OFC INSTALLATION AND ASSOCIATED WORKS FOR KRISHNAPATNAM HYDERABAD PIPELINE AND PIYALA JEWAR PIPELINE

To, REQUEST FOR QUOTATION

M/s. BPCL ESTIMATE Collective RFQ Number/ Purchase Group

MUMBAI . India - 400038. 1000440300 / L40-KHPL

Ph:,Fax:. Contact person/Telephone

Vendor Code:300648 NAMIT CHITTORIA/022-24176486

Email:[email protected]

RFQ No/Date: 6001867499 / 03.08.2025 Quotation Due Date/Time:04.08.2025/15:00:00

Material/Services required at:

M/s. KHPL Krishnapatnam PPL Plant

BHARAT PETROLEUM CORP. LTD.

Krishnapatnam Coastal Installation

Adani Krishnapatnam Port Ltd, Muthukur

Muthukur SRI POTTI SRIRAMULU-

Subject: OFC INSTALLATION AND ASSOCIATED WORKS FOR KRISHNAPATNAM HYDERABAD

Please quote your lowest prices for the supply of materials/services as per

details given below. The quotation shall show separately and clearly (without

any corrections) the basic price, discount (%), packing & forwarding (%), GST,

freight(%), other charges, etc against each item separately, as applicable.

Foreign vendors shall always quote their FOB prices against each item.

Rates/charges quoted in the quotation shall be final and no additional

charges/corrections will be accepted after the receipt of quotation unless the

same is necessitated by BPCL in writing.

Item Material Qty Unit Unit Basic Rate

Description Delivery date (in Figures)

00010 OFC BLOWING AND LAYING ACTIVITIES 04.09.2025

The item 00010 covers the following services:

Mobilisation and Demobilisation charges ()

Mobilisation and Demobilisation charges

Service Item 10: Unit basic rate in words ________________________________

OFC Jointing incl.Sup.of Jointin closure ()

OFC Jointing including Supply of Jointing closures with 4 entry ports,

jointing chamber materials and any other items required for jointing of

Fibres OFC (Fusion splicing only) with sleeve protectors, Factory acceptance

testing, storage, and transportation to site, loading, unloading, jointing of

Page 1 of 6 Vendor Sign & Stamp For Bharat Petroleum Corporation Ltd.

RFQ Number :6001867499 Date : 03.08.2025

To:M/s. BPCL ESTIMATE MUMBAI - 400038 India (300648)

Item Material Qty Unit Unit Basic Rate

Description Delivery date (in Figures)

OFC all complete as per specifications provided in the bid document and

direction of CLIENT/CONSULTANT

Service Item 20: Unit basic rate in words ________________________________

Supply and installation of Jointing Pit ()

Supply and installation of Jointing Pit, including sand, OFC joint

identification marker including GPS coordinates, back filling as required etc.

Service Item 30: Unit basic rate in words ________________________________

Permanently lubHDPE conduit Duct_40mm di (Meter)

Supply of Permanently lubricated HDPE conduit for following sizes in required

length of pressure rating 6 kgf/cm2 to be laid in pipeline trench or in

separate trench directly or inside CS conduit including FAT, storage,

transportation to site, loading, unloading etc. all complete

Duct with nominal diameter 40 mm

Service Item 40: Unit basic rate in words ________________________________

LAY.TEST&COMM. HDPE duct/pipe_40MM DI (Meter)

Laying, Testing and commissioning of the following sizes of HDPE duct/pipe of

pressure rating 6 kgf/cm2, including supply of clamps, small iron structures,

spacers, and duct accessories like push-fit couplers, bends and elbows, end

plugs, simple plugs, sonic heads, etc, and including small civil works,

cleaning with compressed air, calibrating, testing for air tightness, sealing

of ends, including all labour and materials, as per directions of the

Engineer-in-Charge.

Duct with nominal diameter 40 mm

Page 2 of 6 Vendor Sign & Stamp For Bharat Petroleum Corporation Ltd.

RFQ Number :6001867499 Date : 03.08.2025

To:M/s. BPCL ESTIMATE MUMBAI - 400038 India (300648)

Item Material Qty Unit Unit Basic Rate

Description Delivery date (in Figures)

Service Item 50: Unit basic rate in words ________________________________

Site acceptance Testing of the laid OFC (Lumpsum)

Site acceptance Testing of the laid OFC, all complete as per specification and

direction of CLIENT/CONSULTANT.

Service Item 60: Unit basic rate in words ________________________________

SUP.TRSN.INST.48PORTS FTC ()

Supply, handling, transportation to site, installation, testing and

commissioning of 48 Ports Wall Mount Fibre Termination Closure (FTC) with SC

connectors suitable for 2 numbers of 24 Fibres OFC Cable (18 x G.652 & 6 x

G.655 ) including pigtails, Splice protection sleeve, splice tray and splicing

the cables with pigtails, Cable glands, termination of OFC, including supply &

installation of loop box (separate for each OFC), including all labour and

materials all complete suitable for 2 nos. of 24 Fibres OFC (In/Out) with

Service Item 70: Unit basic rate in words ________________________________

I&L OFC /L trench HDPE/CS con_BLOWING (Meter)

Installation & laying of OFC in pipeline trench through HDPE/CS conduit by

blowing method, as applicable to original conditions etc. including supply and

installation of Blowing Pits, including carrying out Duct Integrity Test,

supply and use of all materials required like sand, couplers, end plugs etc.

Service Item 80: Unit basic rate in words ________________________________

Excavation and backfilling (Lumpsum)

Page 3 of 6 Vendor Sign & Stamp For Bharat Petroleum Corporation Ltd.

RFQ Number :6001867499 Date : 03.08.2025

To:M/s. BPCL ESTIMATE MUMBAI - 400038 India (300648)

Item Material Qty Unit Unit Basic Rate

Description Delivery date (in Figures)

Excavation and backfilling for rectification of OFC Duct on integrity testing

for rectification of OFC Duct for already laid OFC duct by BPCL Pipeline

contractor including coupler replacement if required

Service Item 90: Unit basic rate in words ________________________________

Idling charges (Days)

Service Item 100: Unit basic rate in words ________________________________

State GST % : ________ % Central GST % : ________ % Integrated GST % : ________ %

Union Ter. GST % : ________ % GST Comp. Cess % : ________ %

HSN Code / SAC Code : ______________

Billing State : ______________

Grand Total (inclusive of all taxes, duties/charges etc)

Page 4 of 6 Vendor Sign & Stamp For Bharat Petroleum Corporation Ltd.

To:M/s. BPCL ESTIMATE MUMBAI - 400038 India (300648)

TERMS & CONDITIONS

Important Notice

Sr.No Description

001 Quotation received after due date will not be entertained

002 Your quotation must specify exact amount or percentage discount,

GST, Charges, Transport, Packing & forwarding,

etc. as applicable.

003 In case you are unable to quote, kindly send the quotation with a

regret for our records. Non-receipt of a regret will adversely

affect your vendor rating.

004 No quotation will be accepted without your rubber stamp and

005 Your quotation must be strictly in enclosed envelope

indicating Collective RFQ No., RFQ No. and due date.

006 For all future correspondences please mention the vendor code

Collective RFQ Number & RFQ Number.

LIST OF ENCLOSURES

Page 5 of 6 Vendor Sign & Stamp For Bharat Petroleum Corporation Ltd.

To:M/s. BPCL ESTIMATE MUMBAI - 400038 India (300648)

-------Tear off Portion to be pasted on the envelope containing offer------------

Collective RFQ No. :

Our Reference: Due Date : 04.08.2025

RFQ No. : 6001867499 Due Time : 15:00:00

Subject: OFC INSTALLATION AND ASSOCIATED WORKS FOR KRISHNAPATNAM HYDERABAD PIPELINE

Purchase Group : L40-KHPL

Page 6 of 6 Vendor Sign & Stamp For Bharat Petroleum Corporation Ltd.

OFC INSTALLATION AND ASSOCIATED WORKS

1. INTRODUCTION

1.1 To meet the growing demand of Petroleum products in state of Andhra Pradesh and Telangana, M/s Bharat

Petroleum Corporation Ltd. (BPCL), a Maharatna Company envisages to lay a cross country multi

product pipeline from BPCL, Krishnapatnam Dispatch Terminal situated at Krishnapatnam Coastal

Installation to its New upcoming Terminal at Hyderabad with intermediate Tap off point at Ongole Depot

en-route. Also, BPCL is laying Pipeline from Piyala to Jewar Airport.

1.2 This document covers details of Work Tendered, Scope of Work, and Scope of Supply pertaining to Optical

Fibre Cable (OFC) & its associated items, installation Transportation, Testing, Pre-Commissioning,

Commissioning Assistance, stations and associated facilities of the project at all SV, Intermediate Pigging

Stations, DT & RT of the following pipeline sections/parts of these sections. Works shall be carried out

at any of these sections on partial or continuous manner:

Start Ch. End Ch.

A 0.000 138.200 138.200 DT to IP-1 Ongole

C 233.500 308.944 75.444 IP-2 to to Krishna river (AP Side)

D 0 36.000 36000 Piyala Terminal to Jewar Terminal

1.4 This document shall be read in conjunction with Schedule of Rates, List of Attachments,

Specifications, Standards, Drawings and other Documents/ Drawings forming part of Tender Document.

2. WORK TENDERED

2.1 The description and requirements contained in this specification are concise by necessity and cannot

include all details. However, it is the responsibility of the contractor to execute the job on a turnkey

basis in accordance with the specifications and internationally recognized good engineering practices

for smooth and successful operation of various stations & facilities of Pipeline.

2.2 Any activity specifically not listed in this document, does not absolve the contractor of their

responsibility to include such activities in their scope of work and supply, which otherwise is

necessary, to complete instrumentation work for the project. All such activities shall be carried out by

the contractor without any implication.

2.3 Duct is already laid/ is being laid by the pipeline laying vendor along with the pipeline in the same

trench excavated for the pipeline. However for some sections it may be required for the supply and/or

laying of the HDPE Duct along the pipeline.

3. SCOPE OF WORK

3.1.1 Contractor shall be responsible for complete activities involving all including OFC laying for the

complete OFC laying works, as part of his scope.

3.1.2 Scope of work shall be read in conjunction with the Schedule of Rates for OFC and its associated

items, drawings, specifications and other documents forming part of the Contract document.

Wherever there is a contradiction between the above, Schedule of Rates and this document shall take

3.1.3 Scope includes blowing of cable in the already laid permanent lubricated HDPE Duct of 40mm

nominal Diameter in the pipeline ROU. Scope also includes testing of the Duct for integrity,

rectification of any joints in the Duct laid, excavation backfilling for corrections/ supply and

installation of duct joints/

3.1.4 Every month, the contractor shall submit an account for all the materials issued to him by the Owner

(as applicable) in the standard Performa prescribed for this purpose by the Engineer-in-Charge.

3.1.5 On completion of the work, the contractor shall submit `Material Appropriation' statements for all

materials issued by the Owner in the Performa prescribed by the Engineer-in-Charge.

3.1.6 The fieldwork shall be carried out under strict safety regulations and work permits as laid down by

the Client. The contractor shall take extreme care regarding safety and all safety gear like helmets;

hand gloves, safety belts, spectacles etc shall have to be provided by the contractor.

3.2 Scope of Work (Telecommunication- OFC & its associated items Installation)

3.2.1 Collection of data, Liaison with all statutory /public bodies for obtaining permission for OFC

installation in pipeline trench or separately, if applicable. Owner will issue the necessary request

letters seeking permission and pay/reimburse any fees payable to statutory /public bodies for

according permission of OFC laying, as required.

3.2.2 Supply, storage, transportation to site, loading, unloading, etc. to and from designated stores and use

of any equipment, materials including consumables required for laying, jointing, testing, termination

of Optical Fiber Cable.

3.2.3 Excavation in pipeline trench or separate trench, as depicted with diagrams, as per the requirement.

Installation & laying of OFC (Free Issued Material) through permanently lubricated HDPE conduit

in Pipeline trench or Separate trench directly or through CS conduit as required, excavation as

required, padding, backfilling including supply and use of all materials required like couplers, end

plugs etc. all complete as per specification and as per the site requirement.

3.2.4 Laying (through Blowing technique) of two (2) nos. of Optical Fibre cable through two (2) separate

permanently lubricated HDPE conduits (40 mm OD, 6kg/cm2) (i.e. One OFC in each HDPE conduit)

in the same trench of the pipeline on either sides of the Pipeline (Arrangement of OFC w.r.t to

pipeline), installation of jointing closures at jointing locations as required, jointing pits, blowing pits,

metallic marker, electronic markers, back-filling etc. shall be done. Where service crossing exists, in

addition to the general guidelines stated in the OFC laying specification, the Contractor shall follow

all the particular requirements asked for by the Engineer-In-Charge including supply of any materials

3.2.5 It shall be the responsibility of the contractor to ensure that best engineering practices are followed

for laying HDPE conduits (2 nos.) inside CS conduit and OFC (2 nos.) is installed and commissioned

in the HDPE conduits for the entire crossing for respective section. Refer Schematic arrangement of

Pipeline facilities and table below for details of crossings (as a minimum) where pipeline installation

shall be installed by using HDD method under present scope. Supply & Installation of CS Conduit

are covered in the Pipeline laying Section of the tender.

3.2.6 Jointing, testing, Termination (in the FTC) & handing over of the laid OFC.

3.2.7 OFC shall be issued to the vendor as free issue material by BPCL. While handing over the OFC,

vendor shall carry out OTDR for the drum and accordingly attenuation for the OFC drum shall be

calculated and considered for handing over back to BPCL/ Telecom Vendor.

3.2.8 After jointing of OFCs, the optical fibres shall be tested end to end as per the approved acceptance

criteria (to be provided by Contractor and approved by BPCL) for establishing continuity. While

restoring the OFC faults, utmost care should be taken so that the pipeline is not damaged; else the cost

of restoring the pipeline damage and any other damage occurring due to this shall be fully borne by

the bidder). Further any damage to the existing OFC (if any) in the vicinity due to the constructional

activities shall be the attributable to the Contractor.

3.2.9 Laying of earthing cables/ strips for OFC to earth grid and Copper strips for grounding of FTC & loop

box in the control room & other consumer location with earth pit.

3.2.10 Arrange necessary power-supply, all equipment / instruments, manpower, test-gear, accessories, etc.,

necessary for installation/ jointing/ testing/ termination of OFC.

3.2.11 Contractor to supply and install conduiting/ casing of OFC cable inside the building till FTC.

3.2.12 At all stations, Contactor shall place and properly seal the OFC cable in the loop box (specification

of loop box is attached elsewhere in tender) which shall be located in Control/Telecom room.

3.2.13 Mobilisation and demobilisation charges are payable on demobilisation of the team from the site on

non-availability of Workfront. Further idling charges are payable on non-availability of work-front

and site in-charge has kept the team idle without works. idling charges are not payable when team is

idle due to machinery breakdowns, excavation being done by the cable blowing vendor etc. Decision

of the Engineer Incharge shall be final.

3.2.14 OFC jointing charges shall be admissible only for the joints between the pit to pit. OFC jointing

charges shall not be admissible when the OFC is damaged due to workmanship or other faults by the

blowing vendor.

3.2.15 For rectification of OFC duct already laid by BPCL Pipeline contractor, per location charges are

admissible wherein blowing vendor shall replace Duct coupling/ sealing of jointing pit/ lay extra pipe

3.2.16 Ideally 4 km OFC shall be blown continuously. Only in case of EIC approved conditions, OFC may

be blown in sections less than 4 kms.

3.2.17 While handing over of OFC, if there are faults in the OFC beyond the admissible limit for the cable

type, the same shall be rectified by the blowing vendor at no extra cost. Admissible loss for per splice

joint is 0.1dB /splice, 0.5dB per Pigtail connector. Attenuation considered is 0.25dB/ km.

3.2.18 Drawings enclosed with the contract are only for reference and indicative of general nature for scope

of work. Actual installation shall be carried out based on actual site conditions and contractors

drawings/ documents issued to site and as per instructions of EIC.

4 SCOPE OF SUPPLY

4.1 Scope of Supply (Optical Fibre Cable & its associated items installation)

4.1.1 The scope of contractor for supply of HDPE conduits and related items for OFC laying & termination

shall include but not limited to the following:

a) Supply of Permanently lubricated HDPE Conduit as per specification.

b) Supply of Jointing Closures, OFC distance markers, Electronic Marker System with Markers and

Locator, Fiber Termination Closures & Loop Box as per specification.

c) Supply of all materials including consumables required for installation/laying, jointing, testing of

Optical Fiber Cable including supply of Jointing Pits, Blowing pits, Push fit couplers, End plugs,

Cable Sealing Plug, End Cap, metallic markers, joint identification markers, sand, soft soil,

Warning mats (for separate trench inside terminals), OFC Route Markers (for inside the

terminals), cable tags, ties, pulling wire for OFC/Duct Pulling (rugged and durable) etc. all

d) Supply of complete technical literature, alignment sheets, as-built documents and other

4.1.2 Optical Fibre Cable (OFC) comprising of 24 Fibres/Cores shall be free issued to Contractor by

Client. Storage at Site, transportation to Site, loading, unloading, etc. to and from designated stores

of Free Issued OFC scope.

Item: OPTICAL FIBRE CABLE & ASSOC.ITEM

1. AKSH OPTIFIBRE LIMITED

2. BIRLA CABLE LIMITED

4. KEC INETRNATIONAL - MYSORE

5. KABEL RHEYDT

6. PIRELLI CAVI SPA

7. WEST COAST PAPER MILLS LIMITED

8. APAR INDUSTRIES LTD.

9. U M CABLES LTD.

10. VINDHYA TELELINKS LIMITED

1. Contractor may procure material from any of approved vendors listed above. However current

validity and range of approval as per enlistment letter, workload, stability and solvency need to be

verified by the Contractor before placement of order.

2. For equipments/components other than the above, Contractor shall submit past track record for the

proposed sub-vendors and obtain written approval from Owner / EIL before placing order.

3. The sub-vendors list shall be approved by owner/EIL prior to placement of order by Contractor.

Contractor shall list down the proposed suppliers/vendors for such items and submit the same for

owner review/approval along with necessary documents/PTR. Non-acceptance of a particular

proposed vendor due to any reasons whatsoever shall not be a cause of schedule and cost

implication. If equipments are sourced from outside India, Contractor shall obtain prior approval

for make of equipments before placement of order.

1.0 LIST OF ATTACHMENTS

1.0 LIST OF ATTACHMENTS

CONTRACTOR shall carry out all works strictly in accordance with the

drawings/documents/specifications indicated in subsequent paragraphs.

Arrangement of OFC with respect to Pipeline

OFC installation (Inside Terminals)

3. 1 OFC installation (Cased Crossing)

4. 1 OFC Joint Identification Marker

5. 1 OFC Jointing Pit

INSTRUMENTATION (TELECOM)

TECHNICAL CONFIRMATION LIST

INSTRUMENTATION (TELECOM)

TECHNICAL CONFIRMATION LIST

No. CONFIRMATION/ ANSWER

in total compliance to Bid Package requirement.

Contractor shall confirm compliance to Scope of Work for

2 Optical Fibre Cable Installation & Associated Works

enclosed with the Bid package.

Contractor shall confirm compliance to Job Specification,

3 Specification and drawings enclosed with the Bid package.

Contractor shall confirm that there is no deviation to Scope

of Work, Job Specifications mentioned at S. No. 1 to

above. Contractor undertakes to comply with all provisions

of bid package. Any deviations / deletions / corrections

4 made elsewhere in the body of the bid document will not

be taken cognizance of and all such deviations shall be

deemed to have been withdrawn by the contractor.

Contractor shall confirm compliance.

Contractor shall confirm that all items/ materials shall be

procured from Owner approved vendor list.

Contractor shall confirm that all items shall be ordered on

6 the vendors only after review of Purchase Requisition by

Contractor shall confirm that Installation equipments,

7 Special tools & Tackles and other items as required for have

been included by the contractor in his proposal.

1. The Contractor shall furnish duly filled-in Technical Compliance List in the space provided. In case

space provided is not adequate, the reply may be furnished separately under suitably numbered

annexure / attachments duly referred against the comment / query.

2. The Compliance Statements are required to be categorically confirmed / replied by the contractor and

the completely filled in Compliance List shall be submitted together with the Bid.

TABLE OF CONTENTS

1.1 This document provides the following guidelines:

1) Guidelines to be followed for installation of OFC through permanently lubricated HDPE conduit

along with the pipeline in the pipeline trench or in separate trench, as per details provided in this

2) Permanently lubricated HDPE conduits may be further required to be sub-ducted in CS conduits

at crossings at some locations as per the specification.

3) Guidelines for Jointing, Testing & Termination of the OFC are also included.

1.2 The scope of supply, works, and technical requirements are explicitly stated in the Tender document.

Contractor is required to study these requirements in detail and complete all works meeting these

2.1 The Contractor or his sub-contractor shall have experience of installation of Optical fibre cable in a

project of similar nature for minimum 50 km of length in one stretch during the last three years. The

installation of OFC shall include laying, jointing, testing & commissioning.

2.2 Contractor supplied items like Optical Fibre Cable, Jointing Closure, Electronic marker & locator,

Permanently lubricated HDPE conduit , FTC, etc shall be field proven and shall have been working

satisfactorily for a minimum 4000 hours.

2.3 The Contractor shall be completely responsible for the successful completion of the job. However, to

ensure a good quality of workmanship, as also of supplied materials.

2.4 If during the course of execution of the work any discrepancy or inconsistency, error or omission in

any of the provisions of the contract is discovered, the same shall be referred to the ENGINEER-

IN-CHARGE who shall give his decision in the matter and issue instruction directing the manner

in which the work is to be carried out. The decision of the ENGINEER-IN-CHARGE shall be final

and conclusive and the Contractor shall carry out the work in accordance therewith.

2.5 The data provided in the tender document shall be used by the Contractor for reference purposes only.

It shall be the Contractor’s responsibility to verify the data and satisfy himself in regard to accuracy

& utility of this data.

2.6 All splicing and jointing requirements, which are additional to the ones approved by ENGINEER-IN-

CHARGE as per alignment sheets submitted by Contractor before start of OFC installation and also

arising out of any negligence on behalf of the Contractor, shall be the responsibility of the

Contractor. Contractor shall take written permission from ENGINEER-IN-CHARGE before cutting

the cable and going for additional joints. Further, in all such cases, the Contractor shall take

necessary rectification action at his own cost including supply and use of necessary materials. (e.g.

jointing closures, OFC, blowing/jointing pits, jointing/testing material etc. all complete). However,

in worst case, average of 1 joint / km (1 joint=1 jointing closure) shall be allowed between 2 telecom

stations. Otherwise OFC shall be replaced at locations with multiple joints to maintain minimum

average, as defined.

2.7 Contractor may take up any unplanned detour required as per site conditions, only after approval from

ENGINEER-IN-CHARGE.

2.8 The Contractor shall bring all that is required for trenching, OFC installation, jointing, testing, tools

& tackles, etc, as required to complete the project in all respects.

3 LAYING PROCEDURES

3.1 GENERAL REQUIREMENTS

The Contractor shall carry out all works related to the OFC laying, installation, jointing and testing.

All other material and works shall be under contractors scope for successful completion of the OFC

Contractors shall obtain all statutory approvals, appraisal and taking cognizance of of the site

conditions, Government rules and regulations/ bye-laws, applicable Standards and Codes, authorities

having jurisdiction over the work site(s), environmental and pollution concerns including conditions/

stipulations laid down by the concerned authorities etc and implement accordingly after incorporating

All procedures and precautions as required for pipeline laying shall be followed for OFC laying. OFCs

shall be laid in parallel running permanently lubricated HDPE conduit (40 mm outer diameter) on

side of the pipeline along the entire length of the pipeline route using Blowing technique and crossing

of the pipeline shall be avoided (except at the repeater stations and as per exigencies arising due to

site conditions). The trench dimensions shall be so taken as to ensure proper laying of the cable

without slackness.

Contractor shall plan the cable-laying operation such that to the extent possible, complete drum-length

of cable can be laid without cutting in-between. The Contractor shall prepare the cable drum schedule

for this purpose in line with the cable alignment sheets.

3.1.1 Laying Procedure for Permanently Lubricated HDPE conduit

Optical Fibre Cable will be blown into the laid permanently lubricated HDPE conduit with the help

of a compressor and a blowing machine. The permanently lubricated HDPE conduits shall be

continuous in length (drum length to be decided by contractor (approx. ~1km). The permanently

lubricated HDPE conduit will be laid in the same trench as pipeline after lowering of pipeline i.e.

permanently lubricated HDPE laying will follow lowering of pipeline. The permanently lubricated

HDPE conduit shall be laid in pipeline trench bed as shown in Drawing for OFC duct arrangement.

Cable w.r.t. pipeline The permanently lubricated HDPE conduit shall be placed over 50 mm soft

padding of sand or soft soil (riddled earth obtained by passing through a sieve having meshes not

exceeding 15 mm2, or of a natural soft ground not requiring riddling) as shown in the drawing.

Trench bottom for HDPE duct shall be clean, smooth and free from stones. Proper care shall be taken

so that there are no kinks, loops, twist in the duct while laying.

Permanently lubricated HDPE conduits will be sealed with the help of cable sealing plugs after

blowing of optical fibre cable.

This arrangement is typical and shall be applicable for the entire pipeline route, unless specified

otherwise. The burial depth shall be as shown in the drawing referred above. (However, due to any

unavoidable circumstances, if the cable is required to be laid at depth less than this depth, then

Contractor shall obtain the prior permission from ENGINEER-IN-CHARGE giving due justification

& proposing the additional protection measures & work is to be executed in accordance with the

approval by ENGINEER-INCHARGE.)

Contractor has to ensure the laying of HDPE conduit without any snaking or waving and the HDPE

conduit should rest on the trench bed i.e. the pipe should not hang in the trench bed. The trench will

be backfilled after ensuring the correct positioning of HDPE conduit as mentioned above. While

backfilling, the contractor has to ensure that the HDPE conduit is not hanging in the trench bed.

3.1.1.1 Following procedure should be followed for laying permanently lubricated HDPE conduits:

(A) Moving Trailer Method:

This method should be used when the route does not contain any road/railway bores or utility

crossings. Following steps should be followed:

1. Fix the Jack Stand on the trailer properly.

2. Mount the duct coil reel/duct drum on the Jack stand.

3. Bring the trailer at the start point from where the duct is to be laid.

4. Move the trailer slowly along the trench route and uncoil the duct from the bottom of the

reel/drum and place into the trench. Avoid any overspinning of the duct while uncoiling

it from the drum.

(B) Manual Laying:

This method is used when there are obstructions along the route. Following steps should be

1. Place the Jack stand along the side of the trench. Place the drum on the jack with correct

positioning of the drum i.e. the duct reel should uncoil from the bottom of the drum. Duct

reel should not uncoil from the top of the drum.

2. Rotate the drum slowly so that the duct comes off the drum slowly and the duct reel

should not over spin while pulling HDPE conduit for installation.

3. Unroll the duct to the required length spacing the workers after every 15 to 20 mtrs.

4. If any obstruction like utility crossings or road/railway crossings comes in then ensure

the HDPE conduit is drawn under the obstruction or through the crossing without

requiring joint in-between.

5. The contractor can lay the duct into the trench either directly from the drum or temporally

lay the duct along the trench and then place it later in the trench.

(C) Tensioning of the HDPE duct after laying:

1. Determine the direction of installation and set the reel. Duct should be unrolled from the

bottom of the coil.

2. Place the duct inside the trench.

3. Let two workers stand on the duct at start point and two other worker stretches the duct,

thereby giving tension, upto of 30-40 meters.

4. After covering the 30-40 meter backfill the trench at that point to hold the duct in position

and to avoid loss of tension.

5. Repeat the above procedure till the entire duct length of 1 KM laid with proper tensioning.

6. Backfill the entire trenches.

To lay the next HDPE duct drum length, couple the laid HDPE ducts to the new drum to be

laid with the help of a coupler with same procedure explains above.

3.1.1.2 Jointing Of HDPE Conduits:

In case of crossings there may be the possibility that laid HDPE section length may have to be

joined to other laid HDPE section length. The jointing of two ends of HDPE conduit should

strictly be done with the help of Coupler, which will be made of similar material. Installation of

HDPE coupler to join laid HDPE conduits should strictly be done with the help of C-spanners for

proper tightening of Coupler. Joints may also likely to come up due to road/ river/ nallah/ railways

crossing. All efforts shall be made to minimize joints. The coupling should be water and airtight

and should be able to withstand minimum pressure of 10 bar. Following procedure should be

followed for jointing HDPE conduits:

1. Cut the two ducts that are to be jointed at the same place where they overlap. Cutting should

be done in such a way that the duct ends match with the coupler perfectly because is very

important that coupling joints be airtight. Proper pipe shears or cutter must be used for smooth

cutting Hacksaw should not be used to cut the duct.

2. Debar both the inside and the outside edges of the duct with a debarring tool.

3. Apply a small amount of proper lubricant for better installation of plastic coupler.

4. Tighten the plastic coupler with C-Spanner.

3.1.1.3 Sealing Of HDPE Conduit:

Put end plugs to seal the end of HDPE ducts after laying of same to prevent ingress of water, dust

etc. prior to back filling. The end plug should be made of similar material as that HDPE conduit

does not change its position due to heavy impact of soils or due to any other cause.

3.1.1.4 Permanently lubricated HDPE conduit testing after laying

Before blowing of Optical Fibre cable in the laid permanently lubricated HDPE conduit the HDPE

conduits will be tested for proper laying, crush, deformity and pressure testing. The contractor

shall be fully responsible for any obstruction and deformity in the laid HDPE conduit and shall

have to remove the obstruction/deformity of any kind before blowing Optical Fibre cable into the

Following tests are to be carried out on the laid HDPE conduit:

1) Duct Cleaning:

Following steps are to be followed for cleaning the laid HDPE conduit:

Compressed air should be blown through the duct in order to remove any dirt and water that

has accumulated inside the duct with the help of air compressor. A short blast of air of

about 1 bar shall be blown through the duct for about 1 minute.

Duct sponges will be blown through the duct to further remove any dirt and water from the

duct segments. Sponges should be blown into the duct until clean and dry sponge comes

out of the duct.

2) Duct Calibration and Integrity Test:

This test is to be done to check the roundness and the integrity of the duct. During

installation or backfill process there is possibility of flattening, twisting or kinking of the

duct. This testing process shall be conducted by blowing a plug or probe through the duct

segment with compressed air.

Calibration shall be done by a simple sender like small probe, which shall be blown through

the duct by compressed air. This probe shall be detectable using a HF Detector.

The calibration process shall be considered completed once the probe exits the duct at the

other end after an uninterrupted pass.

When obstructions in the duct are found, these obstructions have to be removed by

removing the damaged or deformed portion of the duct and placing a new section of duct.

3) Air Pressure test

A static pressure test is to be carried out in order to verify air tightness for the purpose of

cable blowing as well as to prevent ingress of water or dirt during the lifetime of the duct.

To verify the air tightness, pressure inside the duct should be brought up to 10 bar for two

minutes. A pressure drop of 0 to 0.5 bar per minute of the test is acceptable. If a higher-

pressure drop is detected, no further test should be conducted until the leak has been

located and repaired.

After pressure testing duct ends should be sealed with the help of duct plugs to prevent

entering of any dirt and water inside it.

After testing the HDPE conduit for any obstruction, both the ends of HDPE conduit shall be

plugged again using end plugs.

3.1.1.5 BACKFILLING

A 300 mm soft soil (riddled earth obtained by passing through a sieve having meshes not

exceeding 15 mm2, or of natural soft ground not requiring riddling) padding shall be done on the

top of the HDPE duct/OFC then a warning mat shall be placed. No requirement of warning mat

if HDPE conduit is being laid in same trench of pipeline.

3.1.2 Optical Fibre Cable (OFC) Laying Procedure

3.1.2.1 Blowing / pulling of Optical Fibre Cable:

Optical Fibre Cable will be blown into the laid HDPE conduit with the help of a compressor (with

minimum pressure of 8 bar and maximum pressure of 12 bar) with flow rate of minimum

m3/minute) and a blowing machine. The blowing method involves feeding of Optical Fibre Cable

into the duct with the help of consistent highpressure airflow, equally distributed along the entire

cable throughout the duct. Safe blowing of OFC into the duct without any damage to the cable

either internally shall be ensured.

Optical Fibre Cable drum of 4 km nominal shall be used. Steps for safe blowing of OFC may

be followed as below:

1. Position the compressor and blowing machine at blowing pit C of 2 Km stretch after A &

before B as shown below:

2. Uncoil ~ 2 Km of cable in a figure of eight configuration and blow towards blowing pit A.

Cable received at pit A may be further kept in a figure of eight configuration and blow

beyond blowing pit A and Coil 20 m of OFC in the blowing pit A. Now seal the duct end at

location A with the help of cable sealing plug.

3. Now uncoil the remaining Optical Fibre Cable from the drum at blowing pit C in form of

Figure of 8 to have an access to the other end of the cable.

4. Now blow towards blowing pit B. Cable received at pit B may be further kept in a figure

of eight configuration and blow beyond blowing pit B and Coil 20 m of OFC in the blowing

5. Coil 20 m of OFC in the blowing pit at location C and seal the duct end with the help of

duct sealing compound.

6. After blowing seal the duct end at each location with the help of cable sealing plug.

NOTE: Since the cable will be available in length of 4 KM +/- 5%, the cable length will

accordingly vary. So, plan the location of blowing pits in such a way to ensure that excess OFC

is not coiled in the blowing pit and also Optical Fibre cable does not fall short of the location of

3.1.2.2 JOINTING

In all the jointing locations (normal joints at the end of each drum as well as other joints) at least

20 m of cable from each end of the cable shall be left surplus in a coiled.

During jointing, electrical continuity of each of the metallic layer in the optical fibre cable shall

After completion of each joint at site, it shall be tested for water proof-ness by immersing it is

water along-with OFC for 5 minutes.

The OFC coil shall rest on the floor of the pit after turns being secured with cable ties. The lid of

the jointing pit should be ~1000 mm below the ground level after installation. The HDPE conduit

shall enter the pit at the bottom level of the pit. Proper arrangement should be done for protection

of the cable at the entry points (Sealing of the HDPE

conduit entry points at the jointing / blowing pits e.g. sealing of the cable entry points after cable

Water-Proof Sealing of HDPE conduit after blowing of OFC:

HDPE conduit will be sealed with the help of water-proof cable sealing plugs after blowing of

Optical Fibre into the duct at jointing pit locations. Cable duct Sealing Compound should be non-

toxic, vapor free and should not crack and fail due to vibrations in the duct and temperature

changes. The blowing/ jointing pit will be completely filled with sand up to 30 cm from bottom

level of the pit to prevent entry of rodents after blowing and jointing of OFC covering joint

enclosure and HDPE conduits completely.

3.1.3 CROSSINGS (Road, utility services, water crossings)

a) Crossings by boring

For pipeline crossings executed by boring / jacking method (for both cased and uncased

pipeline crossings) the OFC laid in permanently lubricated HDPE conduit shall be sub-ducted

in a separate casing conduits as per drawing no: B414-000-1651-4703 (Casing conduit

specification, distance from pipeline and installation of casing conduit shall be as per pipeline

laying section of this project).

Easy-to-install OFC sealing plug shall be used to seal the ends of the conduit to prevent the

ingress of water, dirt and rodents, which may damage the OFC. The two ends of each conduit

shall be sealed immediately after installation and re-sealed when the OFC has been installed

inside the conduit.

Two nos. permanently lubricated HDPE conduits shall be sub-ducted in a casing conduit at

each cased crossings where OFC shall be blown in each of the HDPE conduit.

At bends and leading-in-points, a flexible PVC pipe may be used for protection and

maintenance of the required bending radius of minimum 20 time outer diameter of the cable.

b) Open Cut crossings:

For these crossing bidder shall lay the cable through the HDPE conduit. Length of HDPE pipe

shall be estimated with the help of survey documents & alignment sheets. For water crossings,

HDPE conduit shall be used till ~5 m of the normal underground trench depth on either side.

The bank protection measure being provided for line pipe shall also be extended to take care

of Optical Fibre Cable. For road crossings, the HDPE conduits shall be extended for minimum

3 meters on either side of the road.

If casing is provided in open cut crossings then the OFC laying methodology shall be similar

to as explain above.

For all water crossings, the OFC laid in permanently lubricated HDPE conduit shall be further

sub ducted in CS conduits as per drawing no: B414-000-16-51-4703 (specification of Casing

conduit, installation of casing conduit with pipeline, etc shall be as per specification in pipeline

laying section of this project).

c) Crossings by Horizontal Directional Drilling (HDD)

For crossings to be done through HDD, the OFC laid in permanently lubricated HDPE conduit

shall be sub-ducted in a casing conduit (specification of Casing conduit, installation of casing

conduit with pipeline, etc shall be as per specification in pipeline laying section of this project).

OFC shall be laid in both the HDPE ducts for the HDD crossing. At least 20 Meter spare from

each OFC shall be stored properly in a Blowing pit/ Jointing pit (to be provided at the both end

of the HDD crossing section) for present telecom connectivity or any future use. HDD shall

be done/ already done by Pipeline vendor shall be utilized. HDD is not in blowing vendor

d) Utility services

In case the pipeline or any other utility service needs to be crossed, the OFC laid in permanently

lubricated HDPE conduit shall be at least 0.5 m below the service line.

e) Marshy areas

In marshy or swampy areas, the OFC laid in permanently lubricated HDPE conduits shall be

weighed down with bags filled with sand/cement at every 2 m distance.

3.1.4 OTHER SPECIFIC REQUIREMENTS

a) Terminal stations

Inside the boundary walls of the terminals, the OFC laid in permanently lubricated HDPE conduit

from each direction shall preferably follow along the walls of the station upto and inside the room

housing the telecom equipment. The same shall be as per

In case OFC is to be laid in a separate trench along the pipeline route at other locations, due to

site conditions as suggested by Contractor and agreed by ENGINEER-IN-CHARGE, the same

shall also be as per the referred drawing.

The permanently lubricated HDPE pipe used for the leading-in of the OFC into the room housing

the telecom equipment shall be below the ground level without getting exposed outside (the entry

points shall be properly sealed after OFC installation to avoid entry of rodents, insects, etc). To

facilitate termination, a minimum 15 m length of OFC shall be kept in the room housing the

telecom equipment.

b) Tie-in locations

At all tie-in location the Optical Fibre Cable shall be laid in a separate trench 3 meter away from

the pipeline to avoid any damage to the Optical Fibre Cable. The Optical Fibre Cable trench shall

extend to 5 meter on both sides of the tie-in locations. The Optical Fibre Cable shall be suitable

routed in the separate trench at all tie-in-locations considering minimum bending radius of the

Optical Fibre Cable. At all these locations, the cable shall be laid through HDPE conduits for

c) OFC Joint Locations

The trench shall be enlarged at the splicing points as needed to carry out the splicing works. The

enlargement shall be carried out on the same side of the conduits for protection. GPS coordinates

for joint-pit shall be provided and verified during acceptance.

3.2 SPECIFICATIONS OF PERMANENTLY LUBRICATED HDPE CONDUIT

The HDPE duct shall be suitable for underground laying in a trench at a depth of 1.65 meters or

shall be suitable for laying through HDD (Horizontal direction drilling) and optical fibre cable

shall be installed using blowing techniques.

The HDPE conduits (as mentioned above and other places in this tender document) to be supplied

for this project by the vendor shall consist of two concentric layers. The HDPE outer layer shall

be co extruded with an inner layer of solid permanent lubricant to reduce the internal co-efficient

of friction (ICF). The lubricant shall be of a solid layer of uniform thickness so formulated to

provide a permanent, low friction boundary layer between the inner surface of the duct and optical

The base HDPE (High-density polyethylene) resin used for the outer layer of the permanent

lubricated HDPE Duct shall confirm to IS 7328 or to its equivalent. Manufacturer shall furnish

designation for HDPE resin as per IS: 7328, as applicable.

The inner layer of solid permanent lubricant shall be continuous all through and shall not come

out during storage, usage and throughout the life of duct. The inner lubrication material shall be

of friction reducing polymeric material, which shall be integral with HDPE layer. The lubricant

material shall have no toxic or dermatic hazards for safe handling. In the finished permanent

lubricated HDPE duct, the co-extruded inner layer of solid permanent lubricant shall be integral

part with HDPE and shall be white in colour and clearly visible in cross-section of duct.

Permanently lubricated HDPE conduit shall be from manufacturer who shall have manufacturing

facility as well as complete in-house testing facility. The HDPE conduit shall be of Dia. 40 mm

conforming to the following specification and shall be tested at factory as per the test standards

provided below (Contractor is free to use higher sizes of HDPE conduits as felt necessary,

however Contractors offers shall be inclusive of all such costs):

SPECIFICATIONS FOR 40 mm OD PERMANENTLY HDPE DUCTS (As per TEC

G.R. No. TEC/GR/FA/CDS-008/04/AUG-19 and latest amendments (if any))

PARAMETER TEST STANDARD SPECIFICATION

Tests on Raw Materials:

1. Melt Flow Index of IS: 2530 0.2 to 1.1 gms/10min @ 190oC & 5 Kg

HDPE Resin Load

2. Density of HDPE Resin IS: 2530 or IS: 7328 0.940 to 0.958 gm/cc at 270 C.

3. UV Stabilizer Content FT-IR Method Hindered Amine Light Stabilizer

4. Ash Content of Colour TEC / GR / FA / CDS- 12% (Max.)

Master Batch 008 / 04 / AUG-19 and latest

Tests on Finished PLB HDPE Duct:

5. Visual Smooth Inside and outside surface, free

Appearance IS: 4984 of blisters, shrink hole, flaking, chips,

scratches, roughness, break & other

defects. The ducts shall be smooth, clean

& round. Thickness of inside Lubricant

layer shall be uniform throughout the

length and shall be white in color for

clear visibility.

6. Dimensions : (a)

Wall Thickness IS: 4984 3.50 + 0.20 mm

(b) Outside IS: 4984 40.0 +0.4 0.0 mm

(c ) Thickness of Traveling Microscope & 0.28 mm (min.)

Inner Lubricant & 0.42 mm (max.)

(d) Standard Length 1000 + 100 meters

7. Reversion Test IS: 4984 Dimensions shall not change by more

than 3 % in longitudinal direction

8. Environmental ASTM: D 1693 Ducts shall not crack or split when tested

Stress Crack with 10% Igepal (CO 630) solution at

Resistance 50 C for 96 hours.

9. Impact Strength IS: 12235 (Part 9) The duct shall not crack or split

10. Crush Resistance Test The Deflection with load on and after

recovery period shall not exceed 10% &

2%, respectively

11. Oxidation Induction Annexure I of 30 minutes (min.)

12. Hydraulic IS: 4984; 48 hrs at 800 Shall not show signs of localized swelling,

characteristics C, Induced Stress: 3.8 leakage or bursting.

13. Tensile strength at yield ASTM: F 2160 (Type IV Min. 20 N/mm2 (min.) & 500% (min.)

& Elongation Specimens of

ASTM: D 638); Testing

Elongation at break When tested as per > 600 %

ASTM: D 638, Type IV

14. Internal Coefficient of Annexure 2 of 0.06 (max.) - for Nylon Jacketed

Friction unarmoured OFC

0.20 (max.) - for HDPE Jacketed

15. UV Stabilizer Test After ageing for 720 hrs, the variation in

Tensile strength compared to the value

obtained before ageing, shall not be more

Cycle No. 2 of than 20%.

Type IV Specimens of

Inspection & acceptance testing

The test and inspection shall be carried out as per the QAP in accordance with the codes and

standards outlined in the specification. Following test shall be conducted as a minimum as per the

codes and standards indicated in this document in the manufacturers premises. Test results must

comply with specifications as per TEC GR Nos. TEC/GR/FA/CDS-008/04/AUG-19 (with all

other amendments/additions issued by TEC till date) including all the other requirements, which

1. Visual inspection

3. Tensile Strength

4. Elongation under load

5. Reversion Test

6. Environmental Stress Crack Resistance

7. Impact Strength Test

8. Crush Resistance Test

9. Ovality Test

10. Oxidation Induction Test

11. Hydraulic Characteristic Test

12. Internal Coefficient of friction Test

13. Density of finished product

14. Ash Content

Duct Accessories

i. Plastic Coupler

It is used to couple two ducts. The design of this shall be simple, easy to install and shall

provide airtight and water tight joint between the two ducts. The coupler shall ensure that the

two ducts are butted smoothly without any step formation in the inner surface.

This is for sealing the ends of the empty ducts, prior to installation of the Optical Fibre Cable

and shall be fitted immediately after laying of the duct, to prevent the entry of any dirt, water,

moisture, insects/ rodents etc.

iii. Cable Sealing Plug

This is used to seal the ends of the ducts perfectly, after the cable is installed in the duct, to

prevent the entry of dirt, water, moisture, insects/ rodents etc. This is required at all places

where cable has come out of the duct either for jointing or entry into the building as required.

The sealing plug shall be capable of accommodating standard sizes of optical fibre cable taking

into account the variation in diameter due to tolerance limits, etc.

This cap is made of hard rubber, shall be fitted into both ends of duct coil after manufacturing

the duct. This shall avoid entry of duct, mud and rainwater into the duct during the transit and

3.3 SPECIFICATIONS OF OFC JOINTING CLOSURES

Jointing Closures shall be suitable for armoured optical fibres (offered for this project) and

unarmoured optical fibre cables of all construction designs (slotted core, stranded tube, central

tube). Jointing closures shall have 4 entry ports to allow entry/exit of one OFC from each port

with sleeve protectors. The same shall have provision of blocking/sealing of the ports, if not in

The fibres and their storage shall be managed with proper bend radius controls and protection.

There shall be no requirement of any kind of adhesive tape to keep the fibres in the tray. The fibre

organizer trays shall have provision of maximum 12 fibres per tray for future. However at present

only 6 fibres per tray will be spliced (fusion splicing only) per tray and min 4 nos. of trays shall

be provided. The trays should be hinged in such a manner that if moved about the hinge, the fibres

are not strained, kinked or stressed. Also, it should be possible to work on the fibres on one tray

without disturbing the fibres on the other trays. For routing of fibres to the tray that are capable

of moving about the hinge, proper transport tubes shall be provided. These tubes shall be

transparent and non-kinking.

The Jointing Closure shall enable the metal parts of the cable and the internal metal parts of the

closure to be maintained at earth potential. The sealing of the entry ports, shall provide adequate

sealing and shall be capable of withstanding an axial pull applied using 50 kg freely suspended

weight of the cable, without using any additional clamps, etc.

Jointing closures should be Dust tight (No dust ingress) and Protected against immersion in water

(suitable for continuous immersion in saline water under 4 meter water-head) and should be

complete with all accessories including splice cassettes splice protection sleeves and all other

accessories including accessories for electrical continuity of metallic layers of optical fibre cable,

etc along-with instruction sheets. 25% spare splice protection sleeves shall be provided in each

Jointing Closure Tests

The following tests shall be conducted as a minimum:

a) Water Ingress Test

The cable-jointing box shall be assembled in the presence of ENGINEER-INCHARGE

along-with a continuous piece of cable passing through. The jointing box shall then be

secured at the bottom of a immersion tank containing water upto a height of 4.0 m at

normal room temperature for a period of 24 hours. The joint box will then be opened as

per the specified procedure and visually examined for any ingress of water. It shall be

declared to have passed the test in case there is no water present inside the box.

The cable joint box shall be kept on a metal platform. A weight of 5 kg spherical type

having radius of R 50mm at striking end will be made to strike the box at the middle after

having been released from a height of 500mm for 10 times. The joint box will be declared

to have passed the test in case there are no cracks or fracture inside or outside of the box.

c) Drop and topple test

A drop test platform consisting of a steel plate not less than 6.5mm thick is to be used.

The steel plate is bolted to a fully set concrete block at least 460mm thick. The joint box

shall then be allowed to topple and fall freely from a height of 2000mm. The joint box

will be declared to have passed the test in case there is no visible damage to the enclosure.

d) Pulling test

The joint box should be assembled with a long length of cable so that it can be pulled to

the required tension of 50 kg to check the strength of fixing arrangement inside the joint

e) Static load test

The assembled cable joint closure shall be kept on a platform with dimension more than

that of cable joint closure. A curved hollow profiled mandrel shall be used for application

of load and the mandrel shall be at the middle straight part of the joint closure. Weights

shall be gradually placed on the mandrel till the weight becomes 250 kg. The joint box

shall be kept under the weight for a period of 24 hours. The joint closure shall be declared

to have passed the test in case there is no visible damage.

All the tests for the jointing closures shall be done with all the accessories mounted inside, all

complete. In case of the jointing closures, tested and inspected in accordance with this

specification, fail to pass the test (100% success rate) or comply with the specification

requirement, the tests shall be repeated on a further representative set of jointing closures and if

it again fails, the whole lot shall be rejected subject to the discretion of the ENGINEER-IN-

Contractor shall provide detailed test procedures for testing Jointing Closures, after award of work

and test the same as per the approved procedure in owner/owner’s representative presence.

ST Sample test (5%, in case of fraction the next higher rounded figure to be taken))

3.4 OFC BLOWING & JOINTING PIT

3.4.1 OFC BLOWING PIT

The cable-blowing pit is required for blowing cable and keeping extra cable for future use. The

blowing pit shall enclose HDPE section ends from both sides at every 1 Km nominal distance and

shall be as per the OFC Jointing pit shown in drawing no B414000-16-51-4705, OFC Jointing Pit.

The cable-blowing pit shall be circular (Internal diameter ~ 1200 mm) and made of reinforced

concrete with lifting lugs cast into the lids during construction itself. The pit shall be provided

with suitable arrangement for the entry of HDPE conduit (50/40 mm Outer diameter) from both

sides so that HDPE pipes should enter the pit at a height of 150 mm above the bottom level of the

pit and to prevent entry of mud, insects etc. Total 20 m of OFC i.e. 10m from each side in the

blowing pit has to be coiled.

3.4.2 OFC JOINTING PIT

The cable blowing pit as described above will be used as Optical Fibre Cable jointing pit at every

4 Km nominal distance. At every 4 Km nominal distances this pit will be used to enclose the OFC

jointing enclosure. Contractor has to leave 20m coil of Optical Fibre cable from both sides in the

jointing pit i.e. total 40 m of OFC will be coiled in jointing pit. (The name jointing pit and blowing

pit has been used interchangeably in the bid document). Contractor shall submit detailed drawing

for Jointing & blowing pits and gets approval from ENGINEER-IN-CHARGE.

3.4.3 OFC DISTANCE MARKERS

A 300 mm diameter metal plate shall be made by the Contractor on the pipeline warning markers

itself (which are at approx. every kilometer and at crossings). The Contractor shall suitably paint

on these metal plates the following: 1) OFC. 2) OFC progressive physical distance w.r.t. the

nearest repeater station (measured with the help of meter markings on the each OFC drum and

adding up progressively). This repeater station shall be the one nearest to the progressive distance

in the direction of

Dispatch Terminal. 3) Optical fibre cable length

A typical diagram of an OFC joint identification marker is shown at drawing no. B414000-16-51-

4704. OFC markers shall be similar to the diagram except the description of joint number. (Supply

and installation of OFC distance marker (on Pipeline Warning Marker) shall be as per pipeline

laying section of this project).

3.4.4 OFC JOINT IDENTIFICATION MARKERS

All jointing locations shall be marked with proper identification markers. The Contractor shall

supply, fabricate and install the OFC joint identification markers. These markers shall be in line

with the markers as given in drawing no. B414-000-16-51-4704 of this Tender document. The

markers shall show 1) OFC joint 2) The progressive joint number w.r.t the nearest repeater stations

3) Distance of the Joint w.r.t the nearest joint (measured with the help of meter markings on the

OFC) i.e., drum length as per meter marking on the OFC 4) Distance of the Joint w.r.t the nearest

joint location (measured with the help of OTDR before jointing i.e., fibre length. These markers

shall be installed approximately 1m away from the jointing pit.

3.4.5 ELECTRONIC MARKER SYSTEM

Additionally, at each Jointing Pit & Blowing Pit location, Contractor shall provide electronic

locating system suitable for field use to locate underground-buried OFC joint locations.

Electronic markers shall also be provided at each OFC Blowing pit location.

The system shall consist of:

a) Electronic marker (to be buried underground along-with OFC joints)

b) Marker locator (including probe & locator electronics)

The electronic markers shall be placed at all joint pit locations (planned and unplanned).

The electronic markers shall be lightweight and shall have a passive tuned resonant circuit,

enclosed and sealed within a casing. The marker locator shall be able to locate the electronic

markers from a distance of 2 m minimum with the help of audio and visual signals. The markers

shall be of color (Yellow) suitable for Oil & Gas application.

The marker locator and the probe shall be of lightweight and portable enough to be carried (in

suitable carrying case, to be provided) on shoulder. The locator shall be able to work on batteries

(dry alkaline) for continuously 8 hours.

The electronic locating system shall be able to work in saline atmosphere in coastal area and shall

be protected against corrosion.

The electronic locating system shall not be affected by any metal, alternating current, etc. The

casing of the electronic marker shall be resistant to chemicals, minerals, water ingress and

temperature variation normally encountered in underground environments. The material used for

the manufacture of electronic markers shall be protected against any damage due to rodents or

any other insects in the underground environment.

Each marker locator provided shall be complete with its set of accessories (i.e., necessary

interfaces, connecting cables, software, etc). The electronic markers shall be buried underground

30 mm above the lid of each jointing pits and shall not be in direct contact with any metallic body.

3.5 TERMINATION

cable ties (~5m cable from each side being kept in turns in oval form). This Loop Box shall have

suitable chemical coating/ painted to prevent corrosion. In case of painting,

the color shall match the wall color. Further, the cable shall be terminated on Fibre termination

Details of Loop Box:

Sl No. Description Standard Dimensions/Parameter

1 Height 1000 mm

2 Width 1000 mm

4 Earthing Point 01 No.

5 Anchor Bolt 04 Nos. Provided

6 Sheet Thickness 1.2 mm CRCA

8 Degree Of Protection IP -

9 Powder Coating Shade RAL

10 Material Finish Powder Coated RAL

11 Front Door With lock & Key 01 No. Provided

3.5.1 SPECIFICATION OF FIBRE TERMINATION CLOSURE

The FTC shall be wall-mounted type as suitable for the Optical Fibre Cable used (24 Fibres from

each side, i.e. 48 fibres). The FTC shall give grounding arrangement for all the metallic layers of

the cable. The cable shall be spliced to pigtails on trays provided in the FTC. The connector side

for the pigtails shall be secured with suitable coupler/ through adapter provided as integral part of

the FTC itself. The FTC shall have trays suitable splicing maximum of 6 Fibres per tray. The

arrangement inside the FTC should be simple and in straight line. FTC should have entry points

at lower bottom end for a minimum of 2 Nos. of Optical Cable (armoured/ non-armoured) of

diameter up to 20 mm with cable clamps to avoid entry of rodents/ dust in general. FTC shall have

trays for minimum 48 fibres (with connectors & pigtails provided & installed). It should have a

minimum of 2 Nos. of outlets for taking out 48 Nos. pigtails/patch cords. The outlets should have

Grounding arrangement should be provided with the FTC. It should include as minimum 2 Nos.

grounding shield bonds with nut and bolts for fixing to the armour of the OFC. 2 Nos. of grounding

cable of green color with suitable length & lugs clamped to its end for connecting the armor of

OFC with the grounding terminal of the FTC.

SPECIFICATION FOR SINGLE MODE OPTICAL FIBRE PIGTAILS, PATHCORDS &

CONNECTORS TO BE USED IN THE FTC

This specification provides requirements for single mode Fibre Pigtails and connectors. They

should meet the ITU-T recommendations G-652D/G-655. Both connectors and cables should be

robust and should withstand wear and tear due to frequent use, connection and disconnection.

Normal expected life should be 15 years or more.

Optical Fibre Cables, connectors & pigtails shall be fully compatible and matching to each other.

OPTICAL PIGTAILS

OPTICAL PARAMETERS: (In line with the cable specifications provided in this bid document)

CONSTRUCTION OF FIBRE USED IN PIGTAILS

Primary coating Material : Silicone

Primary coating Diameter : 400 µm nominal

Secondary coating Material : Nylon

Secondary Coating Diameter : 900 µm nominal

PHYSICAL PARAMETERS OF CABLE:

Pigtail length : As required

Fibre Reinforcement : Kevlar/ Aramid

Outside dia : 3 mm +/- 10%

Type of connector : SC

A circular sheath of not less 0.5mm thick of suitable material and color free from pinholes and

scratches and other defect etc. shall be provided. A low smoke, Halogen free, fire retardant

material shall be used.

MECHANICAL PARAMETERS FOR PIGTAILS

Performance Parameters of the completed Patch cord and pigtails shall meet requirements of IEC

OPTICAL PARAMETERS OF CONNECTORS WITH PIGTAILS

Insertion loss : Maximum 0.5 dB per connector

plus Fibre loss

Return loss : Better than 30 dB

Temperature Dependency : < 0.3 dB from -200C to +600C

Change in connection losses with : It should be <0.3 dB

passage of time at 60 C for 100 hrs.

Change in Connection Loss due : < 0.05 dB

Reproducibility of Connection : < 0.3 dB

loss by repeated connection and

dis-connection for 500 times

Change in Connection loss in : < 0.05 dB

relation to Tensile Strength

Minimum Bending : (i) Loaded-50 mm

Radius : (ii) Unloaded-30 mm

The complete Fibre Termination Closure including trays, joint/splice protection sleeves, pigtails,

couplers, etc shall be sourced from vendors as a composite item.

After termination, each pig tail/patch cord shall be properly ferruled for identification of station

hall also include earthing of FTC, Loop Box and Optical Fibre

cable including Laying of earthing cables/ strips to earth grid/earth pit.

4 DOCUMENTATION

4.1 VENDOR DATA REQUIREMENT AND DOCUMENTATION

a) Six sets of Documentation shall be supplied with each submission. Prices for all

documentation shall be inclusive in the supply/installation charges and no separate prices

shall be applicable for documentation.

b) All documents shall be in English language only.

c) During engineering stage, ENGINEER-IN-CHARGE shall

review/approve drawings/documents.

4.1.1 After the award of work, the following documents shall be supplied for review and approval in

order to start OFC installation at site:

1) Experience & Proven Track Record details as per Clause 2.1 & 2.2.

2) Detailed testing procedure for OFC, permanently lubricated HDPE conduit & Jointing

3) OFC alignment sheet:

OFC alignment sheets shall comprise the following as a minimum:

i) Detailed measurement of length of OFC laid route along-with details of road, nullah, river

ii) Location of Terminals, repeaters and planned location of joints.

iii) Various rail, road, canal, river crossings, etc.

The Contractor shall thereafter prepare OFC route sheet for the entire route with proper scale

showing all the crossings and topographic details as needed to define the route and its

characteristics. (For the sections where the OFC route may leave the pipeline route, the

Contractor shall make a proper topographic survey to define the route and to determine the

existence of over ground or underground services that could interfere with the installation

(Contractors bid should be inclusive of all such survey/requirements and no separate

payment shall be done)).

4) Quality Assurance program as requested in this tender document and the following:

a) Daily OFC installation/jointing/testing report formats.

b) List of all the materials to be used during OFC installation.

5) Any other data, document not specifically mentioned, but required for the satisfactory

completion, operation and maintenance of the system shall be provided.

1) As built OFC alignment sheets with the following additional details at each joint location.

a) Progressive OFC length, including the additional length at each joint location.

b) Fibre length, Fibre length between joints, as measured by OTDR.

c) Progressive pipeline chain age

d) Distance of joint from nearest pipeline markers & crossings, etc.

2) Final OFC test reports (individual OFC drums, hop to hop between repeaters, section and end

to end, as applicable).

3) Final location of OFC w.r.t the pipeline along the entire route.

4) All final documents for this project in hard as well as electronic (CD) form.

4.2 QUALITY ASSURANCE PROGRAM

4.2.1 QUALITY ASSURANCE PROGRAM

(a) Contractor shall submit the details of Quality Assurance Program. Contractor shall obtain and

forward the Quality Assurance Program for material supplied by SubVendor, if any.

(b) The ENGINEER-IN-CHARGE reserves the right to inspect and test each material/equipment

at all stages of production and commissioning. The inspection and testing shall include but

not be limited to raw materials, components, subassemblies, prototypes, produced units,

guaranteed performance specifications, etc.

(c) ENGINEER-IN-CHARGE shall have free entry and access to any and all parts of

material/equipment at any given time.

(d) It shall be explicitly understood that under no circumstances shall any approval of the

ENGINEER-IN-CHARGE relieve the Contractor of his responsibility for material, design,

quality assurance and the guaranteed performance of the system and its constituents.

4.3.1 FACTORY ACCEPTANCE TESTING

Factory acceptance tests shall be carried out after review and approval of FAT

procedures/documents and shall be conducted at the manufacturing facilities from where the

respective items are offered (e.g. OFC, Permanently lubricated HDPE conduit & Jointing

closures). The factory acceptance testing shall be conducted in the

equipment/items including those supplied by Sub vendors and factory acceptance certificates shall

be issued. The factory tests shall include but not be limited to:

1. Mechanical checks to the equipment for dimensions, inner and outer supports, finishing,

welds, hinges, terminal boards, connectors, cables, painting etc.

2. Check for assuring compliance with standards mentioned in the specifications.

3. Individual check on each/module/sub-assembly in accordance with the modes and diagnostics

programs of the Contractor.

4. Environmental testing.

5. Functional tests.

6. Any other test not included in FAT document but relevant to the project as desired by the

Owner/Consultant at the time of Factory acceptance testing.

4.3.2 ROUTINE TESTING

4.3.3 SITE ACCEPTANCE TESTING (SAT)

Site acceptance testing for handing over of laid OFC shall be done in the presence of ENGINEER-

IN-CHARGE in the format provided (Procedure for OFC Testing).

Upon successful completion of the `Site acceptance testing', any shortfalls when compared to the

contract shall be made good by the Contractor.

The Contractor shall then provide as built documents as asked in this tender document. After this,

ENGINEER-IN-CHARGE shall notify the Contractor in writing, his final acceptance of the laid

OFC and the OFC shall be considered commissioned.

Nothing herein above provided, inclusive of the `Final Acceptance Certificate; shall absolve

Contractor of his full liabilities under the contract inclusive of and relative to the system

performance and Warranty.

OPTICAL FIBRE CABLE SPECIFICATION

1 OPTICAL FIBRE CABLE

The contractor shall be totally responsible for the desired performance of the offered OFC

including design, engineering, manufacture, testing and supply of direct underground burial

The OFC shall be Corrugated steel tape armored cable and shall be of capable of laying in

permanently lubricated HDPE conduits using blowing technology & also capable of direct

burial and shall be required to cross various roads, railways, canals, small rivers, marshy areas

etc. through appropriate casings & directly as per site conditions.

The intent of the following specifications is to establish the minimum requirements and

guidelines for the OFC to be supplied for this project.

BHARAT PETROLEUM CORPORATION LIMITED

KRISHNAPATNAM HYDERABAD MULTI-PRODUCT

PIPELINE PROJECT

PROCEDURE FOR OPTICAL FIBER CABLE TESTING

1.0 TEST PROCEDURE

The Optical fiber cable will be tested for its continuity and average loss in dB/km. The link will be

tested and recorded in the format given in Appendix.

1.1 FIBRE LENGTH MEASUREMENT

Test Description

This test will check the continuity of the fibre from point to point and record the length of fibre.

Average loss per kilometre of fibre length shown in dB/km shall be recorded for information

only. Testing will be done from both ends and average loss will be calculated (for

1310nm/1550nm/1625nm, as applicable).

1.1.1 Test Equipment

Optical Time Domain Reflectometer (OTDR) Patchcords,

1.1.2 Procedure

Power ON the OTDR and make the settings as required for the hop under test.

Connect the OTDR with patchcord to the connector in FTC.

Make the Laser ON and observe the trace till it gets settled up to the end of the trace.

Store the results in the hard disk/floppy disk with proper identification of the fibre under test.

Record the results in format

Repeat the procedure for the opposite direction.

Test Formats are provided in Appendix-1 (A & B)

Repeat above steps for each fiber.

1.2 INSERTION LOSS MEASUREMENT

1.2.1 Test Description

During insertion loss measurement, light is launched (LASER) in the fibre by using a LASER

source from one end at the other end by using an Optical Power meter the received power is

measured. Fiber loss is calculated by subtracting the receive power from the transmit power.

This test also determines the fiber termination continuity on end-to-end basis as the measurement

is done on both the ends of a link.

1.2.2 Tools and Equipment required

Power meter working on 1310nm/1550nm/1625nm.

Laser source working on 1310nm/1550nm/1625nm.

Patchcords (10 mtrs)

1.2.3 Procedure:

One power meter, one laser source and one unit of optical talk set is required at each station

between which the link is to be tested.

At location A, switch ON the laser source, set it to operating wavelength of 1310nm and connect

it to the power meter (set at 1310nm for G.652 fibres) by two FC/PC patch cords (these FC/PC

patch cords will be connected to each other with FC/PC coupler) and record the laser power

transmitted. Subtract 0.5 dB (Coupler Loss) from this reading and record it in the test sheet

Disconnect the power source and power meter by disconnecting FC/PC patchcords from the

FC/PC connector. Do not disconnect patch cords from the power meter and power source.

Connect the power source to the one of the fibres terminated in FTC at location A and the power

meter to the same fibre under test in FTC at location B.

Record the power received in test sheet.

To establish communication between two stations A & B, optionally connect a Optical talk set

to one of the fiber (e.g. No 12) at both the stations. When that particular fiber is due for testing

connect the talk set to one on which testing is complete (e.g. No 1).

Confirm on the talk set that the power received is recorded.

Repeat the test for 1550nm.

Connect the source to next fibre terminated in FTC at location A and power meter at location B.

Repeat the same procedure with source at location B and power meter at location A.

Continue the above process till all fibers are tested.

Average loss of each fiber should be less than the average loss estimated.

Repeat tests for G.655 fibres for 1550/1625nm, as required.

Test Formats are provided in Appendix

COMMERCIAL CONDITIONS OF CONTRACT

Payment will be made after making the necessary deductions as stipulated elsewhere in the

contract document for materials, security deposit or any moneys due to the Owner etc.

75% payment of the Running Account bill (RA bill) shall be released within 15 calendar days of

receipt of RA bill duly certified by Engineer-in-charge (EIC) and the balance payment shall be

released within 30 days of receipt of RA bill by EIC after detailed scrutiny.

Delivery Period:

Contract Period for the job shall be 45 days from the date of LOA/Purchase order.

FIBER LENGTH MEASUREMENT (G.652)

Wavelength: 1310nm & 1550nm

Equipment used: ____________________

Tube No./Color Fiber No./ Color Fiber Length (m) Optical loss dB/km

Cable loss (Average of above): ___________________km

(ALL LOSSES MEASURED IN dB/km)

Signature & date Signature & date

(Tested & handed over (Witnessed & taken over by

Signature & date

Witnessed by CLIENT/CLIENT representative(s)

FIBER LENGTH MEASUREMENT(G.655)

Wavelength: 1550nm & 1625nm

Equipment used: ____________________

Tube No./Color Fiber No./ Color Fiber Length (m) Optical loss dB/km

Cable loss (Average of above): ___________________km

(ALL LOSSES MEASURED IN dB/km)

Signature & date Signature & date

(Tested & handed over (Witnessed & taken over by

Signature & date

Witnessed by CLIENT/CLIENT representative(s)

INSERTION LOSS MEASUREMENT (G.652)

Location A: ______________ Location B: ___________________

Wavelength: 1310nm Equipment used: ______________

Cable length from Appendix 1A: _______km

Number of Splices (including Pigtails-N): _________

Number of connectors-C: ______ Average IL = 0.37L+0.07N+0.5C: ____(estimated)

Tube Fiber No./ A-B B-A Average

No./Color Color Power Transmitted at A Power Transmitted at B IL

Power IL (A-B) Power IL (B-A)

received at received at A

(ALL LOSSES MEASURED IN dB/km)

Signature & date Signature & date

(Tested & handed over (Witnessed & taken over by

Signature & date

Witnessed by CLIENT/CLIENT representative(s)

INSERTION LOSS MEASUREMENT (G.652)

Location A: ______________ Location B: ___________________

Wavelength: 1550 nm Equipment used: ______________

Cable length from Appendix 1A: _______km

Number of Splices (including Pigtails-N): _________

Number of connectors-C: ______ Average IL = 0.22L+0.07N+0.5C: ____(estimated)

Tube Fiber No./ A-B B-A Average

No./Color Color Power Transmitted at A Power Transmitted at B IL

Power IL (A-B) Power IL (B-A)

received at received at A

(ALL LOSSES MEASURED IN dB/km)

Signature & date Signature & date

(Tested & handed over (Witnessed & taken over by

Signature & date

Witnessed by CLIENT/CLIENT representative(s)

INSERTION LOSS MEASUREMENT (G.655)

Location A: ______________ Location B: ___________________

Wavelength: 1550nm Equipment used: ______________

Cable length from Appendix 1A: _______km

Number of Splices (including Pigtails-N): _________

Number of connectors-C: ______ Average IL = 0.24L+0.07N+0.5C: ____(estimated)

Tube Fiber No./ A-B B-A Average

No./Color Color Power Transmitted at A Power Transmitted at B IL

Power IL (A-B) Power IL (B-A)

received at received at A

(ALL LOSSES MEASURED IN dB/km)

Signature & date Signature & date

(Tested & handed over (Witnessed & taken over by

Signature & date

Witnessed by CLIENT/CLIENT representative(s)