Protecting Fiber Optic Cables in Gas Transmission Projects 

Background

Fiber optic cables are installed alongside gas transmission pipelines to support real-time monitoring, control, and communication systems. These fibers enable SCADA (Supervisory Control and Data Acquisition) functionality, allowing operators to detect leaks, stress, temperature changes, and unauthorized excavation activity. They also provide high-bandwidth data transmission essential for safe, efficient, and intelligent pipeline operations—often in harsh, remote environments.

Protecting these fiber optic cables is critical. Rodents and insects pose a significant threat, as they can chew through cable sheathing, damage core fibers, and create pathways for moisture ingress. Such damage can lead to service outages, unreliable data, safety risks, and costly repairs.

Rodent-related damage can sever fiber lines entirely, resulting in immediate and widespread communication failures that disrupt SCADA systems. These failures increase operational risk and can compromise pipeline safety. “Fix-it-after-it-breaks” approaches are expensive, requiring emergency truck rolls, replacement materials, and extended downtime. Even minor damage to the cable jacket can allow moisture intrusion, further degrading fiber performance and long-term reliability. Because these fiber lines directly support pipeline monitoring, any disruption can impair critical safety alerts across the gas infrastructure.

Challenge

At a natural gas transmission site, fiber optic cable was installed inside conduit leading into a control room. The facility experienced recurring issues with mice and insects entering through the conduits, ultimately damaging a 96-fiber cable connected to network equipment.

The contractor needed a sealing solution that could:

• Effectively block rodents, insects, and water
• Be installed easily around an existing fiber cable
• Provide a durable, long-term seal without complex tools or extended cure times

Creating a durable seal around fiber within a small conduit proved challenging using other sealing methods.

Evaluating a Solution

Before specifying a permanent sealing product, the contractor conducted a field trial using Polywater® ZipSeal™ Foam Duct Sealant inside an underground handhole enclosure. The objective was to evaluate ease of installation, overall convenience, and effectiveness in real-world conditions.

Implementation and Results

Installation crews reported extremely positive feedback. ZipSeal was simple to apply and achieved a functional cure in approximately two minutes, allowing the work to be completed quickly without disrupting other tasks. The installers noted that the product held securely within conduit cutouts and formed a tight, uniform seal around the fiber cable.

The crew “loved it” due to the fast cure time and straightforward installation process. The sealed conduit successfully prevented rodent and insect entry.

After the successful trial, ZipSeal was used to seal the 96-fiber cable feeding network equipment inside a remote natural gas pipeline pumping station located on top of a mountain—an environment where pest intrusion had previously been a persistent problem. Following installation, the conduit penetration was effectively secured against mice and insects.

Conclusion

ZipSeal provided an effective solution for preventing rodent and insect incursion in fiber optic conduit applications within gas transmission facilities. Its fast cure time and easy installation reduced labor requirements while delivering a durable, reliable seal. By protecting critical fiber infrastructure, ZipSeal helps prevent costly outages, improves system reliability, and supports the safe operation of gas transmission networks.

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