USERS GUIDE

ELECTRICAL DISTRIBUTION AND TRANSMISSION SYSTEMS ANALYSES AND DESIGN PROGRAMS

CABLE PULLING TENSIONS

EDSA Micro Corporation 16870 West Bernardo Drive, Suite 330 San Diego, California 92127 USA
Copyright 2007 All Rights Reserved

Version 4.10.00

August 2007

Cable Pulling

EDSA MICRO CORPORATION

WARRANTY INFORMATION

There is no warranty, implied or otherwise, on EDSA software. EDSA software is licensed to you as is. This program license provides a ninety (90) day limited warranty on the diskette that contains the program. This, the EDSA Users Guide, is not meant to alter the warranty situation described above. That is, the content of this document is not intended to, and does not, constitute a warranty of any sort, including warranty of merchantability or fitness for any particular purpose on your EDSA software package. EDSA Micro Corporation reserves the right to revise and make changes to this User's Guide and to the EDSA software without obligation to notify any person of, or provide any person with, such revision or change. EDSA programs come with verification and validation of methodology of calculation based on EDSA Micro Corporation's in-house software development standards. EDSA performs longhand calculation and checks the programs results against published samples. However, we do not guarantee, or warranty, any program outputs, results, or conclusions reached from data generated by any programs, which are all sold "as is". Since the meaning of QA/QC and the verification and validation of a program methodology are domains of vast interpretation, users are encouraged to perform their own in-house verification and validation based on their own in-house quality assurance, quality control policies and standards. Such operations - performed at the user's expense - will meet the user's specific needs. EDSA Micro Corporation does not accept, or acknowledge, purchase instructions based on a buyer's QA/QC and/or a buyer's verification and validation standards. Therefore, purchase orders instructions are considered to be uniquely based on EDSA's own QA/QC verification and validation standards and test systems.

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All Rights Reserved. No part of this publication may be reproduced without prior written consent from EDSA Micro Corporation.

Cable Pulling

Table of Contents I. II. III. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. XIV. FOREWORD ....................................................................................................................................................1 CABLE PULLING CAPABILITIES, FUNCTIONS AND FEATURES ........................................................1 INTRODUCTION ............................................................................................................................................1 CABLE PULLING TENSIONS AND SIDEWALL PRESSURES .................................................................2 CABLE CONFIGURATIONS .........................................................................................................................2 CABLE DATA .................................................................................................................................................2 DESIGN CRITERIA ........................................................................................................................................3 COEFFICIENT OF FRICTION........................................................................................................................3 PROFILES ........................................................................................................................................................3 USE OF THE KEYBOARD .............................................................................................................................3 LIBRARIES......................................................................................................................................................3 CABLE REEL BACK PRESSURE..................................................................................................................3 METHOD OF CALCULATION ......................................................................................................................4 TECHNICAL PARAMETERS.........................................................................................................................4 PROGRAM FEATURES................................................................................................................................16 14.1 USING THE PROGRAM'S BUILT-IN HELP FACILITY...................................................................17 14.2 MAIN MENU ITEMS ...........................................................................................................................18 14.3 PROGRAM SUBMENU ENTRIES ......................................................................................................19 XV. XVI. REFERENCES ...............................................................................................................................................21 GLOSSARY OF TERMS AND DEFINITIONS............................................................................................21

XVII. ADDITIONAL NOTES..................................................................................................................................23 APPENDIX A: Cable Pulling Tutorial.................................................................................................................... A-1

ii

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Table of Figures Figure 1..........................................................................................................................................................................2 Figure 2..........................................................................................................................................................................2 Figure 3..........................................................................................................................................................................2 Figure 4..........................................................................................................................................................................2 Figure 5..........................................................................................................................................................................7 Figure 6..........................................................................................................................................................................8 Figure 7..........................................................................................................................................................................8 Figure 8..........................................................................................................................................................................9 Figure 9........................................................................................................................................................................10 Figure 10......................................................................................................................................................................11 Figure 11......................................................................................................................................................................12 Figure 12......................................................................................................................................................................13 Figure 13......................................................................................................................................................................15 Figure 14......................................................................................................................................................................16

Table of Tables Table A: SWBP Equations ....................................................................................................................................... A-2 Table B: Recommended Maximum Sidewall Bearing Pressures ............................................................................. A-2

Copyright 2007 All Rights Reserved

iii

Cable Pulling

I.

FOREWORD This discussion assumes the user is a Professional Engineer familiar with the issues surrounding cable pulling problems. The program's assumptions and definitions are consistent with standard cable tension and sidewall pressure calculation techniques. This document should be used in conjunction with other texts on the subject, and should not be used as the user's sole source of information on cable pulling analysis. Determination of validity of the results, and whether the program is applicable to a system, is solely the responsibility of the user. This program is undergoing continuous development and refinement. As with all our products, EDSA is committed to making the Cable Pulling Tensions & Sidewall Pressures program as current, comprehensive and as easy to use as possible. Any comments, suggestions or errors encountered in either the results or documentation should be immediately brought to EDSA's attention.

II.

CABLE PULLING CAPABILITIES, FUNCTIONS AND FEATURES R R R R R R R R R R R Front, Top, Side Views User control of graphics Single Cable, Three Cables Triangular, Three Cables Cradled, Four Cables Diamond Complete Library of Cables 3-D Isometric View Pull different size cables Pull multiple cables Forward and reverse tension calculation Sidewall pressure calculation PASS/FAIL Option Vertical and horizontal levels

III.

INTRODUCTION The sidewall bearing pressure and pulling tension that cables undergo during installation determine the lengths of cable and splices. Construction field professionals need to know that the pressures and tensions the cables are submitted to do not damage the cable. Electrical contractors and installers of cables seek to make the longest un-spliced runs possible because splices are costly and are frequently the source of circuit failures. Pulling lengths of cables determine the number and location of splices, electrical manholes, and pull boxes. The maximum length of cable, which may be safely pulled into a duct or conduit, depends on the following factors: Type of cable pulling lubricant; Coefficient of friction of duct or conduit; Size, weight and type of conductor; Maximum allowable sidewall pressure and maximum pulling strain on the conductors and/or sheath; Bend angle and directions (horizontal or vertical), number of bends and radius of bends; 1

Cable Pulling

Method of pulling cable (basket weave grip, pulling eyes, etc.); Size of conduit and percentage of conduit fill; Number and configuration of cables in the conduit.

III.

CABLE PULLING TENSIONS AND SIDEWALL PRESSURES This program has been written for professional design engineers. EDSA believes that pulling tension and sidewall pressure should be calculated at the time of design and not at the time of installation. A review of the faults, fires and electrical systems shutdowns indicates that many of these failures are directly attributable to the cable damage that occurred during installation. The magnitude of the pulling tension and sidewall pressure exerted on cables during installation plays a major role in the health of a cable. If pressure is exceeded above the cable allowable limits, the tension and/or sidewall pressure could permanently damage the cable insulation. Mechanical damage (unless severe) usually remains undetected until a breakdown occurs in the insulation system, which is often due to aging and subsequent moisture penetration/carbonization. Cable pulling calculations should be done during the design stage of a raceway-feeder, or cable installation, to find the values for expected tension when pulling cable, and also find the pulling force caused by sidewall pressure on the cable pulled around the bends. The main parameters that must be considered in such calculations are: number and diameter of cable, type of cable, the coefficient of dynamic friction between cable and conduit, type of conduit, and bending radii. The results of the calculations should be within the allowable limits as established by the cable manufacturers.

IV.

CABLE CONFIGURATIONS The manner in which the cables are installed in the raceway plays a very important role in the determination of pulling tension and sidewall pressure. The cables in this program are defined as:

Single Cable Three Cables Triangular Three Cables Cradled Four Cables Diamond

Figure 1 Figure 2 Figure 3 Figure 4 V. CABLE DATA Any size, type, insulation category, or voltage level can be entered. All data entered are for single cable and the program extends the information for the number of conductors pulled.

Cable Pulling

VI.

DESIGN CRITERIA The user can input the maximum design sidewall pressure in pounds per foot and the maximum design tension in pounds. The Cable Pulling Tensions program will give warnings if during the pull sidewall pressure and/or the tension exceed the user defined maximum safe limits.

VII.

COEFFICIENT OF FRICTION The user should enter the coefficient of friction for both high and low sidewall pressure calculations. The user should also specify the pulling compound, or select a compound from the program's lubricating compound library.

VIII.

PROFILES EDSA Cable Pulling program permits the user to input 99 sections in every profile. The number of profiles is limited only by the user's hard disk capacity.

IX.

USE OF THE KEYBOARD This program makes use of FUNCTION KEYS 1-10 and ESC.

X.

LIBRARIES There are three libraries available: A) The Pulling Compound Data, B) Cable Data / Feeder Library and C) Raceway Data. The user may add, modify and delete entries in the libraries.

A)

THE PULLING COMPOUND LIBRARY The Pulling Compound Data Library includes the definition of various types of pulling lubricants with corresponding coefficients of friction for high and low sidewall tensions. The compound type may be selected with the arrow key, and transferred into the profile screen by pressing the ENTER key. The entries in the library can be modified to suit the user's preference.

B)

THE FEEDER LIBRARY The Cable Data Feeder Library includes the feeder size, diameter, area (SQIN), weight per foot of single cable, insulation, material (A = aluminum, C = copper), voltage, area (CMILL) and codeword.

C)

THE RACEWAY LIBRARY The Raceway Data Library includes all standard raceway sizes. User can add, modify and delete the information to suit his or her needs.

XI.

CABLE REEL BACK PRESSURE The cable reel backpressure is a common value expressing the estimated reel back tensions of 100 lbs. 3

Cable Pulling

XII.

METHOD OF CALCULATION The equations used in this program come from standard static and dynamic analysis principles. The references are:

1:

Edison Electric Institute, Underground Systems Reference Book, 1957.

2:

Rifenburg, R.C., Pipe Line Design For Pipe-type Feeders, AIEE Transaction on Power Apparatus and Systems, Vol. 72, part III, December 1953.

XIII.

TECHNICAL PARAMETERS

1:

CABLE DIAMETERS AND WEIGHTS This information is listed in the manufacturers' catalogs (see the program Feeder

Library).

2:

CONDUIT SIZE The National Electric Code, NEC, specifies the permissible conduit fill and conduit sizes (see the program Raceway Library).

3:

CABLE CLEARANCE It is important to calculate the clearance between cables and conduit to ensure that cables can be pulled through the conduit, as follows: D d C = = = conduit inside diameter in inches;
1.05 nominal cable outside diameter in inches;

clearances in inches;

1.05 Safety factor for manufacturer tolerance.

For single conductor cable pull C = D-d (1)

For three-conductor cable pull:

D - 1.366 d + 0.5 ( D - d ) d
2 d 1- D - d

(2)

For four-conductor cable pull:

Cable Pulling

C 4: JAM RATIO

(D- d) -

2 d2 D- d

(3)

When the ratio of the inside diameter of the conduit to the cable diameter is equal to 3, one of the cables in a 3 or 4 cable pull may slip between two other cables, thus causing the cables to jam in the conduit; this is especially true when the cable is pulled around a bend. With: and
D =

conduit inside diameter in inches, nominal cable outside diameter in inches, (4)

dn =

one of the following statements should be satisfied to avoid cable jam:

1.05 D < 2.9 dn D > 3.1 1.03 d n

5:

WEIGHT CORRECTION FACTOR Calculation of weight correction factor is needed for proper distribution of single cables weight in multiple cable pull. Weight correction factors are:

For single cable:

Wc =

(5)

For 3-single cables in triangular configuration:

Wc

1
2 d 1- D - d

(6)

For 3-single cables in cradled configuration:

d 4 3 (D - d)
2

Wc

1+

(7)

For 4-single cables in diamond configuration:

Cable Pulling

Wc

d 1 + 2 D- d

(8)

Note that:
D d

= = =

inside diameter of conduit in inches; nominal outside diameter of a single cable in inches; weight correction factor, no dimensions.

Wc

6:

EFFECTIVE COEFFICIENT OF FRICTION The effective coefficient of friction is expressed as the product of the basic coefficient of friction and the weight correction factor.
K0 Wc K K

= = = =

basic coefficient of friction weight correction factor effective coefficient of friction

K 0 Wc

7:

DYNAMIC COEFFICIENT OF FRICTION The dynamic coefficient of friction is a factor which, when multiplied by the normal force exerted by the cable on the conduit, yields the pulling tension required to keep the cables in motion. The force exerted by the cable is due to its own weight added up to the weight of all other cables resting on it.

8:

SIDEWALL BEARING PRESSURE This is a radial pressure experienced by the cable as it is pulled through a curved

section. With Wc = weight correction factor, R = inner radius of conduit bend, T = maximum tension of cable(s) in pounds, and SWBP = sidewall bearing pressure on cable with greatest radial load:
(Rc 1 D) 2 12

Ri

(9)

where:
Ri Rc

= =

inside radius of bend in feet; centerline radius of bend in inches;

Cable Pulling

diameter of duct in inches.

For single cable: SWBP =

T R

(10)

For 3-cable cradled formation: SWBP =

(3Wc - 2) T 3R

(11)

For 3-cable triangular formation: SWBP =

WcT 2R

(12)

For 4-cable in diamond formation: SWBP =

(Wc - 1) T R

(13)

Cable Sections

Figure 5

STRAIGHT OR HORIZONTAL PULL

T2 =

T1 + WKL

(14)

Cable Pulling

L
K

= =

actual length of the section of cable in feet effective coefficient of friction total weight of cable in conduit in pounds/foot the tension at the beginning of pull in pounds the tension at the end of pull in pounds

W =

T1 = T2 =

Figure 6 HORIZONTAL BEND

T2 =
F =

T1 Cos h(K ) + FSin h(K ) T12 + (WR) 2

= bend angle from horizontal inside radius of conduit bend

R =

Figure 7 SLOPE UP PULL

Cable Pulling

T2 =
X =

T1 + LWX
SIN + K COS

(15) (16)

measured from horizontal axis

Figure 8 SLOPE DOWN PULL

T2 = Y =

T1 - LWY
SIN K COS

(17) (18)

measured from horizontal axis

Note: An upward or downward sloping segment with a specified arc angle of 90 degrees can be used to model a vertical pull.

Cable Pulling

Figure 9 VERTICAL DIP

In vertical dip with D 1 small compared to L (Length of section)

T

T1 eK + RW( eK - 1)

(19)

where

L 2 4 D and R = 4 D L

(20)

Use coefficient of friction f for SWBP p 150 lbs/ft For T

T2

RW
T1 + WKL

(21)

For T
T2 D' S

RW
T1 e4 K + RW[e4 K - 2 e3K + 2 eK - 1]

= = =

(22)

Depth of Dip from horizontal axis

1 length of the Dip Section 2

10

Cable Pulling

Figure 10 CONVEX DOWNWARD BEND

measured from vertical axis

T2 =
Z

T1 eK +

WR Z 1 + k2

(23)

2 K SIN ( 1 K 2 ) ( e K COS )

(24)

Figure 10A

offset angle from vertical axis

measured from vertical axis by angle

11

Cable Pulling

Ta Z1 Tb Z2

= = = = = = =

T1eK a +

WR Z1 1 + K2

(25) (26) (27) (28) (29)

2 K SIN a - (1- K2 )( eK a - COS b )

T1 eK b + WR Z2 1 + K2

2 K SIN b - (1- K2 )( eK b - COS b )

b
and
T2

b a
total angle from vertical axis
Tb Ta + T1

(30) Figure 11

CONVEX UPWARD BEND

measured from vertical axis

T1 eK + WR Y1 1+ K2

T2 Y1

= =

(31) (32)

2 K eK SIN + (1 - K2 )(1 - eK COS )

12

Cable Pulling

Figure 11A

measured from vertical axis by a

Tb T2 Y2 Tb Y3

= = = = =

WR Y2 1+ K2 eK a

(33) (34) (35) (36) (37) Figure 12

2 K eK a SIN a + (1 - K2)(1 - eK a COS a ) T1 eK b + WR Y3 1 + K2

2 K eK b SIN b + (1 - K2 )(1 - eK b COS b )

b a

CONCAVE UPWARD BEND

13

Cable Pulling

measured from vertical axis

T1 eK WR Z 1+ K2

T2 Z

= =

(38) (39)

2 K SIN - (1- K2 )( eK - COS )

Figure 12A

measured from vertical axis by angle a

T1 eK a WR Z1 1+ K2

Ta Z1 Tb Z2

= = = =

(40) (41) (42) (43)

2 K SIN a - (1 - K2 )( eK a - COS a ) T1 eK b WR Z2 1+ K2

2 K SIN b - (1- K2 )( eK b - COS b )

where

and
T2

b a

(44)

Tb Ta + T1

(45)

14

Cable Pulling

Figure 13 CONCAVE DOWNWARD BEND

measured from vertical axis

T2 Y1

= =

T1 eK -

WR Y1 1+ K2

(46) (47)

2 K eK SIN + (1 - K2 )(1 - eK COS )

Figure 13A

15

Cable Pulling

measured from vertical axis by angle a

Tb + T2 Y2 Tb Y3

= = = = =

WR Y2 1 + K2 eK a

(48) (49) (50) (51) (52)

2 K eK a SIN a + (1 - K2 )(1 - eK a COS a ) T1 eK b WR Y3 1 + K2

2 K eK b SIN b + (1 - K2 )(1 - eK b COS b )

b a

Figure 14

Note that arcs and offsets are always measured from vertical.

XIV.

PROGRAM FEATURES The program helps you in quickly and easily performing "What if" type of analysis by permitting you to design and view raceway configurations while testing different lubricating compounds. Provides graphic display of raceway sections in front, side, top and perspective views.

16

Cable Pulling

Converts all quantities from U.S. Customary to SI units at the touch of a button. Provides both graphic and text output. Provides quick access help to virtually every item displayed on a screen. Maintains libraries of standard and user defined cable parameters, raceways and lubricating compounds for quick inclusion into analysis. Performs both forward and reverse pull analyses in a single pass.

14.1

USING THE PROGRAM'S BUILT-IN HELP FACILITY

Help menu consists of Contents, Using Help, and About.

17

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14.2

MAIN MENU ITEMS

Files

This entry will get you into the program's job file manager. Submenu entries can be used to create new files, load existing ones, edit or delete program job data files. Edit the current job file. If no job is currently loaded, the program will automatically generate a list from which to choose. Run an analysis. If you have yet to load a job file, you will be asked to choose from a directory listing. This must be done prior to running any analysis. This entry will get you into the program's general editors. Once there, you can edit any of the program reference library data files. Enter the system online help facility.

Edit

Analyze

Tools

Help

18

Cable Pulling

14.3

PROGRAM SUBMENU ENTRIES

New

This entry will get you into the program's job data editor. It can be used to create a new job data file for analysis. Load an existing job file for editing, viewing, or running an analysis. Close the job file. Save the file under the same name. Save the file under a different name. Print the results to a printer. Setup the document print characteristics. Exit from the program

Open Close Save Save As Print Print Setup Exit

User Tip:

If you want to perform an analysis on a brand new project, whose characteristics are similar to an existing job, simply call up the old job via the "Files/Load

19

Cable Pulling

Existing" menu entry. Edit the old job parameters to match the new project's parameters and save the file to a new job filename.

Cable Library Compound Library Raceway Library

Access the cable parameters library editor. Access the cable lubricating compounds library editor. Access the cable raceway library editor.

20

Cable Pulling

XV.

REFERENCES 1: Buller, F. H., "Pulling Tension During Cable Installations in Ducts or Pipes", General Electrical Review, Schenectady, NY, Vol. 52, No. 8, pp. 21 - 23, August 1949. Mehta, Yash, "Design and Installation of Large Feeders", Electrical Systems Design, pp. 32 - 36, June 1987. Rifenburg, R. C., "Pipe-Line Design for Pipe-Type Feeders", AIEE Transactions on Power Apparatus and Systems, Vol. 72, Part III, pp. 1275 - 1288, December 1953. Vartanian, Sookie, Sandler, Arthur N., "Cable Pulling Design for Practical Applications in Modern Refineries", IEEE Transactions on Industry Applications, Vol IA-10, No. 3, May/June 1974.

2:

3:

4:

XVI.

GLOSSARY OF TERMS AND DEFINITIONS

1. 2. 3. Cable Area Cable Code Word Cable Configuration Enter the cable area, 0.001 - 99.999. Use up to 16 characters to uniquely describe or label the entry. Use either one of the +/- keys, or the <F2> key, to select the cable configuration (e.g. single, triangular, etc.). Enter the cable diameter, 0.001 - 99.999. Enter up to 4 characters to describe the type insulation used in the cable (e.g. "XPC"). Use either one of the +/- keys, or the <F2> key, to select the material used in the core of the cable. (e.g. copper, aluminum). Enter up to 4 characters to describe the cable size (e.g. "1/0"). Enter the cable weight per unit length, 0.001 - 99.999. Enter the coefficients of friction for the compound corresponding to low and high sidewall bearing pressure, 0.001 - 99.999. Use up to 20 characters to describe or label the entry. This field provides you with an area to describe the analysis or note important characteristics of the analysis. (Optional, but recommended). Enter the maximum allowed side wall bearing pressure, 0 - 9999. Enter the maximum allowed tension, 0 - 9999. Enter the nominal size of the raceway, 0.001 - 99.999. You may send the analysis results to a file, or an attached printer, or you may cancel, and return to the view screen. Simply use the "+" and "-" keys to change the entry in the box until the entry matches your desired action. Then depress the <ENTER> key to signify your choices. 16. Phi In the perspective view, the angle of rotation about the x-axis.

4. 5.

Cable Diameter Cable Insulation

6.

Cable Material

7. 8. 9.

Cable Size Cable Weight Coefficient of Friction

10. 11.

Compound Description Job Description

12. 13. 14. 15.

Maximum Allowed SWP Maximum Allowed Tension Nominal Raceway Size Output File Choices

21

Cable Pulling

17.

Pull Direction

Specify the direction of the pull you wish displayed (e.g. forward, reverse). This choice effects the information displayed when a section is chosen for detail information and for section highlighting of cable breaks. Enter the actual diameter of the raceway, 0.001 - 99.999. Enter the reel back tension, 0 - 9999.9 The angle subtended by bend for curved sections or angle of slope measured from horizontal for sloped sections. Enter the angle in degrees of the section element for sections of horizontal bend, concave bend up, concave bend down, convex bend up, convex bend down, slope up, and slope down types. Range: 0 - 90 (-180 - +180 for horizontal bend). Enter the length of the section, 0.001 - 9999.999. Enter the angle in degrees of the offset from vertical in a clockwise direction of the section element for sections of concave bend up, concave bend down, convex bend up, convex bend down, slope up, and slope down types 0 to 90 degrees. Enter the radius of the section for sections of horizontal bend, concave bend up, concave bend down, convex bend up, convex bend down, and vertical dip types 0.001 - 9999.999. Use either one of the +/- keys, or the <F2> key, to select the section type (e.g. horizontal pull, vertical dip, etc.). This field requires you to choose the measurement system (Metric, U.S. Customary) you wish the program to use during data input and output. Note: All calculations performed internally are in the metric system. U.S. Customary measurements will be automatically converted prior to display.

18. 19. 20.

Raceway Diameter Reel Back Tension Section Arc

21. 22.

Section Length Section Offset

23.

Section Radius

24.

Section Type

25.

System

26. 27.

Theta View

In the perspective view, the angle of rotation about the y-axis. Use either one of the +/- keys, or the <F2> key, to select the viewing angle (e.g. front, top, side, perspective) of the raceway path display. Note that by choosing the perspective you can specify the viewing angles. Enter the voltage, 0 - 99999.

28.

Voltage

22

Cable Pulling

XVII.

ADDITIONAL NOTES Limitations/Caveats Program Limitations: Item Sections/Job Cables types in library Raceway sizes in library Lubricating compounds in library Maximum 100 100 100 100

Abbreviations Used: Metric Mass Length kg m cm Kilogram meter centimeter square cm Newton 1000 Pascals = = = = = = U.S. Customary 2.205 lb 3.281 ft 0.394 in pound mass feet inches square inch pound force pounds/sq in

Area Force Pressure

sq cm N kPa -

0.155 sq in 0.225 lb 0.145 psi -

Files Used: File -----------* cpl cablpull hlp cables cbl compound cml raceways rwl Description ----------------------Cable pull project file Help file Cable type library file Lubricating compound library file Raceway library file

23

Cable Pulling

APPENDIX A: Cable Pulling Tutorial A Cable pulling is a critical operation that involves more than just applying lubrication and sheer force. Cables are the interconnecting media between the different elements of the power system. The likelihood of a cable failure turns into an unfortunate reality when they have sustained damage during installation. To ensure that the cable pulling operation does not damage the conductors, one must first evaluate the type and geometric configuration of the raceway. This will determine how the cables will be affected. Some of the issues to keep in mind are: a. Cable Geometric Configuration: Section IV of this manual illustrates that, depending on their number, the cables will occupy the raceway in unique physical configurations. These configurations are referred to as Single Cable, Three Cables Triangular, Three Cables Cradled, and Four Cables Diamond. Refer to Figures 1, 2, 3 and 4 in Section IV of this manual. Cable configuration plays an important role in the integrity of the cable pull; because it has a direct effect on how much frictional force (drag) is placed on the cables during installation. In order to determine the actual configuration that the cables will adopt, the ratio of the inside diameter of the raceway (D) to the outside diameter of an individual cable (d) is used - D/d ratio. When pulling three individual conductors from three separate reels, the following guidelines can be followed to determine the type of configuration: D/d < 2.5: 2.5 < D/d < 3.0: D/d > 3.0: The cables will lay in a Triangular Configuration The cables may lay in a Triangular or Cradled Configuration Cables will lay flat

The diamond configuration occurs when pulling four individual conductors with D/d < 3. When pulling triplexed or quadruplexed single-conductor as assemblies from one reel, the configurations will always be triangular for triplexed and diamond for quadruplexed. b. Cable Weight Correction: When installing two or more single conductor cables in a raceway, the sum of the forces exerted between the cables and the raceway is greater than the sum of the individual cable weights. To properly account for this increased effective weight of the cables, a correction factor must be applied. This factor will help to evaluate the actual pulling tension more accurately. For instance, a cradled configuration with a 40% raceway fill will yield a weight correction factor of 1.441, in contrast to the triangular case, which has a value of 1.222. Unless the cable being pulled is configured as triplexed single conductors, it should be assumed that one is dealing with a cradled configuration. This will result in a more conservative design. c. Sidewall Bearing Pressure: As a cable is pulled through a bend in the raceway system, pressure builds up between the cable and the bend. The term that is used to describe this pressure is sidewall-bearing pressure (SWBP). This phenomenon has dramatic effects on the design parameters of the power distribution feeder, because it directly relates to bending radius, pulling tension, and cable weight.

A-1

Cable Pulling

The SWBP is a function of the tension out of the bend (in lbs.) and the bend radius (in ft). The SWBP is a unit of force per unit length. Table A shows the SWBP equations as they apply to the different types of configurations. Table B lists some of the maximum recommended SWBP for different types of cables. Table A: SWBP Equations Number of cables 1 3 3 4 Configuration Single Cradled Triangular Diamond SWBP equation SWBP=T R (eq.5.) SWBP=[(3W-2) x2T] 3R(eq.6) SWBP=WT 2R (eq.7) SWPB=[(W-1) x2T] R (eq.8)

W = Weight correction factor T = Calculated tension R = Radius of bend (inside radius) Note: For multi conductor cables, the single conductor equation should be used. Table B: Recommended Maximum Sidewall Bearing Pressures Cable Construction type XLPE Insulation/Jacket-600V EPR, Neoprene-600V cable PE & XLPE insulation concentric wire shield: Without jacket With encapsulating jacket PE and XLPE insulation, LC shield LDPE jacket PE, XLPE, EPR insulation, Concentric wire or tape shield, LDPE and PVC sleeved jackets. Lead sheathed cable, with and without jackets: XLPE insulation EPR insulation XLPE insulation, copper ribbon Shield, MDPE sleeved jacket
Note
1

Maximum SWBP (lbs./ft) 1200 1000 1200 2000 1500

2 1

2000 2000 2000 2000

When considering the use of the above limits, the tension on the cable conductor should not exceed 10,000 psi for annealed stranded copper and 6000 psi for half and full hard stranded aluminum. For three single-conductor cables in parallel configuration, the allowable conductor stress should be based on two cables sharing the tension. For pull of three single-conductor cables in parallel, a maximum SWBP of 750 lbs./ft is recommended. The recommended SWBP limit should be reduced to 1500 lbs./ft when the jacket is not applied tightly to the cable core.

Note Note

A-2

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d.

Cable Jamming:

Jamming occurs as three or more cables lying side-by-side are pulled in a single plane. As the cables are pulled through a bend the curvature will squeeze the cables, causing them to jam and consequently damage the insulation. Typically, the risk of jamming cables is not high when pulling one or two single conductors, or a single multi-conductor cable with an overall jacket. The risk is also negligible when dealing with multiconductor cables made up of triplexed or quadruplexed single conductors. To determine the potential for a jamming problem to exist, the ratio of the raceway inside diameter (D) to the individual conductor's outside diameter (d) can be used once again. Keep in mind that bends have oval cross sections; therefore the diameter measurement must be increased by 5%. Following are some guidelines for evaluating the potential presence of a jamming problem: If 1.05 times D/d is less than 2.5, jamming is not possible. If 1.05 times D/d is less than 3.0 but greater than 2.8, jamming is very probable. If 1.05 times D/d is greater than 3.0, jamming is not possible.

Another special note: Avoid jam ratios of 2.8 to 3.2 for extruded dielectric cables.

The following exercise will illustrate how the cable pulling analysis can be conducted using EDSA's "Cable Pulling and Sidewall Pressures" program. The case study is based on the EPRI "Maximum Safe Pulling Lengths for Solid Dielectric Insulated Cables" in Section 5 of Volume 2: Cable User's Guide. EPRI EL-3333-CCM, Volume 2 - Research Project 1519-1.

F.I. 1

Plan View

11

10 9 8

765

Profile View
Figure A-1 Tutorial Example - File: epri.cpd (not to scale)

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The following table describes each of the sections shown in Figure A-1. The order of the sections indicates the forward pulling direction: Sec F.I. 1 2 3 4 5 6 7 8 9 10 11 Description Concave bend down Horizontal pull Horizontal bend Vertical dip Horizontal pull Convex bend down Slope down Concave bend down Concave bend up Slope up Convex bend up Horizontal pull Length (ft) 10.0 80.0 25.0 110.0 30.0 7.0 15.0 7.0 7.0 30.0 7.0 55.0 Arc (Deg) 90.0 0.0 90.0 0.0 0.0 45.0 45.0 45.0 45.0 45.0 45.0 0.0 Deg Off Vertical 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Radius (ft) 6.0 0.0 12.5 3.0 0.0 6.5 0.0 6.5 6.5 0.0 6.5 0.0 Comments Feed-in section

The cable data are as follows: Type of pull: Cable Description: Insulation: Cable Diameter: Conductor area: Weight of 3 cables: Diameter of Conduit: Conduit Material: Type of Lubricant: Low SWBP: High SWBP: Reel back tension: 3 cables in duct 1000 kcmil 15kV shielded aluminum conductor. XLPE; PE jacket 1.86 inches 0.7854 inches2 5.05 LB/ft. 6.065 inches PVC Soap and Water 0.45 0.20 100 lbs.

Before using EDSA's Cable Pulling program the user must keep in mind the following guidelines: 1. There must be a minimum of two sections of cable, the first of which must be defined as the portion that pushes or pulls the cable. There must be an eye on the initial section for anchoring the pulling operation. In other words, it is important for the user to note that the program reserves the first segment to model the characteristics of the cable feeder. An example of this would be to specify a concave bend down section of radius 4 ft. with a 90-degree arc to model a cable coming off a large spool. This section is always referred to as the "feeder" or "feed-in" section in the output. Although the feeder section is not explicitly listed in the forward or reverse pull output tables, careful inspection of the data shows that resulting tension is present in both tables and that the feeder section is always the first section whether in a forward or reverse pull. Although this may initially seem counter intuitive, once you remember that the feeder section is modeling the tension due to the source of the physical cable (in most cases a spool), it becomes obvious that the feeder section is the first section in both a forward and reverse pull situation.

2.

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Step 1. From the main EDSA menu, select Analysis/Additional Calculations/Cable Pulling.

Step 2. Once in the Cable Pull program main interface, proceed to create a new job file by selecting File/New.

Step 3. Proceed to name the new file and select Save. In this example, the file will be designated as EPRI.cdp.

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Step 4. Select Edit / Edit Job File.

Step 5. Proceed to enter the data for the cable under study, as required by the dialog box shown here. In this example, all the information has been manually entered based on the data provided at the beginning of this tutorial. Select Save to continue.

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This screen capture illustrates how to use data from the existing libraries, by selecting their respective pick-lists.

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Step 6. The next step is to add each section of the cable run. To initiate the process, select Edit / Edit Section.

Step 7. This dialog box is where all the different sections of the cable-pull exercise will be entered and characterized according to the example described at the beginning of this tutorial. For the convenience of the reader, the table below describes the sections that will be modeled.

Sec F.I. 1 2 3 4 5 6 7 8 9 10 11

Description Concave bend down Horizontal pull Horizontal bend Vertical dip Horizontal pull Convex bend down Slope down Concave bend down Concave bend up Slope up Convex bend up Horizontal pull

Length (ft) 10.0 80.0 25.0 110.0 30.0 7.0 15.0 7.0 7.0 30.0 7.0 55.0

Arc (Deg) 90.0 0.0 90.0 0.0 0.0 45.0 45.0 45.0 45.0 45.0 45.0 0.0

Deg Off Vertical 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

Radius (ft) 6.0 0.0 12.5 3.0 0.0 6.5 0.0 6.5 6.5 0.0 6.5 0.0

Comments Feed-in section

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Step 8. To add the first section (Feed in section), select the Add command.

Step 9. From the Selection Type pick-list select Concave bend down. For clarity and convenience, the program will automatically display a graphical representation of the geometrical characteristic of each section.

Step 10. Enter the physical dimensions of the section, and select OK.

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Step 11. The first section is automatically labeled as Feed in, and added to the list as shown here. To edit any existing sections, simply select it from the list and press Edit. Double-clicking also works for this purpose. Similarly, to delete any sections of the cable pull, select the section to be deleted and press Delete.

Step 12. Using the same guidelines illustrated in steps 8 to 11, proceed to enter the remaining 11 sections of the cable pull. The final product will look like this. When finished, press OK to continue.

The following pages will show the editor for sections 1 to 11.

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Section 1

Section 2

Section 3

Section 4

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Section 5

Section 6

Section 7

Section 8

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Section 9

Section 10

Section 11

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Step 13. Proceed to save the file by selecting File / Save.

Step 14. To view a graphical representation of the cable run, select Analyze / View. Step 15. The figure shows the Forward Pull Side View of the cable run. The commands on the right of the figure will be explained in the next pages.

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The output report can also be generated as described in step 16 of this tutorial.

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Select the Direction of the pull (Forward or Reverse) and then select the desired view angle. For Perspective, select the Theta and Phi angles and then press Refresh. Select Close to return to the main menu.

This graph was generated as follows: 1. Select Perspective View. 2. Theta = 90 Deg. (rotation about Y axis) 3. Phi = 5 Deg. (rotation about X axis 4. Select Refresh.

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Step 16. To run the analysis and generate the output report, select Analyze / Generate output for Cable Pull.

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The Complete report follows:

EDSA Cable Pulling, Version 4.10.00 Project No. : Page : 1 Project Name : Date : Project Title : Time : Drawing No. : Company : Revision No. : Engineer : Job File Name : EPRI Checked By : Scenario : Checked Date: -----------------------------------------------------------------------System: English Cable Configuration Reel back tension on cables Pulling Compound Basic coefficient of friction Low Sidewall bearing pressure High Sidewall bearing pressure Design maximum allowed tension Design maximum allowed SWP Raceway Data: Size Inner diameter of duct Area Percent fill Cable Data: Library Name : Edsa Standard Insulation XLP 15000 1.860 in 0.785 sq in 1.683 lb/ft 2.356 sq in 5.050 lb/ft 6.000 in 6.065 in 28.89 sq in 28.22 Cradled (3) 100.0 lb SOAP 0.450 0.200 4000 lb 400 lb/ft

Size 1000 Type Aluminum Voltage Diameter of single cable Area Weight Total area Total weight General Information: Cable clearance in conduit with no tolerance with 5% tolerance Jam ratio with 3% tolerance on cable with 5% tolerance on conduit Feed-in Conduit Description Concave bend down Length Radius Tension Sidewall Bearing Presure Arc Angle off vertical axis

2.606 in 2.247 in 3.166 3.424

10.0 6.0 164.9 16.3 90.0 0.0

ft ft lb lb/ft

Sec Description 1 2 3 4 5 6 7 8

Forward Pull Length Arc Deg Off Radius (ft) (Deg) Vertical (ft) 0.0 90.0 0.0 0.0 45.0 45.0 45.0 45.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 12.5 3.0 0.0 6.5 0.0 6.5 6.5

Actual Tension (ft) (lb) 90.0 115.0 225.0 255.0 262.0 277.0 284.0 291.0 394 966 1281 1367 1663 1640 1981 2419

SWP (lb/ft) 0.0 45.9 0.0 0.0 152.0 0.0 181.1 221.1

Horizontal pull 80.0 Horizontal bend 25.0 Vertical dip 110.0 Horizontal pull 30.0 Convex bend down 7.0 Slop down 15.0 Concave bend down 7.0 Concave bend up 7.0

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9 10 11

Slop up Convex bend up Horizontal pull

30.0 7.0 55.0

45.0 45.0 0.0

0.0 0.0 0.0

0.0 6.5 0.0

321.0 328.0 383.0

2587 3171 3329

0.0 289.9 0.0

All tension distributed on 2 cables All tension distributed on 3 cables

1664 lb/Conductor 2119 psi 1110 lb/Conductor 1413 psi

Sec Description 11 10 9 8 7 6 5 4 3 2 1

Reverse Pull Length Arc Deg Off Radius (ft) (Deg) Vertical (ft) 0.0 45.0 45.0 45.0 45.0 45.0 45.0 0.0 0.0 90.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 6.5 0.0 6.5 6.5 0.0 6.5 0.0 3.0 12.5 0.0

Actual Tension (ft) (lb) 65.0 72.0 102.0 109.0 116.0 131.0 138.0 168.0 278.0 303.0 383.0 322 509 463 693 1077 1161 1842 1928 2470 3671 3900

SWP (lb/ft) 0.0 46.5 0.0 63.4 98.4 0.0 168.4 0.0 5.8 174.5 0.0

Horizontal pull 55.0 Convex bend down 7.0 Slop down 30.0 Concave bend down 7.0 Concave bend up 7.0 Slop up 15.0 Convex bend up 7.0 Horizontal pull 30.0 Vertical dip 110.0 Horizontal bend 25.0 Horizontal pull 80.0

All tension distributed on 2 cables All tension distributed on 3 cables

1950 lb/Conductor 2483 psi 1300 lb/Conductor 1655 psi

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Step 17. To edit the programs Cable, Compound and Raceway databases, refer to the Tools menu and select the desired library.

Step 18. Each library can have its existing components deleted or modified, and new components added. Simply use the Edit, Add and Delete commands as shown.

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Enter the new cable name and data; click OK.

After the library is closed and reopened, the new cable and its properties have been added to the library.

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