reels, a cable pull can still go sour if you damage the cable's outer insulation during the process. However, with the help of a few calculations and a working knowledge of arithmetic, you can prevent problems in recently energized feeders by calculating the maximum allowable pulling tension for any installation and you don't even need to know calculus. Mathematical proficiency aside, you do have to know the following installation parameters:
Raceway size Cable configuration Correction factor for cable weight Jamming potential Conductor clearance Sidewall bearing pressure Now, let's see how these factors apply in a sample pulling tension calculation.
Fig. 2. The number of single-conductor cables of equal weight and diameter and the ratio of the raceway inside diameter to the conductor outside diameter will determine the geometric positions in which the cables sit.
Triangular (option B in Fig. 2): This occurs when you pull three individual conductors from three separate reels, and their D/d ratio is less than 2.5. If you pull individual triplexed conductors from a single reel, they also will sit in this position. Cradle (option C in Fig. 2): This position may occur when you pull three individual conductors from three separate reels, and their D/d ratio is between 2.5 and 3.0. This position is the least favorable because it yields the worst-case scenario of drag during the pull. Diamond (option D in Fig. 2): This position occurs when you pull four individual conductors from four separate reels, and their D/d ratio is less than 3.0. If you pull quadruplexed individual conductors from a single reel, the multiconductor cable will also sit in this position. To determine how the conductors will sit in the conduit, refer to Table 4 for the inside diameter (D) of the 5-in. GRS conduit, which is 5.07 in. Use the ratio of the conduit's inside diameter (D) to the cable's outside diameter (d) to find how the single conductors will sit in the conduit. In this case, this ratio is: Dd 5.07in. 1.60 in. = 3.17 Because this ratio results in a number greater than 3.0, the individual conductors will sit in a cradle configuration in the conduit.
If the value is less than 2.5, you will not have a jamming problem. If the value is less than 3.0 but greater than 2.8, jamming is very possible. If the value is greater than 3.0, you won't have a jamming problem. Note: Keep away from jam ratios of 2.8 to 3.2 for Type MV extruded dielectric power cables. Using the values for inside diameter of the raceway and the outside diameter of the individual conductor from the example, you get the following value: 1.05 x (D d) 1.05 x (5.07 in. 1.60 in.) = 3.33 Because this calculation results in a number greater than 3.0, you probably won't have a jamming problem.
as small as in. and still be safe. For more complex pulls, you should have between in. and 1 in.
Table 4. Tension multipliers for various bending radii. Note: These multipliers are based on a coefficient of friction of 0.5. If the coefficient of friction is 1.0, you must square the multiplier. If the coefficient of friction is 0.75, you must raise the multipier to the 1 1/2 power.
Assuming you're pulling from Point A to Point H, you should begin the calculation in incremental parts. Refer to Table 4 for bend multiplier values: Step 1: TA-B = 10 ft x 6.6 lb/ft x 0.5 x 1.28 TA-B = 42 lb Step 2: TA-C = TA-B 90 bend multiplier TA-C = 42 lb x 2.2 TA-C = 92 lb Step 3: TC-D = 75 ft x 6.6 lb/ft x 0.5 x 1.28 TC-D = 317 lb Step 4: TA-D = TA-C + TC-D TA-D = 92 lb + 317 lb TA-D = 409 lb Step 5: TA-E = TA-D x 90 bend multiplier TA-E = 409 lb x 2.2 TA-E = 900 lb Step 6: TE-F = 635 ft x 6.6 lb/ft x 0.5 x 1.28 TE-F = 2,682 lb Step 7: TA-F = TA-E + TE-F TA-F = 900 lb + 2,682 lb TA-F = 3,582 lb Step 8: TA-G = TA-F x 90 bend multiplier TA-G = 3,582 lb x 2.2 TA-G = 7,880 lb Step 9: TG-H = 30 ft x 6.6 lb/ft x 0.5 x 1.28 TG-H = 127 lb Step 10: TA-H = 7,880 lb + 127 lb TA-H = 8,007 lb Based on the proper calculations, you'll need approximately 8,000 lb of pulling tension to pull the 15kV conductors, but you're not done yet.
This pressure has a very dramatic effect on power feeder raceway system design because it relates directly to the radii of bends, pulling tension, and the cable or conductors' weight. Most of the time, you can omit this weight factor from your SWBP calculation because it's relatively small in comparison to pulling tension.
Cradle position: center conductor. Diamond position: bottommost conductor. Triangular position: bottom two conductors.
Table 6. Recommended maximum SWBP limits per cable constructions. Note 1: When using these limits, make sure you do not exceed 10,000 psi for annealed stranded copper and 6,000 psi for half and full hard stranded aluminum. For three single-conductor cables in parallel, you should base the allowable conductor stress on two cables sharing the tension. Note 2: For a pull of three single-conductor cables in parallel, a maximum SWBP of 750 lb/ft is recommended. Note 3: You should reduce the recommended SWBP limit to 1,500 lb/ft when the jacket is not applied tightly to the cable core.
Refer to Table 6 (right) for recommended SWBP limits for various cable types and constructions. You can use these limits in your raceway system design efforts. For example, if the design calls for pulling three single-conductor 600V XLPE conductors around a bend and your pulling tension calculation yields a value of 3,600 lbs, then the minimum bend radius would be 3,600 lbs divided by 1,200 lbs/ft, or 3 ft. Verify the three 90 bends have a sufficient radius to limit the SWBP on the conductors to 750 lb. Because tension TA-C (92 lb) is relatively small, you can use standard elbows and not worry about exceeding the 750-lb SWBP limit. Tension TA-G, however, is another matter it is imperative that you don't exceed the 750-lb SWBP limit. Use the SWBP equation for a cradled position and solve for radius (R):
SWBP = [(3W - 2) x T] 3R 750 = {[(3 x 1.28) - 2] x 7,880} 3R R = 14,499 2,250 = 6.44 ft This means you need to bend a 10-ft length of conduit into a large-radius sweep. (You'll need the extra length to compensate for the bend.) Pulling cable is hard enough if you know what you're doing, so failing to follow the proper procedure can make the job that much more arduous, not to mention pointless if your feeders fail shortly after the pull. Because even the slightest oversights in determining maximum allowable pulling tension can cause problems in new feeders, it's crucial that you implement the correct calculations to get the job done right the first time.