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PROPRIETARY INFORMATION

This document contains proprietary information developed by and for exclusive use of Saudi Electricity
Company. Your acceptance of the document is an acknowledgement that it must be used for the identified
purpose/application and during the period indicated. It cannot be used or copied for any other purposes nor
released to others without prior written authorization of Saudi Electricity Company. Saudi Electricity Company
ci will not be responsible for misuse and/or misapplication, and any harm resulting therefrom. Saudi Electricity
z Company also reserves the right to take any necessary actions to protect its interest against unauthorized use.

APPROVED BY

Engr. Ghazanfar A. Iqbal Engr. Abdullah M. AI-Garni Engr. S~-Sohaibani

DivisionManager, Department Manager, Executive Director,
Transmission Lines Specifications Transmission Standards & Engineering & Projects
Specifications
Date of Approval: December 03, 2008
f ,
TRANSMISSION CONSTRUCTION STANDARD
TCST111.02RO/AGG PAGE NO. 1 OF 13
TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

TABLE OF CONTENTS

1.0 SCOPE

2.0 GENERAL

3.0 REQUIREMENTS FOR SEALING CONDUITS

4.0 SEALING COMPOUND (INSTALLATION)

5.0 SOLID RUBBER CONDUIT PLUGS (INSTALLATION AND REMOVAL)

6.0 SPLIT RUBBER CONDUIT PLUGS (INSTALLATION AND REMOVAL)

7.0 COMPLETION PROCEDURES

APPENDIX

TABLE 1 SOLID RUBBER CONDUIT PLUG SIZES

TABLE 2 SPLIT RUBBER PLUG SIZES
FIGURE TC-1102-0100-00 LEAD SHEATH STRIPS
FIGURE TC-1102-0200-00 SOLID RUBBER CONDUIT PLUGS
FIGURE TC-1102-0300-00 SPLIT RUBBER CONDUIT PLUGS
FIGURE TC-1102-0400-00 SPLIT RUBBER CONDUIT PLUGS WITH ELONGATED
BOLTS
FIGURE TC-1102-0500-00 SPLIT CONDUIT PLUG WRENCH
FIGURE TC-1102-0600-00 SPLIT CONDUIT PLUG REMOVER
FIGURE TC-1102-0700-00 INSERTING SLEEVE
FIGURE TC-1102-0800-00 PRESSING EXTRACTOR INTO POSITION
FIGURE TC-1102-0900-00 TURNING EXTRACTOR
FIGURE TC-1102-1000-00 PLUG REMOVAL

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 2 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

1.0 SCOPE

This Standard provides specific information and materials required to seal the conduits of
underground communication cable system of Saudi Electricity Company (SEC), Saudi
Arabia against entry of gas and water into the building from the conduit system and to
prevent the entry of water and other foreign material into the conduits from the building.

2.0 GENERAL

For all installation of conduits into cable vaults and other than cable vaults, the ducts shall
be sealed in accordance with this Standard.

3.0 REQUIREMENTS FOR SEALING CONDUITS

3.1 All conduits entering communication sites cable vaults or other buildings shall be
kept sealed at all times except when it is necessary to remove seal for performance of
work. When work extends overnight, a temporary seal shall be placed until the work
is resumed.

3.2 All conduits entering communication sites cable vaults shall be sealed with solid or
split rubber conduit plugs.

3.3 Conduits entering the buildings other than communication sites shall be sealed with
sealing compound. Conduits for drop wire or entrance cables (6 pairs or 2 pairs) to
buildings shall be sealed at the manhole if it is impractical to seal the conduit in the
buildings.

3.4 Sealing compound shall be used to seal all vacant cable riser openings between
switch rooms and cable vaults. Sealing compound shall be fire-resistant and self-
extinguishing.

3.5 Termination of conduits on poles and building wall shall have the ducts sealed with
rubber conduit plugs or sealing compound.

3.6 Unoccupied pipe conduits and pipe bends shall be sealed with pipe caps.

3.7 Conduits that are within the conduit system shall not be sealed except that sealing
compound will be used for temporary installations in individual manhole during
splicing or other tasks in the manhole.

3.8 Conduit not connected to conduit systems such as steel pipe clipped under other
structures, between poles to buildings and similar construction shall be sealed at both
ends. Seal occupied ducts with conduit plugs and unoccupied ducts/subducts with
pipe caps or sealing compound whichever is permissible.

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 3 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

4.0 SEALING COMPOUND (INSTALLATION)

4.1 The sealing compound is a substance suitable for sealing conduits. It shall be fire-
resistant and self-extinguishing.

4.2 All surfaces which are to come in contact with the compound shall be dry and
thoroughly cleaned to remove any grease, paraffin or other foreign material.

4.3 When the cable is inside in a horizontal conduit, apply a wrapping of either lead or
polyethylene tape as follows:

4.3.1 Wrap 25 mm wide strip of lead sheath around the cable to center it in the duct
and to act as backing from the compound (see Figure TC-1102-0100-00).

4.3.2 Wrap the cable to a diameter so that it just enters the conduit 50 mm in from
the face of the conduit.

4.3.3 Apply the sealing compound as described in Section 4.4.

4.3.4 25 mm wide strip of polyethylene sheath may be wrapped around the cable in
the same manner as for lead sheath. It will be necessary to apply two layers
of vinyl tape over the polyethylene strip bundle to hold the strips in place.

4.4 When sealing cables located in vertical conduits, work the sealing compound firmly
against the walls of the conduit and the cable. The remaining space shall be filled by
rolling a quantity of the material between the hands to form a rope slightly larger
than the space between the cable and the conduit. With the cable centered in the
conduit, wrap the material around the cable and force it into the conduit to a depth of
50 mm. Force the additional lengths of material into position until the seal can be
beveled slightly downward from the cable to the edge of the conduit.

NOTE: Do not use lead or polyethylene strips to center vertical cables.

4.5 When sealing vacant ducts other than cable vaults, prepare the vacant conduits for
sealing by first forming a backing of paper about 75 mm back of the conduit face.
Then, work the sealing compound firmly against the walls of the conduit. Fill the
remaining space by working the sealing compound in the conduit.

5.0 SOLID RUBBER CONDUIT PLUGS (INSTALLATION AND REMOVAL)

5.1 The solid rubber conduit plug shall be as described in Specification 23-TMSS-02.

5.2 Solid Rubber Conduit Plug sizes are listed in Table 1 and are used to seal vacant
ducts of a conduit system at cable vaults and such other locations as specified on the
work order plans.

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 4 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

5.3 Figure TC-1102-0200-00 illustrates the solid round conduit plugs. The individual
parts shown are available for replacements.

5.4 Remove any dirt, grease or loosely adhering material from the duct end and from the
edges of the plug. With the bolt and washers in place, insert the plug into the duct
with the nut outward and to a depth to afford the best bearing surfaces, and to permit
effective use of the wrench in tightening the nut. The plug shall be inserted far
enough into the duct to clear the bevel and beyond any large cracks on chipped areas
that may exist in the walls or webs of clay conduit.

5.5 Using the lineman's wrench, or other wrench suitable for use with a 12.5 mm
(1/2 inch) nut, turn the nut until the rubber is expanded firmly against the duct walls.
Excessive tension shall not be applied since extreme pressure (causing the rubber to
bulge out around the edges of the washer(s) is usually unnecessary and, in case of
clay conduit, may crack the walls. The recommended torque by the duct sealing unit
manufacturer shall be observed.

5.6 To extract the solid plug, first back off the nut a few threads to relieve the
compression in the rubber. By this, the plug can usually be withdrawn easily. If
relieving the pressure does not restore the rubber to its, original size or if it adheres
to the walls of the duct, it will be necessary to apply force to the plug to work it
loose. This can be done either by unscrewing the nut until about half the threads in
the nut are exposed and screwing another bolt into the exposed threads to act as a
handle on by twisting a piece of steel construction wire under the nut to which a
prying lever can be attached.

6.0 SPLIT RUBBER CONDUIT PLUGS (INSTALLATION & REMOVAL)

6.1 The split rubber conduit plug shall be as described in Specification 23-TMSS-02.

6.2 Split rubber plug sizes are listed in Table 2. These plugs are used to seal occupied
ducts of a conduit system at cable vaults, and such other locations as specified on
work-order plans.

6.3 Refer to Figure TC-1102-0300-00. The rubber portion of the plug is molded to fit
around the cables of varying diameters. The plug has a diagonal cut in one wall to
allow it to be placed over the cable and is furnished with sectional shaped to conform
to the plug. Compression of the rubber is accomplished by means of four 6.25 mm
carriage bolts which extend through the plates and the rubber portion of the plug.

6.4 In sealing 87.5 mm round conduit containing full size stalpeth or other polyethylene
sheath cable, a plug of the types shown in Figure TC-1102-0400-00 is used. The
restricted space between such cable and the duct wall requires the elongated bolts
with pipe spacers to make the nuts accessible to the split conduit plug wrench.

6.5 Before installing split rubber conduit plugs, examine the duct and remove any rough
spots or accumulations of grease on silt. Inspect the cable for kinks just inside the

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 5 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

duct, as the existence of such kinks will determine to some extent the depth to which
the plug is to place in the duct. Minor indentations of the sheath will be sealed by the
plug; but when deep kinks are found, it may be necessary to place the plug beyond
the kink or to use an alternative method of sealing to obtain water-tightness.

6.6 Inspect the rubber plug to see that the parts are properly assembled, with the nuts, all
in the same end and the split in the rubber covered by a section of metal plate of each
end. Examine the nuts to see that they are free and not compressing the rubber.

6.7 To place a round split plug, remove one of the bolts from the plugs having four
plates on each end of the one that passes through the cut in the rubber.

6.8 Slide the plug along the cable and into the duct. If difficulty is experienced in sliding
the plug into the duct, apply B or C pressure testing solution as a lubricant to the
cable and the inside of the plug. After the plug has been inserted in the duct, it will
usually be found possible to insert it completely by the application of steady
pressure. If it is necessary to apply additional force, proceed carefully to avoid
damage to the sheath by the metal washers. The plug shall be placed far enough into
the duct to be flushed with the inner edge of the bevel of the conduit on to clear any
breaks extending into the bore.

6.9 Plugs equipped with elongated bolts shall be inserted into the duct only far enough to
make the seal and yet leave the nuts outside the face of the duct when the plug is
fully compressed.

6.10 Tighten the nuts with the split conduit plug wrench illustrated in Figure TC-1102-
0500-00, turning down each nut a little at a time so as to keep the pressure as
uniform as possible on all sides. Too much tightening of one nut may displace the
cable to one side and make access to the remaining nuts difficult.

6.11 When all the nuts are tight and the rubbers are evenly compressed, there will be a
slight bulging on the rubber around the edges of the compression plates. If the plug is
found leaking after it has been in place for a few days, the condition can usually be
corrected by drawing up slightly on bolts. If this does not stop the leak, remove the
plug and examine the cable and duct for irregularities that may be overcome by
changing the position of the plug. Failure to this, seal around the cable with sealing
compound.

6.12 To remove split rubber conduit plugs, first remove the nuts and outside plates from
the plug, then push the bolts all the way back through the holes in the rubber to free
the back plates from the rubber.

6.13 Plugs which have been in place for only a short time can sometimes be removed by
using long nose pliers to grip the rubber through one of the holes near the cut. Grip
the plug at the hole in the free end of the rubber and attempt to pull out the rubber by
peeling it from around the cable. If this is not successful, it will be necessary to use
the split conduit plug remover.

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 6 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

6.14 The split conduit plug remover consists of three parts, sleeve, extractor and wrench
as illustrated in Figure TC-1102-0600-00.

6.15 The following steps explain the use of the extractor in removing round split plugs:

6.15.1 Insert the tongue of the sleeve between the rubber and the duct wall at the
hole in the free end of the rubber near the cut as it appears in the face of the
plug. See Figure TC-1102-0700-00.

6.15.2 Push the tongue of the sleeve to its full depth between the rubber and the
duct wall. It may be found convenient to insert the handle end of the
extractor into the sleeve to provide an extension which permits a firmer grip.

6.15.3 Assemble the wrench on the extractor and pass the extractor through the
sleeve. There is an eccentric point on the handle end of the extractor which
is in line with the grooved tip. Turn this point toward the center of the duct
and away from the wall of the conduit. This will place the tip approximately
in line with the bolt hole in the rubber.

6.15.4 Press the extractor forward until the tip is completely embedded in the
rubber. This position is reached when the annular groove in the extractor
shaft is even with the end of the sleeve. See Figure TC-1102-0800-00.

6.15.5 Engage the wrench with the hexagonal end of the sleeve. By means of the
wrench, hold the sleeve to prevent it from turning while rotating the
extractor just one-half turn. This causes the tip of the extractor to grip the
rubber between it and the tongue of the sleeve. The eccentric point on the
handle end will be toward the corner of the duct when the grip is fully
tightened. See Figure TC-1102-0900-00.

6.15.6 Slide the wrench back against the handle of the extractor. Gripping both the
wrench and the extractor, pull gently on the extractor while shaking the
cable slightly until the plug separates at the cut and starts to come out. See
Figure TC-1102-1000-00. As pulling is continued, the rubber will stretch
and tend to unwrap from the cable.

6.15.7 If the rubber adheres to the duct or cable and makes removal difficult,
release the grip on the rubber, disassemble the tool and reinsert the tongue
of the sleeve by itself in a number of places around the duct to break
whatever bond exists. Then reassemble the tool in the plug and resume
pulling.

6.15.8 As the rubber emerges from the duct, move the tool around the cable while
pulling on the rubber so that the tool will be opposite on slightly ahead of
the point where the rubber is emerging.

6.15.9 After the rubber is out, remove from the duct all of the bolts and the two
back plates of the plug, and reassemble the plug.

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 7 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

6.16 Plugs in use over a long periods in dry locations may be cemented so firmly to the
conduit that they cannot be removed in a condition suitable for reuse. In removing
such plugs, care shall be exercised not to damage the cable sheath.

7.0 COMPLETION PROCEDURES

7.1 Upon completion of work in cable vaults, buildings, and manholes, examine all
conduit seals and replace those which may have been weakened as a result of cable
movement, or have otherwise defective.

7.2 Upon completion of work in manholes, remove any temporary conduit seals which
have been placed during splicing on other work operations.

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 8 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

APPENDIX

Table 1: Solid rubber conduit plug sizes

Duct Sealing Unit Size (mm) Conduit Size (mm)
31.8 Solid Round Unoccupied 31.8 Round Conduit
89.0 Solid Round Unoccupied 89.0 Round Conduit
101.6 Solid Round Unoccupied 101.6 Round Conduit

Table 2: Split rubber plug sizes

Duct Sealing Unit Size (mm) Cable Diameter Range (mm)
89.0 Split Round × 27.0 12.5 to 27.0
89.0 Split Round × 41.3 28.5 to 41.0
89.0 Split Round × 52.4 42.7 to 52.4
89.0 Split Round × 63.5 54.0 to 63.5
101.6 Split Round × 27.0 12.5 to 27.0
101.6 Split Round × 31.8 28.5 to 31.8
101.6 Split Round × 38.1 33.3 to 38.1
101.6 Split Round × 44.5 41.3 to 44.5
101.6 Split Round × 52.4 42.7 to 52.4
101.6 Split Round × 66.7 54.0 to 66.7
101.6 Split Round × 71.4 68.3 to 71.4
101.6 Split Round × 77.8 73.1 to 77.8

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 9 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

Figure TC-1102-0100-00: Lead or polyethylene sheath strips

a. Round solid rubber conduit plug b. 31.8mm Round solid rubber conduit plug

Figure TC-1102-0200-00: Solid rubber conduit plugs

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 10 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

Figure TC-1102-0300-00: Split rubber conduit plugs

Figure TC-1102-0400-00: Split rubber conduit plugs with elongated bolts

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 11 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

Figure TC-1102-0500-00: Split conduit plug wrench

Figure TC-1102-0600-00: Split conduit plug remover

Figure TC-1102-0700-00: Inserting sleeve

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 12 OF 13

TRANSMISSION CONSTRUCTION STANDARD TCS-T-111.02, Rev. 0

Figure TC-1102-0800-00: Pressing extractor into position

Figure TC-1102-0900-00: Turning extractor

Figure TC-1102-1000-00: Plug removal

TCST111.02R0/AGG Date of Approval: December 03, 2008 PAGE NO. 13 OF 13