must provide cable entries for terminating and distribution to other equipment. 9.2.6. The unit must be supplied with all cable glands, screws, nuts and bolts to secure to a concrete or brick


surface. 9.2.7. The unit must be supplied with standard accessories -splice organizers, connector plate,

cable clamps, fan-out devices and transportation tubes. 9.3. 19 inch stackable ODF sub rack

9.3.1 The 19-inch stackable ODF sub-rack must have a combined splicing, termination and storage function

with a capacity for the termination, cross-connecting, store excess fibre and patching of minimum 24 fibers.

9.3.2 Each unit must be easily accessible and easy to terminate and patch fibers. 9.3.3 Each unit must have a maximum height of 3U and must include a patch- lead routing scheme. 9.3.4 The unit must be designed to optimize accessibility allowing minimum movement of pigtails and fibers

when the unit is opened and closed while connected systems remain fully operational. 9.3.5 The unit must be designed with a front panel for the protection of optical fibre patch-leads. 9.3.6 The unit must be designed to organize excess patching cords with the option for distribution via the

front or rear of the rack. 9.3.7 The unit must be supplied with standard accessories -splice organizers, connector plate, cable clamp,

fan-out device and transportation tubes. 9.4 Specialized main ODF Rack or Cabinet

9.4.1 The main ODF cabinet must have a maximum height of 47U, free standing and be able to

accommodate standard 19-inch sub-racks. 9.4.2 Each cabinet must be designed to facilitate various configurations based on optimized modular units

and to enable a variety of cabling requirements. 9.4.3 The cabinet must be designed to provide a complete management and storage system for the cabling

of long optical patch-leads and pigtails.

10. SPLICE PROTECTORS 10.1. Heat crimping type

a) b) A. Splice protectors must be manufactured from a durable crimping material. B. It must have a non-corrosive material insert for strengthening purposes. C. The length of splice protectors offered must be 60 mm. D. All splice protectors offered must have a crimping temperature range of 210 "C ±10 "C.

10.2. Mechanical Crimping Type

Tenderers may offer mechanical splice protectors, which must comply with the requirements of this specification. Comprehensive technical application and testing information must be provided to the METRORAIL KZN Project Manager for approval before mechanical splice protectors will be used.

11. JOINT CLOSURE WITH SPLICE ORGANISER

11.1 This specification also covers the quality requirements and testing of the completed

patch-leads and pigtails as per Appendixes A, B and C. 11.2 All closures must be re-enterable designed to protect splices and bare fibre from environmental and

mechanical damage. 11.3 Closures must be available in various sizes and designed to accommodate splice organizers for a

minimum of 48, 96, 144 and 288 splices. 11.4 All closures must be designed with a minimum of 6 cable entry ports. At least one entry port must be

oval or be able to do a "loop through" facility with minimal fibre splices. 11.5 All cable entry ports must normally be sealed off and will only be opened when required. 11.6 The closure must be suitable to simultaneously accommodate conventional cables as well as micro-

tubes and micro cables. On the large type closures, multiple entry ports will be preferred as well as ports that can accommodate multiple micro tubes or micro cables.

11.7 Every component of the closure and organizer must be corrosion proof. 11.8 All closures must be UV stabilized for outdoor installation. 11.9 All closures must be water tight and suitable for direct buried applications suitable for any environment -

aerial, pedestal, and direct buried and underground applications. 11.10 All closures must be designed for numerous splice applications; expressed, tap-off, branch and repair.


11.11 All closures must accommodate a mounting bracket for wall or aerial mounting. 11.12 The mounting type will be specified during ordering for 6, 12, and multiple fibers per tube. 11.13 The Splice Closure Organizer must provide proper fibre management.

12. MANUFACTURING

12.1 The customer reserves the right to inspect and approve the Contractors production facility. 12.2 The preferred requirements for such a production facility are:

12.2.1 Approved termination, inspection and test equipment which will guarantee a final product that

will conform to customer specifications. 12.2.2 "On site" customer audits may be conducted prior and during tenders for new contracts.

13. EXTENT OF TESTING 13.1 Optical tests must be done on each assembly, and must comply with specification IEC 60874, as per

Appendix A and B. 13.2 Mechanical tests required for ruggedised tails or patch leads only, must be considered type approval

tests as per Appendix C, and may be at the discretion of the customer. 13.3 The tenderer must have equipment to do the tests called for in this specification. 14. INSPECTION 14.1 The customer reserves the right to call for the inspection of goods on any contract or order, at any

stage before final acceptance. When such inspection is required, the relevant contracts and orders will be endorsed accordingly.

14.2 The Contractor must prepare, without charge to the customer, samples and specimens for testing at any laborite or testing agent under supervision of the customer

15. SAMPLES

15.1 A sample of any item covered by this specification must be submitted within fourteen (14) days if called

for. The sample will be regarded as being identical with the items for which this tenders are submitted. 15.2 The sample will be non – returnable unless specifically qualified by Tenderers. Some items may be

tested to destruction.

16. PACKAGING 16.1 Pigtails, patch-leads and components must be dispatched as per order. 16.2 Each assembly must be individually coiled with a minimum diameter of160mm. 16.3 Each item must be individually wrapped in a suitable plastic packet. 16.4 All items must be dispatched in suitable packaging to prevent damage during normal handling. Rigid

packaging is required


APPENDIX A: OPTICAL PERFORMANCE OF CONNECTORS OPTIMISATION

The positioning of the connector key-way must be as indicated in Appendix B, test method A.

INSERTION LOSS

The insertion loss throughout the range 1260 nm and 1558 nm must not be greater than:

Type connector 1 Specification

Single mode 00 PC 0.3dB

Single mode 80 PC 0.3dB

The test method is shown in Appendix B test method B. Insertion loss is defined as: Where P1 is referred optical power P2 is transmitted optical power

RETURN LOSS

The return loss throughout the range 1260 nm and 1580 nm must not be greater than or equal to:

Type connector Specification

Single mode 00 FC-PC 45dB

Single mode 80 APC 70dB

The test method is shown in Appendix B test method C. Return loss is defined as: 101oglO (P 1 / P3) dB Where P1 is reference optical power and P3 is reflected optical power

A4 E-2000APC Specification

Item Parameter

Strain Relief 100N

Operating Temperature -250 to 70

0 Celsius conditioned by the table

Durability Min 1000 cycles

Assembly procedure Epoxy and polished

Connection Physical contact

Lock mechanism Snap-on

Standard En186-27/cecc86 275-801/802/IEC 61 754-15

Ferrule Materials Full ceramic zirconia

Connector Material UL 94-VO

APPENDIX B: TESTING OF ASSEMBLIES GENERAL

All tests must be conducted between 20 "C and 25 "C. For convenience, the optical measurements are performed on cable terminated at both ends. On completion of the measurements, the cable may be cut to provide two optical terminations (pigtail). If equipment or test methods used are other than those specified below, prior permission must be obtained from Customer Test methods must comply with specification IEC 60874. MEASUREMENT SYSTEM

The source and power meter combination must be stable to within +0, 05 dB over a period sufficiently long to enable to measurement to be completed. The source must consist of a 1310 nm and 1550 nm laser (+20 nm) for


Single mode and at 850 nm and 1300 nm LED for Multi-mode testing. MASTER CORD

A master cord must be used specifically for the purpose of measuring insertion loss and return loss. It must employ the same connector as the one to be tested and must have a core eccentricity of less than 0, 5 pm. The error vector must be within 1130 degrees from the alignment key vector. The ferrule end face must be of the APC/PC type. The master cord must effectively remove cladding modes within its length. TERMINATOR

An optical terminator must be employed such that the reflected power from the end of the fibre is reduced to a negligible value.

c)

d) TEST METHODS e) f) Optimization

An example of the test configuration required is shown in figure 2 NOTE: Optimization has to occur before angle polishing because the angle has a specific relation to the key

which cannot be changed.

FIGURE 2 After the optical transmission of the connector is optimized, the key-way must be fitted. Insertion Loss using the configuration shown in Figure 3, the reference power P1 must be measured.

The connectorised cord under test must then be inserted into the system as shown in Figure 4, and the transmitted power P2 must be measured. The insertion loss of the mated connector id defined as Insertion loss = lOLog10 (Pl/ P2) dB

FIGURE 3 (Reference Power, PI)


FIGURE 4 (Transmitted Power P2) Return Loss

Return loss unit

FIGURE 5 (Reference Power P 1)

Using the configuration in Figure 5, the reference power P1 must be measured. Return loss unit

Connector under test FIGURE 6 (Reflected Power, P3)

The cord under test is then inserted into the system, and a connectorised fibre tail is connected to the cord under test as shown in Figure 6. The fibre tail must be terminated in such a manner that the reflected power from the fibre end is negligible. Using the configuration shown in Figure 6, the reflected power P3 must be measured. The return loss of the two connectors under test is defined as:

Return loss = 10Log10 (P 1 / P3) -X dB Where X = insertion loss of the directional coupler from port C to port B.

Note: This method of measuring return loss ignores the fibre loss, and also the far end connector contributes to

the reflected power measured. Quality of Polish When the ferrule end face is examined with microscope at X 300 magnification, there must be no visible cracks, scratches or other marks over the surface of the end face. Interferometer testing Interferometer testing is required to check radius of curvature, fibre height, and apex offset, fibre angle, and fibre and ferrule roughness. Interferometer reports must be available when required by the customer.

END OF APPENDIX B


APPENDIX C: MECHANICAL PERFORMANCE OF RUGGEDIZED ASSEMBLIES (Unruggedised pigtails are excluded from these tests) FLEXIBILITY The fibre or any other component part of the cable must not suffer permanent damage when the cable is repeatedly wrapped and unwrapped 4 complete turns for 10 complete cycles around a mandrel 20 mm in diameter. The cable must be coiled with sufficient tension to maintain continuous contact with the mandrel. COMPRESSIVE STRESS The fibre and component parts of the cable must not suffer damage when subjected to a compressive load of 1000 N applied between two rigid and parallel plates of dimensions 50 mm by 50 mm. The load must be applied for 60 seconds. Tensile Test The connector under test must be mated via a bulkhead to the optical test equipment. At a maximum point of 300 mm from the boot, the cable must be anchored on a mandrel, without detriment to its optical performance. The free end of the cable must be connected and routed via a bulkhead to the optical test equipment. A load of 100 N must be applied at a rate of 5 mm/min and held for 10 minutes. The load must then be increased to 150 N and held for 5 minutes. The insertion loss must be measured and recorded through the duration of the test. The test must then be repeated for return loss measurements. At the 100 N / 10 min stage the insertion loss must be less than 0, 6 dB and the return loss as per Appendix A specification. At the 150 N / 5 min stage the insertion loss must be less than 0, 7 dB and the return loss as per Appendix A specification. After the completion of the test the cable must be removed from the assembly and allowed to relax for 5 minutes. Insertion loss and return loss must be measured and recorded. The insertion loss must be as per Appendix a specification. TORSION TEST The connector under test must be mated via a bulkhead to the optical equipment. At a point 1000 mm from the rear of the boot, a force of 5 N must be applied. The weight must then be rotated through the range 0 + 180" for a total of 10 cycles. See figure 1 The insertion loss must be continuously, recorded throughout the duration of the test. The test must then be repeated while the return loss is measured. During the duration of the tests, insertion loss must be less than 0, 6 dB and the return loss. The return loss must be as per Appendix a specification. There must be no failure of the boot bonding materials.

On completion of the test the insertion loss and return loss must be as per Appendix a specification.

TEMPERATURE CYCLING


The optical tails under test must be connected together using bulkheads and then be connected to the test equipment. The optical tails under test must then be subjected to ten complete cycles of four hour duration's each cycle commencing at 20 "C rising to 70 "C, falling to 15 "C and ending at 20 "C to permit a dwell time of 1 hour at both 70°C and a transition time between temperature extremes of one hour. For the duration of the test, the tails must be monitored for insertion loss. The insertion loss must be equal to or less than 0, 4 dB. The test must be repeated while the return loss is monitored. The return loss must be as per Appendix a specification. REPEATABILITY Two pairs of connectors must be tested for endurance and repeatability of performance. A pair of connectors must be mated by hand via a bulkhead and the insertion loss and return loss be measured and recorded. The pair must be removed from the bulkhead and mated 1000 times with the insertion loss and return loss being measured after every 10 parting / mating cycles. The connector must be cleaned with Isopropyl alcohol after every 10 cycles and the relevant measurements have been completed.

The insertion loss must not increase by more than 0, 2 dB from start value or exceed 0, 4 dB the return loss must be as per Appendix A specification.

END OF APPENDIX C


PART D: Trenching of Optic Fibre Cable 1. INTRODUCTION

This specification has been compiled for the purpose of providing guidelines, alternatives or solutions to such situations where built manholes may be required.

2. SCOPE

This specification covers the methodology that shall be applied when constructing an underground route for Telecommunication cables as well as built manholes and access termination points (buildings)

3. TECHNICAL REQUIREMENTS 3.1 Trenching and Laying of Cables

The Trenching/pipe and chamber system must be installed on the property of METRORAIL KZN between the fence line and the track formation, 3.0 meters from the center line of the nearest track. The exact location will be decided at the site inspection and/or as shown on the attached line or trench route plans.

3.1.1 Trench dimensions

a) All trenching shall be a depth of 900mm and 400mm wide

3.1.2 Bedding and Padding

a) The trench must be laid with padding of 150 mm of approved material before cable laying is

commenced. The soft material must past thru a 12 mm riddle, before the ducting (3 x 32 mm direct berried duct) is installed.

b) Padding can only be pleased in the trench once the Site Manager is satisfied that the 32 mm duct

is installed properly. The padding material will consist of the same material as the Bedding used before. A layer of 150 mm of Padding must be placed on the installed ducts, and tampered by hand. No mechanical device is allowed at this stage. The force of these types of machines can deform and damage the ducts.

3.1.3 Back-fill

a) Once the Padding is installed properly, the trench can be backfilled with the remaining material that

was excavated from the trench. No large rock must be used as backfill material; the Site Manager must ensure that any material that can potentially damage the ducts must not be allowed as backfill material.

3.1.4 Reinstatement

g) The compacted surface must be cleaned of any remaining material. The surface should be raked; and all additional material must be removed from site.

3.1.5 T-Off point from main route

a) Under no circumstance must this route be deviated above ground. The same trenching methods must be adhere to up to the first line (track), only then must the crossing under the rail comply with the stander under rail crossing specification. Only certified contractors with the necessary permission from the local Per-way office will be allowed to do the construction under the rail.

b) All routes must enter the building underground. If not possible due to construction restraints (possible damage to foundation est.) can the contractor apply to secure the final entry on the outside of the building.

c) Should this route be used as a redundant route, must the contractor ensure that the entry point to

the building of two routs be kept apart as far as possible.


4. ACCEPTANCE OF WORK

Only when the contractor is satisfied that the standards have been obtained shall he/she notify the Technical Officer, in writing, that the work is within the specified standards and tolerances and that he requires an inspection of the work. After receipt of his/her request, the engineer will arrange for an inspection of the works to be carried out.

5. CONTAMINATION OF BALLAST AND DRAINS

If the action of the contractor leads to the contamination of the ballast and existing drains, rehabilitation will be at the contractor own cost. If the contractor fails to comply then Metrorail KZN will take the initiative to return ballast and drains to the required specification and Metrorail KZN will recover all costs from the contractor.

6. DURATION

Metrorail KZN requires that the WORKS will take place within two to four week after award and be completed within FIVE MONTHS of which three months will be for installation and splicing, One month for snags and payments, which period shall include holidays falling within this period.

7. OCCUPATION

Occupations will be between trains from 09h00 until 15h30 and Total occupations during weekends. 8. WARRANTY (a) Tangent support and dead ends shall include a factory warranty that equipment is free from rust in

design, material, manufacturing and operation. (b) Factory warranty period shall be for 24 months from date of installation. 9. GUARANTEE (a) All items provided must be guaranteed for a period of two year starting on the date of completion of

project (handover – date), from rust. (b) If, within the guarantee period mentioned above, any corrosion should be found which, in the opinion of

Metrorail, are due to improper or faulty materials, poor workmanship, design and/or methods of manufacture, and/or from any other fault or neglect on the part of the Contractor or his/her sub-contractor/s, then not withstanding any superintendence, inspection, approval or certificate that may previously have been carried out or given, or any payment that may have been made to the contractor on account of the work, the Contractor shall immediately, at his own cost entirely, remove and replace any defective parts or otherwise make good and remedy all such defects to the satisfaction of Metrorail.

(c) In default of compliance by the Contractor with this obligation, Metrorail may remove and replace the corroded parts or otherwise make good and remedy all such defects, or may engage any other person to carry out the work involved, or any portion thereof and the contractor shall be liable to Metrorail for all cost and expenses incurred by it in doing so.

10. PENALTIES (a) In the event of the Contractor failing to complete the work on or before the completion date, the

Contractor shall pay to Client as penalties the amount of R 200 (Rand) for every day thereafter that the work remains uncompleted. In addition the Client shall have the right to complete the work and to recover from the Contractor all the expenditure incurred in so doing. The Client may in its absolute discretion, wholly or partly, relieve the Contractor of his liability in respect of penalties if in the opinion of the Telecoms Manager.

(b) Penalties will also be incurred on trains which are delayed by contractor in the event that the contractor exceeds the agreed occupation time. The penalty will be R 80 per minute train delayed. It must be noted that the delays to the peak Metrorail train service can affect many trains in a short time, and it is required that the contractor stick to the agreed occupation times.

11. WORK PROGRAM


(a) The contractor shall issue a work program which shall be agreed upon and signed by the project manager a week before commencement of this work.

(b) The contractor shall issue a method statement which shall be agreed upon and signed by the project manager a week before commencement of this work

(c) The contractor shall issue a risk assessment document which shall be examined and approved by Metrorail KZN risk department a week before commencement of this work.

(d) When the Contractor considers that for any reason to additional time to complete the WORK or portions of the WORKS, he shall inform the project manager, setting out in detail the reasons and stating the specific additional time required. Such additional time will only be authorized by the project manager in writing or penalties will be applicable as per the penalty clause.

(e) The contractor shall issue a safety file upon appointment and safety file to be built in within their prices. 12. PROTECTION

The contractor will provide protection for the train service only. This protection will be in the form of 2 flagmen and 1 track-master and supervisor with C-Green certificate. The Contractor will provide all other protection including protection for his own staff. Work will not be allowed to continue without the necessary protection.

13. MATERIAL TO BE SUPPLIED BY THE CONTACTOR

The contractor shall supply material as per the BOQ, labour, plant, consumable materials, tools, safety equipment and fuel necessary for the completion of the works unless otherwise stipulated elsewhere in this specification. The contractor shall provide all the Supervision and Labour necessary for the proper execution and completion of the WORKS.

END OF SPECIFICATION

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