Communications Design and Installation

Ma’aden Engineering Manual Rev.
Date: 31 Aug 2011

Specification Rev: C01
Table of Contents
1. Introduction ............................................................................................................................................ 4
1.1 Scope ............................................................................................................................................. 4
1.2 Purpose .......................................................................................................................................... 4
2. Key Terms and Definitions ...................................................................................................................... 4
3. Applicable Documents ............................................................................................................................ 5
3.1 Statutory Regulations ...................................................................................................................... 5
3.2 Industry Codes ................................................................................................................................ 5
3.2.1 Local Standards ................................................................................................................... 7
3.2.2 Alternative Design Codes .................................................................................................... 7
3.2.3 Ma’aden Standards .............................................................................................................. 7
3.2.4 Site Data ............................................................................................................................. 7
4. Design and Installation Requirements ..................................................................................................... 7
4.1 Design Criteria................................................................................................................................ 8
4.2 Hazardous Areas............................................................................................................................. 8
4.3 Earthing .......................................................................................................................................... 9
4.4 Quality of Workmanship ................................................................................................................ 9
4.5 Safety .............................................................................................................................................. 9
4.5.1 Tagging and Isolations......................................................................................................... 9
4.5.2 Excavations and Surface Penetrations .................................................................................. 9
4.5.3 Licensing and Registration................................................................................................... 9
4.5.4 Optical Communications – Lasers ..................................................................................... 10
4.6 Testing and Commissioning .......................................................................................................... 10
4.7 Documentation ............................................................................................................................. 10
4.8 Handover ..................................................................................................................................... 10
5. Information Technology Cabinet Design and Installation ..................................................................... 10
5.1 Design and Construction .............................................................................................................. 10
5.2 Mounting ...................................................................................................................................... 12
5.3 Power Supply ............................................................................................................................... 12
5.4 Earthing ........................................................................................................................................ 13
5.5 Internal Operating Temperature .................................................................................................... 14
5.6 Equipment Installation .................................................................................................................. 14
6. Communications Cable Design and Installation .................................................................................... 15
6.1 Optical Fiber Cable....................................................................................................................... 16
6.1.1 Selection ........................................................................................................................... 16
6.1.2 Storage and Handling........................................................................................................ 18
6.1.3 Installation ........................................................................................................................ 18
6.1.4 Termination ...................................................................................................................... 21
6.1.5 Testing ............................................................................................................................. 22
6.2 Data Communications Cable ........................................................................................................ 23
6.2.1 Selection ........................................................................................................................... 23
6.2.2 Installation ........................................................................................................................ 24
6.2.3 Termination ...................................................................................................................... 26
6.2.4 Certification Testing .......................................................................................................... 26
6.3 Low Voltage Power Cables ........................................................................................................... 27
6.4 Cable Tray .................................................................................................................................... 27
PROPRIETARY & Communications Design and Installation

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CONFIDENTIAL Doc No: MD-101-SMEM-EG-CS-SPC-0006
Ma’aden Engineering Manual Rev. Date: 31 Aug 2011
6.5 Conduit ........................................................................................................................................ 27

7. Quality Assurance ................................................................................................................................. 28
8. Inspection and Testing .......................................................................................................................... 28
8.1 General ........................................................................................................................................ 28
8.2 Factory Acceptance Testing .......................................................................................................... 28
8.3 Site Testing ................................................................................................................................... 28
9. Transport, Packaging, Handling and Shipping ....................................................................................... 28

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1. INTRODUCTION
1.1 Scope
This document specifies the minimum requirements for Communications Design and
Installation for all Ma’aden projects.
This Specification covers the minimum requirements for the:

• Design, fabrication, testing, supply and installation of Information Technology Cabinets.
These cabinets house communications and Information Technology equipment,
including but not limited to network communications switches, network computer
servers, fibre optic breakout trays, network cable patch panels, and associated power
supplies and electronic equipment.
• Design, supply, installation and testing of communications cabling, including but not
limited to optical fiber cables and Category 5e screened and Category 6 network
cabling.
This document is intended to be used in conjunction with the applicable documents listed
herein.
1.2 Purpose
The purpose of this specification is to set the minimum engineering standard for
Communications Design and Installation.
2. KEY TERMS AND DEFINITIONS

ABS Acrylonitrile Butadiene Styrene
CCTV Closed Circuit TV
EDC Electrical Distribution Centre
EMC Electro Magnetic Compatibility
Employer Saudi Arabian Mining Company (Ma’aden) and its authorized
representatives and respective affiliates
Ex Mark followed by level of protection in hazardous atmosphere
FOBOT Fiber Optic Break Out Tray
GPO General Purpose Outlet
IT Information Technology
ITC Information Technology Cabinet
KVM Keyboard Video Monitor unit
LAN Local Area Network
LED Light Emitting Diode
MCB Miniature Circuit Breaker
OPGW Optical Pilot Ground Wire
OTDR Optical Time Domain Reflectometer
PCS Plant Control System

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PVC Poly Vinyl Chloride

RTD Resistive thermal device
SASO Saudi Arabian Standards Organization
TIA Telecommunications Industry Association
UPS Uninterruptible Power Supply
WAN Wide Area Network
3. APPLICABLE DOCUMENTS
Applicable parts of following regulations, industry codes and standards, and references shall
be considered an integral part of this document. The edition in effect at date of contract
award shall be used, except otherwise noted.
3.1 Statutory Regulations
All work performed and materials furnished shall comply with the applicable statutory
regulations, codes and other requirements of the Kingdom of Saudi Arabia (including but not
limited to directives of the High Commission for Industrial Security, Royal Commission
regulations applicable to the Site, regulations of the Presidency of Meteorology and
Environment, Saudi Building Code and other applicable codes and regulations). The
Contractor shall ensure that he is fully aware and informed of all Government laws, local
ordinances, regulations and all orders and decrees of bodies or tribunals having any
jurisdiction or authority over the Project and/or Site, which in any manner affect the Project
and those engaged or employed on the Project, or which in any way affect the conduct of
the Work. The Contractor shall at all times observe and comply with all such Government
and/or Ministry laws, bylaws, ordinances, codes, regulations, orders and decrees.
3.2 Industry Codes
All equipment and systems shall conform to the following:
EIA 359-A Standard Colors for Color Identification and Coding

EN 50290 Communication cables
IEC 60189 Low-frequency cables and wires with PVC insulation and PVC
sheath
IEC 60227-5 Polyvinyl Chloride Insulated Cables of Rated Voltages up to and
Including 450/750 V – Part 5: Flexible Cables (Cords)
IEC 60364-5-52 Low-voltage electrical installations – Part 5-52: Selection and
erection of electrical equipment – Wiring systems
IEC 60364-6 Low-voltage electrical installations – Part 6: Verification
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60793-2 Optical fibers – Part 2: Product specifications
IEC 60794 Optical Fiber Cables (Parts 1 to 5)
IEC 60825 Safety of Laser Products – Parts 1, 2, 4, 10 and 12
IEC 60950 Information Technology Equipment – Safety

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IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards

– Emission standard for industrial environments
IEC 61034 Measurement of Smoke Density of Cables Burning Under Defined
Conditions
IEC 61156 Multi-core and symmetrical pair/quad cables for digital
communications (Part 5: Symmetrical pair/quad cables with
transmission characteristics up to 1 000 MHz-horizontal floor
wiring, Part 6: Symmetrical pair/quad cables with transmission
characteristics up to 1 000 MHz – Work area wiring)
IEC 61558-2-16 Safety of transformers, reactors, power supply units and similar
products for supply voltages up to 1 100 V – Part 2-16: Particular
requirements and tests for switch mode power supply units and
transformers for switch mode power supply units
IEC 61918 Industrial communication networks – Installation of
communication networks in industrial premises
IEC 62255 Multi-core and symmetrical pair/quad cables for broadband digital
communications (high bit rate digital access telecommunication
networks) – Outside plant cables
IEC 62443-2-1 Industrial communication networks – Network and system
security – Part 2-1: Establishing an industrial automation and
control system security program
IEC TR 62443-3-1 Industrial communication networks – Network and system
security – Part 3-1: Security technologies for industrial automation
and control systems
IEC TS 62443-1-1 Industrial communication networks – Network and system
security – Part 1-1: Terminology, concepts and models
ISO 11801 Telecommunications installations – Generic cabling for customers
premises
ISO 24702 Telecommunications Installations – Generic Cabling – Industrial
Premises
ISO 24764 Information technology – Generic cabling systems for data centers
ISO 80000-1 Quantities and units Part 1: General
TIA TIA-568-C.2 Balanced Twisted-Pair Telecommunications Cabling and
Components Standards
TIA TIA-598-C Optical Fiber Cable Color Coding
TIA TSB-32-A Overall Transmission Plan Aspects for Telephony in a Private
Network

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3.2.1 Local Standards
SASO 752 Tests on Electric Cables Under Fire Conditions Part 1: Test on a Single
Vertical Insulated Wire or Cable
SASO IEC 61241 Electrical apparatus for use in the presence of combustible dust
(Series)
SASO IEC 60331 Tests for electric cables under fire conditions – Circuit integrity
SASO IEC 60332 Tests on electric and optical fiber cables under fire conditions
SASO IEC 60079 Electrical apparatus for explosive gas atmospheres – Classification of
hazardous areas (IEC 60079-10-1 and IEC 60079-10-2)
SASO IEC 60079 Electrical apparatus for explosive gas atmospheres
SASO IEC 60079.28 Explosive Atmospheres – Protection of equipment and transmission
systems using optical radiation
SASO IEC 60079-14 Explosive atmospheres – Part 14: Electrical installations design,
selection and erection
SBC 401 The Saudi Building Code – Electrical
3.2.2 Alternative Design Codes

British Standards, American (ANSI/TIA) or JIS standards to be used where no pertinent SASO
or IEC standards are available.
Alternative design codes may be used for Communications Design and Installations if
approved by the Employer.
3.2.3 Ma’aden Standards
MD-101-SMEM-EG-ME-SPC-0007 Standard Specification – Protective Coatings

MD-101-SMEM-EG-EL-SPC-0001 Standard Specification – Electrical and Instrumentation
Installation
MD-101-SMEM-EG-EL-CRT-0001 Design Criteria – Electrical
3.2.4 Site Data
All materials, equipment and work methods shall be suitable for the Site conditions as
defined in the applicable Site Data Specification.
4. DESIGN AND INSTALLATION REQUIREMENTS

Equipment and workmanship shall be suitable for continuous, safe, trouble free operation
when subjected to the operating conditions as detailed in the Standard Specification – Site
Data.

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4.1 Design Criteria

The Works shall be designed to ensure satisfactory operation in which the safe continuity of
service is the first consideration. The design shall also facilitate inspection, cleaning and
repairs. All equipment and cabling employed shall be selected and/or designed to ensure
satisfactory operation under the atmospheric conditions prevailing at the Site, and under
such variations of load as may be met with under working conditions on the system. Due
consideration shall be given to the environment in which equipment shall be installed at the
Site. The Site is characterized by the presence of the following conditions:
• Salt laden air
• Dust
• Direct sunlight and ultraviolet light
• Vermin
• Rodents
• Vibration
• Hazardous area installations.
4.2 Hazardous Areas

Installation of equipment in hazardous areas shall be in accordance with the requirements of
the standard specification for electrical installation. Electrical communications equipment
installed in hazardous areas shall be IEC certified as follows:
• Ex e in accordance with SASO IEC 60079 part 7 or Ex d in accordance with SASO
IEC 60079 part 1 for electrical equipment in Class 1 Zone 1 areas
• Ex i in accordance with SASO IEC 60079 part 11 for instrument equipment in Class II
combustible dust areas
• Ex i in accordance with SASO IEC 60079 part 11 or Ex d in accordance with SASO
IEC 60079 part 1 for instrument equipment in Class 1 Zone 1 and Class 1 Zone 2 areas
• Ex n in accordance with SASO IEC 60079 part 15 or Ex e in accordance with SASO
IEC 60079 part 7 for electrical equipment in Class 1 Zone 2 areas, and
• DIP in accordance with SASO IEC 61241 for electrical equipment in Class II combustible
dust areas.
The communication network designers, suppliers and installers shall consider the content
and requirements of SASO IEC 60079.28 (Explosive Atmospheres – Protection of equipment
and transmission systems using optical radiation), during the design, manufacture,
installation and commissioning phases of the Work. The intent is to ensure that optical
radiation from network equipment (especially high power long range laser or LED
transmission equipment) and from the fiber cable cannot be a source of ignition in a
hazardous area.

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4.3 Earthing
The installation of earthing cables shall be in accordance with the earthing requirements of
the standard specification for electrical installation. All equipment requiring earthing shall
be earthed with green/yellow PVC insulated cable sized and installed in accordance with the
requirements of standard specification for electrical installation.
4.4 Quality of Workmanship
All communications design and installation work carried out shall be to a high standard.
Personnel carrying out any particular task shall be suitably qualified, trained and possess the
necessary skills to complete the task safely and to a high standard of workmanship. The
Employer Representative reserves the right to inspect all works and direct re-work in the case
that the quality of work is not acceptable to the Employer.
All communications design and installation works shall be continuously and competently
managed and supervised at the workplace to ensure that the quality of the workforce is
commensurate with the level necessary to complete the installation activities to adequately
satisfy the requirements of this Specification and best trade practices. All installation works
shall be closely coordinated with all other site construction activities to ensure the safe,
quality and timely completion of all works.
4.5 Safety
All communications design and installation works shall be carried out in accordance with all
Site safety requirements in particular but not limited to those discussed in this section.
4.5.1 Tagging and Isolations
Tagging and isolations shall be in accordance with the standard specification Site
Requirements for Isolation from Hazardous Energy.
4.5.2 Excavations and Surface Penetrations
Excavations and surface penetrations shall be subject to the excavation permits procedure as
per site requirements for excavation and surface penetration.
4.5.3 Licensing and Registration
4.5.3.1 Electrical Licenses
All electrical work must be carried out or directly supervised by licensed electrical trades
persons holding current Electrical Workers Licenses (as per the Electrical Licensing
Regulations). A copy of the Electrical Workers License and residential address of each
electrical trades person shall be submitted to the Company Representative prior to the person
commencing work.
4.5.3.2 Data Cabling and Optical Cable Installation and Termination
All installation and termination of network cable, data cable and optical fiber cable, must be
carried out by persons who are registered telecommunications cable installers (Cabling
providers) as defined by Saudi Authority.

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4.5.4 Optical Communications – Lasers

The network equipment that shall be installed transmits data using optical devices which fall
under the safety requirements for laser devices. The requirements of IEC 60825.1,
IEC 60825.2 and IEC 60825.10 shall be complied with to ensure that the communications
network, optical equipment and optical fiber paths are installed and labeled correctly. In
particular, all optical sources that emit laser type light that can affect the eyes or sight of a
person, at any point in the transmission path, shall have labeling installed as described in
IEC 60825. Labeling shall be installed centrally on the outside of the cabinet door and in a
prominent position near the position where the optical path can be opened. This
requirement serves to provide installation, commissioning and ongoing maintenance staff
with a safe working environment.
4.6 Testing and Commissioning
Testing and commissioning of the communications design and installation works shall be
carried out in accordance with the requirements of this Specification.
4.7 Documentation
All communications design and installation works shall be fully documented in accordance
with this Specification. Design and “As-built” drawings and other documentation shall be
supplied in all instances to confirm the installed arrangement of all equipment.
4.8 Handover
Formal handover of all communications design and installation works shall occur upon
practical completion, the completion of all testing and commissioning and the submittal of
all appropriate “As-Built” documentation and test records.
Handover, where appropriate, shall be progressive, based upon the schedule of the works
being undertaken.
5. INFORMATION TECHNOLOGY CABINET DESIGN AND INSTALLATION

Information Technology Cabinets (ITCs) shall be designed and installed to house all
communications equipment including all FOBOTS, Patch Panels, servers and network
equipment. In some cases equipment power supplies, CCTV equipment and other electronic
equipment may also be installed in these cabinets. This section details requirements for the
design, assembly, outfitting and installation of IT Cabinets.
The types and quantities of equipment to be installed in each cabinet are nominated in the
ITC data sheets.
5.1 Design and Construction
IT Cabinets shall be either full height, free standing, floor mounting or compact, wall
mounted units, depending on the location and the available space at the cabinet location.
All cabinets shall have the following characteristics:
• Be fit for purpose, of the same manufacturer, using the same component types – e.g.
Rittal
• Be of the same depth where they are bayed together

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• Be of an identical design and layout where they contain the same type and quantity of
equipment – e.g. Substation etc
• Be designed from a metal framework with bolt on top, bottom and side metal covers and
front and rear metal doors with windows where required. The cabinet shall have four
lifting eye bolts at the top and secured to the cabinet frame, and a full width and depth
bottom cable entry plate.
• Be designed for front rack mounting equipment, with the equipment height specified in
rack units (ru), or din rail mounting equipment. Equipment shall be mounted between
300 mm and 1800 mm above the building floor level or false floor level for full height
cabinets.
• Be provided with louvered and filtered air vents at the top of each cabinet mounted
within a building, to allow air movement by convection. The louvers and filters shall
not diminish the ip rating of the cabinet.
• Be provided with a three point door latching mechanism. A door key lock is not
required.
Overall cabinets dimensions and characteristics shall be as follows:

• Data Centre IT cabinets for computer servers and network equipment shall be 800 mm
wide by 1000 mm deep, have front and rear doors, and be of the manufacturer’s
standard color. Data Centre IT Cabinets shall have a degree of protection rating of IP42.
• IT cabinets installed in substations and switchrooms shall be 800 mm wide by 800 mm
deep, have a front door only, and be painted in color specified by the Employer.
Substation and switchroom IT Cabinets shall have a degree of protection rating of IP53.
• IT Cabinets installed in outdoor locations in switchyards, outside buildings or within
plant structures shall be 800 mm wide by 800 mm deep and 1500 mm high and shall
have a front door only. The cabinet shall have a 90 mm channel mounting base and a
slanted roof with front and rear overhang to reduce internal heating from solar radiation.
The cabinet shall have sun shades on each side and the back to reduce internal heating
from solar radiation. IT cabinets for outdoor installation shall be manufactured from type
316 stainless steel with a type 4 finish. Switchyard and externally mounted IT Cabinets
shall have a degree of protection rating of IP66.
• IT cabinets installed in other buildings shall be 800 mm wide by 800 mm deep, have a
front door only, shall be painted in color specified by the Employer and shall have a
degree of protection rating of IP53
• all IT Cabinets Doors shall have a metal holder for drawings and documents welded to
the inside of the IT Cabinet front door. The metal holder shall be painted in the same
color as the door and the rest of the IT Cabinet.
• IT cabinets installed in buildings with space constraints shall be wall mounted and of
standard dimensions capable of housing all equipment adequately. The IT Cabinet color
shall be determined by location, being B12 Royal Blue in substations, switchrooms and
of the manufacturer’s standard color elsewhere.

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All internal floor mounted cabinets shall have a maximum height of 2000 mm and a 90 mm
channel plinth. Cable entry shall predominantly be from below; however, in some instances
may be from above. If cable entry is from above the cabinet or above a row of cabinets, then
the Contractor shall provide a purpose built horizontal cable duct with removable top cover
above the cabinet(s) and for the full row length of the cabinet(s). The horizontal cable duct
shall have an enclosed vertical duct which connects to the top of each IT cabinet for
protection of the cabling in and out of the cabinet.
For cabinets installed within Data Centre Rooms, the weight of each cabinet and all the
specified equipment within the cabinet, shall not exceed the maximum loading per square
meter of the Data Centre false floor. In addition, each cabinet within the Data Centre shall
have a clearly visible label on the front of the cabinet framework stating the maximum
permissible equipment load in kilograms.
5.2 Mounting
Each cabinet shall be bolted to the floor in the room or building in which it is installed or to
the concrete footing for outdoor cabinets, as shown on the building and cabinet plan. The
bolting mechanism shall be sufficient to prevent the cabinet from falling over if any of the
sliding rack mounted equipment is extended outside of the cabinet. Note that this may
require special securing arrangements for cabinets installed in the Data Centre above the
false floor. Holes in the building floor or false floor for the installation of cables and conduit,
directly below the cabinet shall be cut following approval from the Company. The method
for cutting any holes in building floors shall be approved by the Company before the hole is
cut.
After the installation of the cables, the Contractor shall seal all holes that they have cut, in
accordance with the requirements of the standard specification for electrical installation,
except in the case of the Data Centre false floor where the penetrations will be made tidy
and left unsealed to aid cool air movement from below the floor.
5.3 Power Supply
Power shall be provided to IT Cabinets as follows:
• In Data Centres where the cabinet contains computer server or process control
equipment – dual 220 V AC feeds from UPS circuit breakers where the cabinet requires
power, one from UPS A and one from UPS B
• In substations where the cabinet contains IT or process control network equipment or
process control equipment – dual 220 V AC feeds from circuit breakers, one from the
substation UPS distribution board, the other from the substation mains distribution board
• In Site/office buildings where the IT Cabinet contains IT network equipment or other non
process control equipment – single 220 V AC feed from a circuit breaker
• In field locations where the IT Cabinet contains IT or process control network equipment
– dual power supplies from the nearest substation UPS distribution board and mains
supply distribution board.

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Each cabinet shall be provided with individually switched power outlets rated at 10amp and
220V AC. Each cabinet shall have sufficient switched power outlets for all the equipment
installed within the cabinet, as well as at least two spare switched power outlets. The
switched power outlets shall be mounted at least 500 mm above the cabinet floor level, and
in positions that allow maintenance personnel direct access to the switched power outlets
when the cabinet doors are opened. A cable duct shall be provided on each side of the
cabinet to hold the equipment flexible power supply cord. For cabinets with dual power
supplies (either UPS/UPS or UPS/Mains), switched outlets shall be arranged such that the
outlets from one source are on one side of the cabinet, and outlets from the alternate source
are on the other side of the cabinet.
Where required IT Cabinets will be fitted with the ancillary equipment nominated in Table
5-1.
Table 5-1 : IT Cabinet Ancillary Equipment
Ancillary Equipment Required For/Use
Two switched outlets fed from a non UPS 220 VAC For maintenance personnel to power
distribution board. diagnostic and configuration
equipment.
Dual redundant 220 VAC/24 VDC 10 amp power To provide redundant power to process
supplies. One 24 VDC power supply shall be fed network communication switches.
from the first source (UPS) while the other 24 VDC
power supply shall be fed from the second source
(UPS or Mains).
24 VDC 11 watt fluorescent light fitting, installed at To provide internal light to

the top of substation cabinets and outdoor mounted maintenance and fault finding
cabinets with a door operated switch. The light shall personnel during low light and night
be powered from the 24 VDC UPS cabinet supply. time conditions.
Terminal strips and miniature circuit breakers (MCBs) For cable and core connections, supply
for distribution of the 220 VAC and 24 VDC supplies. distribution and isolation and
The terminal strips and MCBs shall be selected from protection of cables and equipment.
the types given in the standard electrical
specification.
5.4 Earthing
All Information Technology Cabinets shall have:
• An earth stud. An earth cable shall be connected between the earth stud and the
cabinet’s power supply(s) earth. A separate 4 mm2 earth cable will be connected
between the stud and the substation or building earth bar or to the plant earth grid.
• Earth straps between the cabinet framework and each cabinet door and removable
panel.

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5.5 Internal Operating Temperature

Each cabinet shall be designed such that the internal temperature within the cabinet remains
below the lowest maximum operating temperature rating of the equipment within the
cabinet, when all the equipment is powered and operating, and the cabinets doors are shut.
For example, if the lowest maximum operating temperature rating of all the equipment is
35°C (as specified by the equipment manufacturer), then the maximum internal temperature
within the cabinet must remain below 35°C when all the equipment is operating, and the
cabinets doors are shut.
Cabinets installed in a Data Centre, shall be installed over a false floor. The air volume
below the false floor shall be pressurized from the room or building air conditioning system,
to allow cool air to flow into the cabinets, and assist equipment cooling.
Each substation, switch room and switch yard cabinet shall be fitted with a volt free contact
adjustable temperature switch which shall be wired to the Plant Control System (PCS). The
temperature switch shall be fail safe, i.e. it shall provide a positive signal to the PCS when
the temperature is within the set limit and shall open when the temperature exceeds the set
limit. The temperature switch shall be mounted at the top of the cabinet.
Each data centre cabinet shall be fitted with an RTD (PT100) or equivalent temperature
sensor to provide an analogue signal of the internal cabinet temperature. The temperature
sensor shall be wired to the PCS. The temperature sensor shall be mounted at the top of the
cabinet, in a position where it is exposed to the main air stream rising from the equipment.
5.6 Equipment Installation
The following type of equipment shall be installed in the IT Cabinets:
• Network communication switches and routers for IT networks
• Network communication switches and routers for the plant control system equipment
• Computer servers and KVM units
• Fiber optic breakout trays for termination of optical fiber cables
• Network cable patch panels for termination of network cables
• Cable organizers for network patch leads and fibre optic patch leads
• 220 VAC power distributor units
• UPS units if practical
• 24 VDC power supplies for plant control system equipment
• Slotted cable ducts, and
• Electronic equipment such as CCTV video encoders that connect to the network
equipment.
Exact details of the equipment are provided in the contract scope specification and IT
Cabinet data sheets.

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Network and server equipment that produce heat shall be installed in accordance with the
equipment manufacturer’s recommendations for mounting equipment and cooling gaps
between equipment. Network equipment and computer server equipment shall be mounted
to ensure that there is a clear air flow path for air into the equipment fan and out of the
equipment.
Heavy equipment shall be mounted at the bottom of the cabinet, to prevent consequential
damage if the securing screws fail or while the equipment is being installed or removed.
Equipment layout and cabinet general arrangement drawings shall be produced for each IT
Cabinet and shall be approved by the Employer before any equipment is installed in the IT
Cabinet.
Where equipment is mounted onto 483 mm (19”) rack mounting rails, the equipment shall
be secured with the correctly sized slotted screws, spring washers and caged nuts in each
and every mounting hole of the equipment. All slotted screws shall be clearly accessible
from the front or the rear of the cabinet.
Where equipment (e.g. computer servers) are supplied with draw out rails which clip into
the racking rail mounting holes, then each draw out rail shall have two clips at the front and
two clips at the rear of the IT Cabinet, to support the equipment.
Where equipment is mounted onto DIN rail, an appropriate DIN rail shall be installed so that
the equipment is flush with the front of the cabinet, in line with any 19” rack mount
equipment. The DIN rail shall be secured to the 483 mm (19”) rack mounting rails with
slotted screws, spring washers and caged nuts. The DIN rail mounted equipment shall be
fully accessible from the front of the cabinet for connections, configuration and maintenance.
Electronic equipment such as CCTV video encoder units shall be mounted in the ITC on a
pan with draw out rails to gain access to the equipment and cable connections. The
electronic equipment shall be held in place on the pan with a metal strap and nuts and bolts.
Where the electronic equipment requires a 220 VAC/12 VDC power converter, it will also
be strapped on the pan. The 220 VAC power cable will be plugged into an outlet on the
UPS supply.
The field cabling (external to the IT cabinet and building) to electronic equipment such as
CCTV video encoders shall have surge protection devices to prevent transient voltages from
damaging the equipment and subsequently damaging the network switch. The surge
protection equipment shall be installed on all field cables for the equipment, e.g. the CCTV
video coaxial cable and the serial communications cable for camera control data (e.g. RS485
signals).
6. COMMUNICATIONS CABLE DESIGN AND INSTALLATION
Communications equipment shall interconnect via communications cables. Optical fiber,

Category 6 data cabling and Category 5e screened data cabling shall be used. This section
details the selection, installation, termination and testing requirements for all
communications cabling for use into and out from IT Cabinets.

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6.1 Optical Fiber Cable

6.1.1 Selection
Optical fiber cable for use on the Project shall meet the requirements of the following
standards and codes:
• ISO 24702
• IEC 60793
• IEC 60794.
6.1.1.1 Optical Fiber Cable

The fibers and tubes of all optical fiber cable shall be color coded. The color code for
optical fiber cores and buffer tubes shall comply with TIA TIA-598-C using the color
sequence Blue, Orange, Green, Brown, Grey, White, Red, Black, Yellow, Violet, Pink, Aqua.
Optical fiber cables shall have a clearly legible cable length marker at regular intervals not
exceeding five meters along its outer sheath. The cable marker shall indicate manufacturer,
ACA identification code, cable type/model, the number of fibers and the cable length
marker.
Optical fiber cables shall meet the following requirements:

• Be of high strength construction
• Loose buffer tube internal construction
• Loose buffer tubes shall be filled with an electrically non-conductive gel (jelly filled)
• Loose tube cables shall have a maximum of 12 optical fiber cores per tube, with up to 5
tubes per cable.
Outer construction:
• A polyethylene inner sheath, then
• A corrugated steel tape (for protection against rodents and vermin), then
• A polyethylene sheath, then
• A jacket of compound providing resistance to insects (termites), then
• A sacrificial uv resistant pvc or polyethylene sheath for protection against damage during
installation.
All optical fiber shall be single-mode (9/125 µm) employing single-mode optical glass fiber
(Corning SMF-28e or similar quality) and have the following physical characteristics:
• A nominal mode field diameter of 9 µm
• A cladding diameter of 125 µm
• A nominal primary coating diameter of 250 µm.

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All optical fiber cables shall be supplied on a drum, with a schedule showing the drum
tested total attenuation per fiber core for the total length of the optical fiber cable. The tests
shall be carried out at a wavelength applicable to the cable type, namely 1300 mm. The
schedule shall include the drum number that the optical fiber cable is wound on, as well as
the Company’s purchase order number and the purchase order item number.
Tight buffered cable shall be 900 µm with 3 mm jacket and shall only be used for pigtails
and for installation within cabinets.
6.1.1.2 Optical Fiber Patch Leads
All optical fiber patch leads shall be single-mode and have the following characteristics:
• Be tight buffered 9/125/250/900 µm figure-8 duplex cable with Kevlar buffering and
3 mm PVC jacket
• Be terminated by SC connectors with a ceramic ferule with an insertion loss of less than
0.4 db
• Have PC polishing
• Be provided with dust caps for all connectors
• Be yellow in color.
The SC connector plugs on each patch cable shall be color matched with the SC connector
socket on the fiber optic breakout tray.
Where network equipment cannot be supplied with SC connectors, the supplier/contractor

shall advise the Company in writing of the alternate optical fiber connector type required for
the equipment. The supplier/contractor shall not purchase the network equipment or
alternate fiber patch leads without approval from the Company.
All fiber patch leads shall be labeled at both ends using self laminating vinyl white labels.
6.1.1.3 Optical Pilot Ground Wire
Optical Pilot Ground Wire provides optical fibers installed in loose tubes in an aerial ground
wire conductor.
The construction of the Optical Pilot Ground Wire (OPGW) shall conform to the
requirements of IEC 60794-3-20 and IEC 60794-4.
The OPGW construction shall consist of:

• 12, 24 or 36 single mode optical fibers
• Loose buffer tube internal construction
• Loose tube OPGW shall have a maximum of 12 optical fiber cores per tube, with up to
3 tubes per cable. The color code for the optical fiber cores and buffer tubes shall
comply with tia-598-c using the color sequence blue, orange, green, brown, grey, white,
red, black, yellow, violet, pink, aqua.
• Loose buffer tubes shall be filled with an electrically non-conductive gel (jelly filled)
• Each loose tube shall have a heat resistant high strength aramid yarn

Page 17 of 29
• The optical fiber core loose tubes shall be contained in an aluminum tube, with a
hydrogen absorbent jelly between the loose tubes and the aluminum tube internal wall
• The aluminum tube shall be surrounded by at least one layer of aluminum clad steel and
aluminum alloy wires which comprise the earth conductor. The physical size and
current carrying capacity of the aluminum clad steel and aluminum alloy wires shall
meet the electrical requirements of the overhead line. The ratio per layer of aluminum
clad steel to aluminum alloy wires shall be 1:2.
6.1.2 Storage and Handling

Optical fiber cable shall be supplied and transported on drums. Drums shall be lifted and
moved by applying force to the drum rim or centre axis only. Care shall be taken to prevent
any possible damage to the cable surface, the cable construction and cable cores.
Prior to installation, the cable drum shall be checked for any sign of damage or mishandling.
The outer layer shall be examined carefully for signs of scratching or tearing.
6.1.3 Installation
6.1.3.1 Optical Fiber Cables
Optical fiber cables shall be installed strictly in accordance with the manufacturers
specifications, the requirements of the standard specification for electrical installation, and
the following specific requirements.
The optical fiber cable manufacturers recommendations for maximum installation tension,
crush resistance and minimum bending radius shall be carefully observed at all times. The
ends of optical fiber cables shall be sealed to prevent the drying out of the jelly fill and to
prevent the intrusion of air, moisture and dust during installation and while in storage.
Optical fiber cables shall be installed in one continuous length from building to building. If
the length of cable run exceeds the length of cable left on a drum then the Company shall
decide if it is acceptable to splice two cable lengths together. If a splice is required, then the
fusion splice between the two cables shall be carried out in accordance with Section 6.1.4,
and the splice cassette housed in a type 316 stainless steel field junction box with a bolted
cover.
Labels shall be fixed to cables in suitable locations near termination points and building
entries to allow clear visibility following cable installation. Cable labeling shall be in
accordance with the requirements of the standard specification for electrical installation.
Optical fiber cable shall generally be installed via three methods, namely:
• Above ground in cable ladder/tray in ABS conduit
• Below ground where required in conduit/duct for cable runs less than 400 m
• Direct buried where required for runs exceeding 400 m in length.

Page 18 of 29
Above ground, optical fiber cables shall generally be installed in control, instrument and
communications cable trays. However, optical fiber cables may be installed on HV or LV
cable trays where required. Optical fiber cables installed on cable trays shall be installed in
50 mm minimum diameter ABS conduit along straight runs of cable tray. The conduit shall
be secured to the cable tray using metal saddles. The ABS conduit is required to prevent
physical damage to the optical fiber cable, resulting from the installation of other cables or
from impacts from other objects.
Between cable trays or where cable trays intersect, the optical fiber cable shall be installed in
flexible ‘Anaconda’ 50 mm minimum diameter conduit, securely connected to the ABS
conduits. At one of each pair of ABS/Anaconda connections, a removable cover draw box
shall be installed to assist future installers to run in new cables. A draw wire shall be
installed in the ABS/Anaconda conduits to allow future installers to draw in the new cable.
Where two optical fiber cables follow the same path and form a redundant communications
pair, then the cables shall be installed in ABS conduit on separate cable trays
(control/instrumentation tray and HV tray/ladder), and as far apart as practicably possible.
This is to minimize damage to both optical fiber cables if the cable trays are physically
damaged.
For below ground installations within the plant (runs less than 400 m) optical fiber cables
shall be installed in 100 mm minimum diameter white (telecommunications) underground
PVC conduits. Conduits shall be installed in straight lines wherever possible. A draw wire
shall be run for future cable installations. A minimum separation of no less than 300 mm
shall be maintained between conduits carrying optical fiber cables and other cables and
services.
Cable draw pits shall be provided at all changes of direction and every 100 m along straight
runs for cables installed below ground in conduit. Pits shall also be provided on either side
of any road crossing. Pits shall be sized to allow pulling of cables without exceeding the
manufacturers recommended bending radius of the optical fiber cables to be installed.
Conduits shall enter pits on the vertical centre line with a minimum clearance of 50 mm
from the bottom of the pit, and shall extend into the pit by a minimum of 50 mm.
Cable draw pits shall be an approved, prefabricated, fiber reinforced concrete type or formed
of concrete in situ. Lids for locally poured pits shall be galvanized steel and shall be fitted
with handles to aid in removing the lids. The handles shall lie flat when not in use.
Where optical fiber cables run through cable pits or pull boxes or enter or exit a building a
loop of cable with a sufficient radius to allow at least one splice shall be installed. The cable
loop shall be adequately secured and supported.
Optical fiber cables shall be direct buried for run lengths greater than or equal to 400 m. A
minimum separation of no less than 300 mm shall be maintained between optical fiber
cables and other cables and services.
Where two optical fiber cables follow the same underground path and form a redundant
communications pair, then:

Page 19 of 29
• Direct buried cables shall be installed on either side of the service trench, and as far
apart as possible
• Cables in conduit shall be installed in a separate conduit and the two conduits shall be
installed on either side of the service trench as far apart as practicable.
At building penetrations that shall be sealed with mortar after cable installation, the optical
fiber cable shall be installed in a galvanized steel conduit for the length of the optical fiber
cable that passes through the penetration and for 200 mm on either side of the building wall.
This requirement is to prevent damage to the optical fiber cable if a contractor installing
another cable, punctures through the mortar with a sharp implement and spears the optical
fiber cable. After the optical fiber cable and conduit are installed, both ends of the conduit
shall be filled with a waterproof sealer.
Where optical fiber cables enter a substation, switch room, or building from a cable ladder,
or enter a cabinet from below a false floor a loop of 5 m of cable shall be left on the cable
ladder or below the false floor to allow a future re-termination of the optical fiber cable.
Where there is no cable ladder or false floor below the cabinet, then a double loop of cable
(minimum of 2 m) sufficient to allow a re-termination shall be left inside the termination
enclosure.
An additional allowance of 10 m shall be made for termination at each end of the optical
fiber cable run prior to cutting. The ends of the optical fiber cable shall be sealed
immediately after cutting to prevent loss of the tube gel, and to prevent ingress of
contaminants.
6.1.3.2 Optical Pilot Ground Wire
Since Optical Pilot Ground Wire is part of the aerial ground wire for an overhead line
installation, then installation of the ground wire will be carried out by the overhead line
installer.
The extraction and termination of the optical fiber cores shall be carried out by a qualified
optical fiber termination contractor who has experience in the extraction of the optical fiber
aluminum tube and the termination of the optical fibers from OPGW. The OPGW shall be
clamped at the top of the pole to support and tension the line, and the OPGW shall be
brought down the pole for termination in a splice enclosure. Within the splice enclosure the
fibers may be:
• Fusion spliced to the next section of OPGW and continue to the next pole, or
• Fusion spliced to an optical fiber cable to loop into and out of a building and an IT
Cabinet, and then continue in OPGW to the next pole.
Each section of OPGW shall have two loops coiled on steel support brackets on the pole,
before the OPGW enters the splice enclosure. The OPGW loops and the splice enclosure
shall be no less than 3 m above finished ground level to prevent accidental damage or
malicious damage to the OPGW and splice enclosure.

Page 20 of 29
The optical fibers in the aluminum tube shall only be extracted from the OPGW and
aluminum tube when the OPGW is within the splice enclosure. The splice enclosure shall
be specifically manufactured for the extraction and termination of fibers from the OPGW.
The splice enclosure shall be securely bolted to the pole. The extraction of the optical fibers
and fusion splicing within the enclosure shall be carried out in accordance with the splice
enclosure manufacturer’s instructions and recommendations.
The OPGW shall be secured to the pole at a minimum of two locations between the OPGW
support and tension clamp and the splice enclosure. The method of securing the OPGW to
the pole shall provide an earth path to the pole to direct transient voltages away from the
splice enclosure. If the pole is a not a steel pole, then a 120 mm2 earth cable shall be run
from the OPGW securing point to an earth stake at the base of the pole.
If the splice enclosure has an optical fiber cable to connect the fibers to a building and IT
Cabinet then the optical fiber cable corrugated steel tape shall not terminate or touch any
part of the splice enclosure or the aerial line pole. The optical fiber cable corrugated steel
tape shall be insulated from the glanded entry into the IT Cabinet in the building. This is to
prevent any induced transient voltage from travelling down the OPGW and then along the
optical fiber cable steel tape and into the metal frame of the IT Cabinet where the transient
voltage may damage electronic equipment.
6.1.4 Termination
Termination of optical fiber cables shall be performed only by qualified personnel with the
appropriate training and who have been approved by the Company.
Each fiber shall be cleaned and prepared in accordance with the manufacturer’s instructions
prior to cleaving and splicing. Care shall be taken not to exceed the manufacturer minimum-
bending radius for the individual fibers.
All cores of the optical fiber cable shall be broken out, cleaved and fusion spliced to SC
pigtails within a fiber optic breakout tray (FOBOT). Cleaving shall be performed using a
purpose built cleaving tool.
Each fusion splice shall be supported in clear heat shrink tube with a stainless steel rod to
provide structural strength to the fusion splice. The splices shall be individually secured
within a splicing cassette. The minimum fiber pigtail length shall be 500 mm. Each pigtail
shall be labeled with the fiber number/color.
After removal of the outer sheath, heat shrink shall be applied to the end of the cable to
prevent the loss of gel. The central strength member of the optical fiber cable shall be
secured to the FOBOT to prevent stress or strain on the individual fibers.
The pigtail SC connectors shall be plugged into an SC connector alignment socket on the
FOBOT front panel and fitted with dust caps. The fiber core number shall be marked on the
FOBOT.

Page 21 of 29
6.1.4.1 Fiber Optic Breakout Trays (FOBOTs)

Fiber optic break out trays (FOBOTs) shall be 483 mm (19 inch) rack mount type with
internal dimensions sufficient for coiling of fibers without exceeding the fiber bending radius.
One FOBOT shall be provided for each optical fiber cable. A clamping arrangement for the
splice cassette shall be provided. The FOBOT shall allow for labeling of each connector and
shall have a core usage sheet. The FOBOT front panel shall have a label:
• Stating the FOBOT number
• The optical fiber cable number
• The FOBOT number for the remote end of the optical fiber cable
• The location of the remote end of the optical fiber cable (e.g. Sub 4, Data Centre).
All labels shall be Traffolyte type with black lettering on a white background. All FOBOT SC
connectors shall be supplied with dust caps.
FOBOTs shall be installed in IT cabinets at a height between 300 mm and 1800 mm above
building, substation or false floor level. Wherever possible, FOBOTs shall not be installed at
eye level, to remove eye hazards associated with laser radiation. All FOBOTs shall have a
label in accordance with IEC 60825 advising personnel that the fibers are transmitting laser
type radiation. The label text shall be determined from the Class type of the laser radiation
in accordance with IEC 60825.
6.1.5 Testing
The following sections specify the tests required at each stage of the optical fiber cable
installation, to confirm that optical fibers have not been damaged or have an attenuation in
excess of the manufacturer’s specified tolerance and the calculated design tolerance. Two
tests shall be carried out. The first is performed while the cable is on the drum, while the
second test is performed following splicing and termination.
6.1.5.1 Drum Testing
The purchaser of the optical fiber cable shall ensure that the cable manufacturer carries out
OTDR tests on each fiber core on the cable drum prior to transportation to site. The
wavelength to be used for testing is 1300 nm for single mode cable. The cable manufacturer
shall supply a schedule of the attenuation results per fiber core for the cable.
After transportation to site the same tests as performed by the manufacturer shall be repeated.
OTDR tests shall be performed on each fiber core on the cable drum to check for cable
damage during transportation to, and handling on Site. The tests shall confirm the length of
the cable, check the integrity of each fiber core and provide an attenuation value of each
fiber core in dB/km. These tests shall serve as a reference for the cable after installation and
termination. The measured results shall be within 0.2 dB of the cable manufacturer’s results.
If the measured results are not within 0.2 dB of the cable manufacturer’s results, then the
Company shall be informed with probable reasons as to the discrepancies. The Company
shall decide the appropriate course of action for the drum and cable.

Page 22 of 29
All tests shall be witnessed by the Company. The cable shall be accepted when the OTDR
results are in alignment with the cable manufacturers specification and the cable
manufacturer’s OTDR measurements. Optical fiber cable installation shall only proceed
following approval of the drum tests by the Company Representative.
Prior to installation, each optical fiber cable shall be inspected for any signs of scratching,
denting or damage to the outer sheath of the visible portion of the cable. Any such damage
shall be reported to the Company.
6.1.5.2 Termination and Splice Testing
On completion of the fiber optic breakout procedure, termination and pigtail fusion, all fiber
splices and terminations shall be tested to ensure that total FOBOT to FOBOT losses are
within the calculated losses for the design, connections and cable route. All fibers
terminated shall be tested in both directions with an OTDR. These tests shall be witnessed
by the Company. The acceptance criteria shall be:
• Splicing, termination and testing of the optical fiber cable shall be to the satisfaction of
the Company and comply with all contract documents, including this specification
• Losses due to fusion splices and terminations shall be less than 0.2 db
• The loss for each mated connector shall not exceed 0.4 db
• Cable losses shall be within the cable manufacturers specified tolerance
• The variation in attenuation between cores in any one cable shall be no more than
0.3 db
• The optical power margin for each optical fiber path in the system shall be more than
10 db when measured with an in-line optical fibre attenuator.
The criteria for system failure shall be a signal to noise ratio of less than 3 dB for analog
systems and a bit error rate (BER) worse than 10-7 for digital systems.
If the OTDR and optical power test results for each fiber core indicate that the acceptance
criteria listed above have not been met, then the splice, termination or cable shall be cut, re-
spliced and re-tested.
6.1.5.3 Test Reports
A test report signed by the optical fiber cable tester and identifying each cable and fiber
tested, shall be presented to the Company for approval. The report shall include the test
results at each stage of the optical fiber cable testing. The report shall include print-outs of
OTDR traces complete with set-up and measurement information and tables of all measured
values including cable numbers, cable lengths, insertion losses and attenuation values.
6.2 Data Communications Cable
6.2.1 Selection
All data communications cable and cable termination equipment for Ethernet Networks,
shall be Category 6 as defined by the Telecommunications Industry Association (TIA)
standard TIA TIA-568-C.2. The only exception to this shall be the network cabling and
equipment for the plant control system, where Cat 5e screened cable shall be used to
connect controllers and workstations in substations, Data Centre rooms and control rooms.

Page 23 of 29
Screened network cable will be used to reduce the impact of electromagnetic interference
from electrical equipment within the building. In this case all termination equipment (plug
and socket connector hardware) shall be designed for use with Cat 5e screened cable.
Category 6 cable and cable termination equipment are designed for a data transfer rate of
1000 Mbps (1GBps). This performance must be maintained throughout the site installation.
Category 6 cable installed within buildings (e.g. offices, laboratories, warehouses and
workshops), shall be unscreened cable.
Category 6 patch leads for connecting between telecommunications outlets and network
equipment, and network switches and network equipment shall be unscreened Category 6
cable with certified Category 6 RJ45 connectors.
Category 6 cable shall be used on the Company’s information technology network – for
computer servers, personal computers, printers, plotters and Voice over IP telephone system.
Category 5e screened cable shall be used on the Company’s process control system network
– for control system servers, control system workstations, process controllers and remote I/O
networks.
Where there are separate and distinct sections and uses for the Company’s site IT Network,
the Category 6 cables for each section and use will follow a color scheme. The Contractor
shall design a network cable color scheme to suit the sections and use of the network. The
color scheme shall be approved by the Company before purchase, supply and installation of
the network cables. The color of the outer sheath of network cables shall not conflict with
any existing cable sheath color that has been identified, wherever practicable.
All Category 6 cable termination equipment, connecting hardware and fittings shall be rated
as Category 6, to ensure that the bandwidth and performance of the channel achieves the
Category 6 requirements. Category 5 or 5e cable terminating hardware and connecting
equipment shall not be used, as this shall reduce the performance of the network installation
below the Category 6 requirements.
All Category 6 data cabling and equipment design and installation shall be warranted for a
minimum of 10 years.
6.2.2 Installation
Installation of Category 6 cable or Category 5e screened cable shall be carried out in
accordance with the following specifications and standards:
• ISO 11801 – Telecommunications installations – Generic cabling for customer premises
– for office based installations (applicable to Category 6)
• ISO 24702 – Telecommunications installations – Generic cabling for industrial premises
– for industrial and process plant based installations (applicable to Category 5e
screened).
Category 6 and Category 5e screened cabling shall be installed between:

• Network switches and patch panels (installed in itcs)

Page 24 of 29
• Patch panels and network outlets within buildings and substations

• Network outlets and equipment.
All Category 6 and Category 5e screened cables and patch leads shall be labeled at both
ends using self laminating labels.
Specific requirements for installing Category 6 cables are listed below:

• Where Category 6 cables do not leave the ITC, they shall be neatly bundled together and
held in place with cable ties. There shall be no more than 24 Category 6 cables per
bundle. The cable ties shall not be tightened such that the physical shape of each
Category 6 cable is distorted, which may result in a system performance below the
Category 6 specification. Cable ducts shall be installed on the sides of the cabinets to
neatly contain the Category 6 cable bundles. The cable ducts shall be sized to contain
the cables from the network equipment to the network patch panels, with 24 cables per
bundle. The Category 6 patch cable lengths shall be chosen to ensure that excess cable
is not folded into the ducts or is minimised in the duct. The design and layout of the IT
Cabinet cabling shall consider the number of network switch ports installed in the
cabinet, the number of patch panel ports installed in the cabinet and the quantity and
length of patch cabling between the network switch ports and the patch panel ports.
These parameters shall be used to determine the size of the cable ducts to meet the
design criteria and ensure that all patch leads are contained in the cable ducts with the
cable duct cover in place.
• Where Category 6 cables leave an ITC they shall be routed through a 24 port Highband
Category 6 Patch Panel installed in the ITC. The patch panel shall be supplied with a
label above each patch port, and the label shall state the port number. All network port
numbers within a building shall be consecutive, there shall be no duplication of port
numbers in the IT Cabinets or in the building. A separate schedule within the cabinet
shall cross reference the patch port number with the destination port or equipment that
the Category 6 cable is connected to.
• Where Category 6 cables leave an ITC they shall be run in conduit or on cable tray, from
the ITC to either the building roof space or in the building false floor. Vertical runs of
the Category 6 cable shall be properly supported within the ITC to prevent tension and
stress to the cable cores and connectors.
• Where Category 6 cables are run in the building roof space or under a false floor, they
shall be neatly bundled on cable tray and held in place with cable ties, with 24 cables
per bundle. The cable ties shall not be tightened such that the physical shape of each
Category 6 cable is distorted, which may result in a system performance below the
Category 6 specification.
• Where Category 6 cables are run in wall cavities, they shall be run in conduit
• Where Category 6 cables must be run on a wall surface, they shall be run in conduit,
and the conduit color shall be white.
Specific requirements for installing Category 6 cables or Category 5e screened cables in
substations, switch rooms and switch yards are listed below:

Page 25 of 29
• Where Category 6 or Category 5e screened cables do not leave the ITC, they shall be
neatly bundled together and held in place with cable ties, with no more than 24 cables
per bundle. The cable ties shall not be tightened such that the physical shape of each
Category 6 cable or Category 5e screened is distorted, which may result in a system
performance below the cable specification.
• Where Category 6 cables or Category 5e screened cables leave the ITC they shall be run
in conduit, from the ITC to the cable destination e.g. Equipment or a
telecommunications outlet. Multiple Category 6 cables or Category 5e screened cables
may be bundled in the conduit, provided that each cable is run in conduit for the entire
path. Where possible, the conduit containing the Category 6 cables shall be installed on
cable ladder. The conduit colour shall be white.
• Where Category 6 cables or Category 5e screened cables are run in wall cavities, they
shall be run in conduit
• Where Category 6 cables or Category 5e screened cables must be run on a wall surface,
they shall be run in conduit, and the conduit color shall be white.
6.2.3 Termination
Category 6 cable shall always be terminated in equipment that has been designed for and is
rated as Category 6.
Where the Category 6 cable plugs into a patch panel or a wall socket telecommunications
outlet, it shall be terminated in a Category 6 RJ45 plug. Where the Category 6 cable
terminates at a wall socket telecommunications outlet, the socket shall be a Krone Highband
Flush Mount Category 6 outlet. The termination of the cable pairs in an RJ45 plug or on the
socket outlet shall be in accordance with the TIA TIA-568-C.2 standard. The Category 6
outlets shall be mounted in a Krone flush mounting plate, with a label above each stating the
outlet port number.
Category 5e screened cable shall always be terminated on equipment that is designed for
and is rated as Category 5e screened. The patch panels in the ITC for Category 5e screened
cables shall have RJ45 sockets with a shield. The Category 5e screened patch cables and
outgoing Category 5e screened network cables shall make contact with the RJ45 socket
screen, such that there is electrical continuity of the screens from the patch cable to the
outgoing network cable. For a Category 5e screened network cable path, the cabling screen
shall only connect to earth at the patch panel. The cable screens shall not connect to earth at
the network switch equipment nor at the end equipment communications module.
Where a Category 5e screened cable terminates at a wall socket telecommunications outlet,

the socket shall be an AMP SL Series 110 Category 5e modular shielded jack with rear entry
– AMP part number 1375189-1. The termination of the cable pairs in an RJ45 plug or on the
socket outlet shall be in accordance with the TIA TIA-568-C.2 standard. The Category 5e
shielded outlets shall be mounted in a Krone flush mounting plate, with a label above each
stating the outlet port number.
6.2.4 Certification Testing
All network cabling including:
• Category 6 cable installations

Page 26 of 29
• Category 6 patch leads

• Category 5e screened installations
• Category 5e screened patch leads
shall be tested using certified and calibrated network cable test hardware. The test hardware
shall be capable of carrying out tests for both Category 6 and Category 5e screened cables to
confirm:
• Cable bandwidth
• Cable near end crosstalk (next), equal level far end crosstalk (elfext) and return loss (rl)
• Cable core end to end continuity.
Certification and calibration sheets shall be provided to the Company. The Company shall
witness the tests on all the installed:
• Category 6 cables
• Category 6 patch leads
• Category 5e screened cables, and
• Category 5e screened patch leads.
The testing includes a complete cable path test from the cable end that plugs into the
network switch to the cable end that plugs into the destination equipment. The acceptance
criteria for the network cabling is that each cable path from the network switch to the
destination equipment provides the required Category 6 performance and bandwidth.
Certification testing shall be carried out by personnel who are qualified to use a Certification
Tester. The Certification Tester shall be a Fluke Networks DTX Cable Analyzer or
equivalent. Prior to cable certification, tests may be carried out to confirm the cabling
integrity and qualification using a Fluke Networks Cable IQ tester or equivalent.
Qualification tests shall not replace Certification tests. At the completion of the Certification
tests, the tester shall provide the Certification test results including graphs of the cable
performance for each cable, as a pdf file and in native test equipment format.
6.3 Low Voltage Power Cables
Selection and installation of copper cables for low voltage power and control signals shall be
in accordance with the requirements of the standard specification for electrical installation in
the plant.
6.4 Cable Tray
The routing and installation of cable tray and their supports shall be in accordance with the
standard specification for electrical installation in the plant.
6.5 Conduit
The routing and installation of conduit shall be in accordance with the standard specification
for electrical installation in the plant.

Page 27 of 29
7. QUALITY ASSURANCE
The Contractor shall provide all equipment, including inspection and testing in accordance
with the Contract equipment specification and the contract Quality System Requirements.
8. INSPECTION AND TESTING

8.1 General
Testing and commissioning of the works shall be carried out in accordance with the
requirements of:
• The contract specification for Electrical Equipment Testing and Inspection
• The Factory Acceptance Test procedure
• The Site Acceptance Test procedure.
8.2 Factory Acceptance Testing

All manufactured and assembled equipment covered by this specification shall be inspected
at the Contractor’s factory and then Factory Acceptance Tested to prove that the cabinets,
equipment and connection points meet the contract specifications.
The Contractor shall prepare a Factory Acceptance Testing (FAT) procedure for the Factory
Acceptance Tests for approval by the Company prior to testing being carried out. Within
one week after successful completion of the FAT, the Contractor shall issue to the Company
a FAT Report showing the results of all the tests carried out.
8.3 Site Testing
Site Acceptance Testing shall be carried out on all communications installations in
accordance with the inspection and test plan and procedure for each individual piece of
equipment nominated in this Specification.
The Contractor shall prepare the Site Acceptance Inspection and Test Plan and procedure.
Site testing and quality assurance activities may be witnessed and overseen by a third party
consultant appointed by the Company.
9. TRANSPORT, PACKAGING, HANDLING AND SHIPPING

All equipment shall be suitably packed to prevent damage during transport, handling and
extended storage on Site open to atmospheric conditions.
All assemblies and components supplied shall be adequately protected from damage during
transport.
Assemblies shall be wrapped in polythene, bolted to wooden bases and fully crated. All of
the equipment shall be adequately packed to permit storage in an outdoor environment
without deterioration for extended periods prior to installation in the final locations.
Components considered prone to damage such as servers and switches shall be removed and
packed separately for transportation. No loose items shall be transported in any part of an
assembly.

Page 28 of 29
Doors shall be closed and secured to prevent opening under the effects of vibration during
transport. Details showing how cabinets can be lifted and handled to allow transport and
installation shall be provided and attached to the cabinet when delivered.
All shipping items shall be:

• Clearly marked to facilitate erection and assembly on site
• Provided with lifting and handling instructions
Labeled with the company address, equipment number and order number.

Page 29 of 29

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Ma’aden Engineering Manual Rev.

Date: 31 Aug 2011

PROPRIETARY & Communications Design and Installation

6.5 Conduit ........................................................................................................................................ 27

PROPRIETARY & Communications Design and Installation

This Specification covers the minimum requirements for the:

2. KEY TERMS AND DEFINITIONS

PROPRIETARY & Communications Design and Installation

PVC Poly Vinyl Chloride

EIA 359-A Standard Colors for Color Identification and Coding

PROPRIETARY & Communications Design and Installation

IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards

PROPRIETARY & Communications Design and Installation

3.2.1 Local Standards

3.2.2 Alternative Design Codes

MD-101-SMEM-EG-ME-SPC-0007 Standard Specification – Protective Coatings

3.2.4 Site Data

4. DESIGN AND INSTALLATION REQUIREMENTS

PROPRIETARY & Communications Design and Installation

4.1 Design Criteria

4.2 Hazardous Areas

PROPRIETARY & Communications Design and Installation

PROPRIETARY & Communications Design and Installation

4.5.4 Optical Communications – Lasers

5. INFORMATION TECHNOLOGY CABINET DESIGN AND INSTALLATION

PROPRIETARY & Communications Design and Installation

Overall cabinets dimensions and characteristics shall be as follows:

PROPRIETARY & Communications Design and Installation

PROPRIETARY & Communications Design and Installation

Ancillary Equipment Required For/Use

24 VDC 11 watt fluorescent light fitting, installed at To provide internal light to

PROPRIETARY & Communications Design and Installation

5.5 Internal Operating Temperature

PROPRIETARY & Communications Design and Installation

6. COMMUNICATIONS CABLE DESIGN AND INSTALLATION

Communications equipment shall interconnect via communications cables. Optical fiber,

PROPRIETARY & Communications Design and Installation

6.1 Optical Fiber Cable

6.1.1.1 Optical Fiber Cable

Optical fiber cables shall meet the following requirements:

PROPRIETARY & Communications Design and Installation

Where network equipment cannot be supplied with SC connectors, the supplier/contractor

The OPGW construction shall consist of:

PROPRIETARY & Communications Design and Installation

6.1.2 Storage and Handling

PROPRIETARY & Communications Design and Installation

PROPRIETARY & Communications Design and Installation

PROPRIETARY & Communications Design and Installation

PROPRIETARY & Communications Design and Installation

6.1.4.1 Fiber Optic Breakout Trays (FOBOTs)

PROPRIETARY & Communications Design and Installation

PROPRIETARY & Communications Design and Installation

Category 6 and Category 5e screened cabling shall be installed between:

PROPRIETARY & Communications Design and Installation

• Patch panels and network outlets within buildings and substations

Specific requirements for installing Category 6 cables are listed below:

PROPRIETARY & Communications Design and Installation