Installation of Oil Filled BNC

S5: Cable Installation
Section 5
Cable Installation
Introduction
The installation of a power cable can look deceptively simple it isnt!
There are many aspects to be considered, as usual too many to be dealt in
any detail within our time constraints. So in these notes we will look at
some points with regard to installing cables in trenches (the commonest
situation for power cables), leaving the student to extrapolate to other
situations as they arise.
Objectives
At the end of this section you will be able to
state the main items of legislation that need to be considered

when installing cables
list key points for route preparation
describe cable installation methods
calculate pulling loads for cables in straight trenches and ducts
describe methods of minimising pulling loads
Time
You will need about 3 hours for this section.
Resources
PC with Windows Excel or some other spreadsheet package.
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EEE8050 Power Cables
5.1 Excavation, Blinding, Backfilling & Reinstatement

Some definitions first:
138
Excavation obvious really, the digging of the hole!
Backfilling the placing and compaction of material to fill the

remainder of the trench, up to the level where the road or
footpath sub-structure commences.
Blinding the placing and compaction of backfill material in

the immediate vicinity of the cable(s), typically 75 mm below
the cable, 75 mm above, and the full width of the trench.
Blinding material is almost invariably imported to site soft
sand for circuits that dont require specific material properties;
thermally stable or stabilised backfill where rating
requirements demand material of known thermal properties.
Reinstatement the placing and compaction of the sub-base,

base and surface materials to restore the surface to its original
condition and strength.
5.2
Legislation
Although not appropriate to deal in detail with the various items of

legislation that affect our work when installing cables and their
accessories, the student should be aware of the following items in
particular. But please note: the following items are by no means an
exclusive list, and you should always be aware of any and all legislative
items that might affect your works.
5.2.1 New Roads & Street Works Act 1991
The New Roads & Street Works Act deals with virtually every aspect of
cable installation in public land with the exception of actually
installing the cable! It applies to all undertakings who work in roads,
footpaths, etc. It is legally binding, and there are severe penalties for not
complying with its requirements. It covers such things as:
Liaison with local authorities, police forces, etc.
The rights and duties of the various parties involved it is

notable that the rights of local authorities etc. far outweigh
those of the undertakings, who now have few rights but lots of
duties!
Signing and guarding of the works, traffic control, pedestrian

access, etc.
Technical requirements for backfilling and reinstatement of

the excavations, to ensure that the finished works are to a
satisfactory standard and will perform as required without
further attention, e.g. support the intended traffic without
subsiding.
In the case of the Highways, the Secretary of State is the manager of the
highways under the Highway Act 1980. Highway Authority is here the
Street Authority. For non highways, then Street Managers are the
authority body or person responsible to the management and control of
the street example Local Authorities.
5.2.2 Health & Safety at Work etc. Act, 1974
This major piece of health & safety legislation (www.legislation.gov.uk)
affects every aspect of our lives whilst at work, visiting the supermarket,
139
riding on fairground rides whatever. The Act itself contains little of

direct relevance to any specific activity. Its significance being principally
two-fold.
1. It places a duty of care on both the employer and employee to
work safely, identify hazards and take steps to reduce those
hazards to acceptable levels, and:
2. It is enabling legislation, under which the Secretary of State can
introduce specific regulations etc. applicable to particular
activities or circumstances. For example:
The Management of Health & Safety at Work (Amendment)
Regulations 2006
Construction (Health, Safety and Welfare) Regulations 1996
Construction (Design and Management) Regulations 2007
Electricity at Work Regulations 1989
The UK Health & Safety Executive (HSE) publishes a large number of
supporting documents such as (in decreasing order of legal obligation)
Codes of Practice, Guidance Notes and Information sheets. One of
particular interest in the present context is their Guidance Note:
Avoiding danger from underground services
The list of these health & safety publications can seem almost endless,
and is too extensive to be covered here in detail. A visit to
http://www.hse.gov.uk is highly recommended for anyone undertaking
site works.
140
5.3 Some Points Regarding Cable Installation

Having designed the installation, carried out the route survey, got
agreement to the route, the timings of the works, etc., complied with your
legal requirements, specified, tendered, ordered and taken delivery of the
cable, you can actually start digging the hole!
5.3.1 Trenches & route preparation
Always bear in mind that cable routes can be dangerous places, and
always think first and foremost of the safety aspects of the works safety
of site personnel, the public (including traffic), your equipment and
materials, and, of course, the safety of other undertakings apparatus.
Trenches should be carefully set up bearing in mind the following points
(it goes without saying that, once again, this is not an exclusive list!).
141
Trench sides stable, full or half timbered as necessary to

support the sides.
Spoil to be placed away from trench edge to avoid it falling

back in.
Walkway along at least one side of the trench workmen

walking on piles of spoil is asking for trouble.
Maximise bend radius and ensure that the bends are uniform.
Smooth bottom, with gradual transitions in level.
Soft material to be placed and compacted before pulling the

cable.
No stones, sharp objects or protrusions.
Ducts should be proved with mandrel and cleaned

immediately before cable pulling.
A bellmouth should be installed in the start of the duct,

irrespective of the duct material.
A sump should be dug beneath the start of the duct to

prevent soil, stones, etc. being carried in to the duct.
Rollers placed every metre, or more frequently for heavy

cables.
Rollers should actually roll (!) and have no sharp projections.
Skid plates installed at bends, NOT vertical rollers.
Rollers and skid plates to be adequately secured.
Rollers and skid plates to be properly greased.
5.3.2 Alternative excavation methods

Numerous alternatives to open cut excavation methods are available, and
can often be used to advantage none provide the perfect solution. All
should be evaluated for their suitability for the particular job in hand:
impact moling
guided boring/directional drilling
rockwheel
chain trencher
mole ploughing
micro-tunnelling
jack heading
thrust boring
auger boring
deep tunnelling
5.3.3 Installation equipment

The installation of large cables involves the handling of large weights,
and the application of large forces so the equipment needs to be:-
142
suitably proportioned
in full working order
properly set up and properly applied.

Cable drum set up

The drum stand or drum jacks must obviously be of adequate rating for
the drum weight, and they must be firmly supported on stable ground,
with plating beneath the stands/jacks if the ground is incapable of
supporting the weight directly.
The jacks must be erected vertical before any attempt is made to lift the
drum as any deviation from vertical will result in instability as the drum
is raised.
The drum spindle must be capable of bearing the weight of the drum.
Collars should be fitted to the spindle on either side of the drum in order
to prevent a) the drum from shifting along the spindle and fouling the
drum stand/jacks, and b) the spindle shifting in the stand/jacks.
The spindle should sit in bearing blocks and be greased to allow rotation
of the drum on the spindle. Minimising friction here is important to
minimising the pulling loads required to install the cable.
The drum should only be raised to a height just sufficient to allow the
drum to rotate, and the spindle must be set up level.
The drum should be positioned so that the cable is pulled off the top of
the drum so that in the event of an overrun a loop of cable is thrown over
the side of the drum. If the cable is pulled off the bottom, any overrun
will result in the cable becoming trapped between the drum and the
ground and quite possibly severely damaged.
The drum must not be allowed to rotate freely a braking system needs
to be available to stop the drum continuing to rotate under its own inertia
in the event of the pulling operation having to be interrupted.
Pulling equipment
Once again it goes without saying that the equipment used to pull the
cable must be of adequate strength for the job, properly maintained and
correctly applied.
The winch must be capable of exerting the required pulling load, and
firmly anchored so that the cable is moving towards the winch rather than
the winch moving towards the cable a condition that is not unknown!
143
The winch should be fitted with a dynamometer to monitor/measure the

pulling load, and ideally should be provided with a device that can be set
to limit the pulling tension to a value that will not damage the cable.
The pulling wire (or bond) must be suitable for the task, and in good
condition. Broken strands, rust (which may not be visible on the outer
surface of the bond) and kinks can singularly or in combination weaken
the bond significantly. A bond that breaks under tension is a very
dangerous animal indeed.
NO ONE SHOULD BE IN THE TRENCH WITH THE BOND WHEN
THE BOND IS UNDER TENSION.
All pulling bonds should be of the type referred to as killed bonds,
where the natural tendency of the wire to untwist as tension is applied has
been reduced (or preferably removed) by virtue of the construction of the
bond and pre-conditioning.
Although rarely seen on site, a sheathed bond is to be highly
recommended. An extruded plastic covering is applied over the wire
bond, which serves to protect the wires against damage and corrosion. It
reduces the tendency to kink and significantly reduces the coefficient of
friction of the bond against the rollers, skid plates, duct walls, etc.
Sheathing also reduces abrasion damage to plastic ducts.
A swivel must be installed between the bond and the attachment to the
cable so as to prevent any residual twist in the bond transferring to the
cable, and vice versa.
If the winch is not fitted with a dynamometer, a portable dynamometer
should be fitted between the swivel and the attachment to the cable.
All shackles etc. used to connect the various components need to be of
adequate rating, in good condition and properly installed and secured.
A length of rope should be tied to the nose of the cable and used to lift
the cable onto each roller failure to adopt this simple precaution can
result in rollers becoming displaced and misaligned, risking damage to
the cable itself.
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5.3.4 Backfill & reinstatement

The best advice here is refer to the New Roads & Street Works Act,
which goes in to these matters in some considerable detail! Two points
are worth stressing here.
Proper compaction is essential to satisfactory performance, both
thermally and mechanically. Compaction by mechanical means is
essential, the material being compacted in 75 mm layers with each layer
being tested before the next is placed and compacted.
The moisture content of the materials is critical to correct compaction. If
it is too wet or too dry, correct compaction cannot be achieved. Materials
must therefore not only be delivered to site at the right moisture content,
they must also be stored in such a manner as to maintain it! If the
moisture content moves outside limits, the moisture content must be
corrected, or the material discarded.
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5.4 Cable Pulling Tensions

Reference has already been made to the high forces involved in the
installation of power cables, and the need for the equipment to be up to
the task we will now look at the magnitude of those forces, and the
factors that determine them.
Most engineers will be familiar with the simple arithmetic of pulling a
cable on a straight route:-
Coefficient of friction =
Pulling tension, T
= W.L. kg
Cable - W kg/m
L metres
Figure 5.1 Calculating cable tension
Some typical coefficients of friction are given in the table below:
Situation
Coeff. of friction
Rough surfaces
0.5 - 1.0
Cement ducts
0.4 - 0.5
Plastic ducts
0.3 - 0.4
Lubricated plastic ducts
0.25
Cable rollers
0.2
Ball bearing rollers
0.1
Table 5.1 - Coefficients of friction for different surfaces
146
When a bend is involved, the situation becomes more complex:T1

T2
L1
L2
R
T3
Figure 5.2 Cable pulling tensions on a cable with a single bend
is the angle of the bend in radians, and R its radius in metres. T1, the
load on the nose of the cable as it approaches the bend, is given by
T1 := W L1
(5.1)
Actually, T1 = T0 + W.L1. , where T0 is the input tension to the first

part of the route the amount of pulling load required to pull the cable
off the drum. Even for a small drum T0 might amount to 50 kg, for large
drums it can be several hundred kg.
When the nose has passed round the bend, the new nose load T2 is given
by
T2 := (T1 cosh ( )) + T1 + ( W R)
2
sinh ( )
2 0.5
(5.2)
Fortunately for most purposes this horrendous expression can be replaced

by the slightly more memorable:T2 := T1 e
(5.3)
There is a small error involved when using the simpler expression, about
3% when T1 = 100 kg, but the error decreases to zero at T1 = 750 kg.
Hence:-
T2 := (W L1 ) e
(5.4)
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By the time the cable has reached position 3 the nose load T3 has
increased to:-
T3 := (W L1 ) e
+ W L2
(5.5)
Multiple bends further complicate matters:T1

T2
L1
R2
L2
R1
T3
T5
L3
T4
Figure 5.3 Cable pulling tensions on a cable with multiple bends
and the number of s required escalates:T1 := W L1

T2 := (W L1 ) e
T3 := (W L1 ) e
T4 :=
+ W L2
(W L1 ) e 1 + W L2 e 2
T5 := (W L3 ) +
(W L1 ) e 1 + W L2 e 2
(5.6)
Note: The above equations have a further simplification. They assume

that the coefficient of friction is uniform throughout the route. If this is
not the case, different values have to be used for each section.
Even so, it is apparent that multiple bends can result in very high pulling
tensions being required at the cable nose, and that as the bend angle
increases, so does the resulting pulling tension. And since the
equations involve powers of powers, the increase is, to put it mildly, not
exactly linear!
The equations are for cables pulled horizontally, and have to be modified
for uphill and downhill pulls. And strictly speaking, they only apply to a
148
single circular cable and have to be modified for twisted trefoil

assemblies; the equations for three single core cables pulled into the pipe
simultaneously (cradle formation) are different again.
Exercise 5.1
It is suggested that you set up a spreadsheet program in order to more
conveniently undertake the following exercises.
Imagine that the cable drum is to be positioned to the left of the above
route, and the cable pulled towards the right. Ignoring the load needed to
pull the cable from the drum (i.e. T0 = 0), evaluate the above equations
for T1 T5 for the following conditions:
W = 30 kg/m
1 = 30 degrees
= 0.25
2 = 90 degrees
L1 = 100 m
R1 = 5 m
L2 = 100 m
R2 = 3 m
L3 = 50 m
Your answer to Exercise 5.1
149
Your answer to Exercise 5.1 continued
Turn to the end of the book for suggested answers to the exercise
150
Exercise 5.2
Repeat the above exercise, but now let T0 = 100 kg.
151
5.4.1 Limits on pulling tensions

The pulling bond is commonly attached to the cable via a pulling
stocking, slipped over the end of the cable. Such arrangements are only
suitable for very light work, as the pulling load is concentrated on a short
length of cable, and the loads are applied to the mechanically weak outer
components of the cable.
These difficulties are overcome by pulling on the conductors, using a
specially designed pulling eye. This may be connected to the conductors
by soldering, by compression techniques, or simply by mechanical
clamping to the conductors. Of course, the pulling eye must also
incorporate suitable means of sealing the cable end.
The conductors are the strongest components in the cable, but they are
not infinitely strong. Pulling loads must be limited, depending upon the
conductor material.
Conductor
Allowable load in N/sq.mm of
material
conductor area
Copper
50.
Aluminium
35
Table 5.2 Pulling loads for conductor metals
For 3-core cables, the maximum allowable load is calculated on the basis
of two conductors only. For a 3-core 185 sq.mm. cable, copper
conductors can withstand 1.85 tonnes, whilst an aluminium conductored
cable would be limited to 1.3
tonnes
5.4.2 Bond pulling
Where very heavy cables have to be
installed, even conductor pulling
may
be
insufficient
to
accommodate the tensions needed
for a nose pull, particularly on
difficult routes. The answer is to
adopt the bond pulling technique
that distributes the pulling load
along the cable. And since the
cable goes round the bends without
152
Figure 5.3 Bond pulling
contact with skid plates, there are no bend effects to increase the pulling
tension so effectively the pulling load is simply:
weight/metre x length x coeff. of friction
5.4.3 Side loading limits
But the pulling tension is not the only important parameter. When the
cable travels round a bend it experiences a side load, and the amount of
side loading that a cable can withstand depends upon its construction.
Excessive side loading can flatten metallic sheaths and apply continuous
pressure to the dielectric, insulating papers can be fractured, voids
produced in solid dielectric cables, screen wires indented into XLPE
cores, and strippable screens separated from the XLPE insulation. Not to
be recommended!
The side loadings on the bends (sidewall pressure P n ) are given by the
equation.
P n :=
Tn
Rn
where
(5.7)
T n = Pulling tension at the bend (kg)

R n = Radius of the bend (m)
Taking the second bend of the earlier example.
P2 :=
1
2
+ W L2 e
(W L1 ) e
R2
(5.8)
The following are maximum side load limits with the cable against skid
plates, and wherever possible pulling should be arranged to provide lower
loads.
153
Cable construction
Maximum side load

skid plates (kg/m)
Polymeric cables, no metallic sheath
400
Cables with corrugated aluminium sheaths
2000
Cables with lead sheaths
500
Table 5.3 Maximum side loads using skid plates for three cable types
If vertical rollers are used on bends, the small diameter of the rollers
results in the side loading increasing dramatically.
Consequently,
vertical rollers should NEVER be used on bends well-greased skid
plates are essential when heavy and/or arduous pulls are required. But if
you must use vertical rollers, the following side load limits must be
applied. See Table 5.4.
Cable construction
Maximum side load

rollers, kg/m
Polymeric cables, no metallic sheath
100
Cables with corrugated aluminium sheaths
200
Cables with lead sheaths
50
Table 5.4 Maximum side loads using rollers for three cable types
This means that the pulling tension must be greatly reduced, and hence
the length of cable that can be pulled is reduced.
Obviously, the tension plays a major role in determining the sidewall
pressure.
154
Exercise 5.3
Using the same parameters as for the previous exercises, calculate the
sidewall pressure on the cable at the second bend (2, R2) of the above
route, when pulling from left to right, with T0 = 0 kg and T0 = 100 kg.
155
Exercise 5.4
Now imagine that the drum is to be positioned at the right hand end of
the above cable route, and the cable pulled from right to left you will
have to re-write the equations accordingly. Using the same parameters
as for the previous exercises, and again ignoring the drum load (i.e. T5 =
0 kg) calculate the tensions on the cable nose at the positions
corresponding to T0T5, and the sidewall pressure on the cable at the
(2, R2) bend.
156
Exercise 5.5
Repeat the calculation, but this time set the drum load to 100 kg.
157
5.4.4 Minimising pulling loads

It should now be apparent that careless setting up of a route can result in
pulling loads being much higher than necessary, thereby restricting the
amount of cable that can be installed in a single pull, and increasing the
risk of damage being inflicted upon the cable. Consideration of the
equations, together the examples that you have worked through, will
show how the tensile and sidewall loadings on the cable can be
minimised. In summary:
1. Maximise the radii of all bends and wherever possible minimise
their included angle.
2. Calculate the pulling loads for both directions of pulling before
deciding which way the cable should be pulled.
3. Reduce the coefficients of friction by:
lubricating ducts and skid plates
ensuring that adequate number of rollers are used
ensuring that the rollers are well lubricated.
4. Pay particular attention to the start of the route, as high loads here
have the most significant effect on the pulling load. In particular:
minimise the load needed to pull the cable off the drum.
Powered rollers or caterpillars can also be used, either at the start of the
route or part way along it, to further reduce the loads. As an alternative,
multiple winching positions can be set up along the route the cable
output from one section of the route is then the input to the next section,
but the input tension is reduced to zero, effectively splitting the route in
several smaller pulls.
5.4.5 Other factors affecting maximum pulling lengths
It should be obvious from the foregoing that, so far as nose pulling is
concerned, the route itself can determine the maximum length of cable
that can be pulled in one go when the pulling and side loads are at the
158
maximum values that the cable can withstand, then thats it, you cant go
any further without damaging the cable.
Thats not the case with a full bond pull of course, which distributes the
pulling load along the whole cable length and eliminates side wall
pressure limitations for a bond pull the length that can be installed in
one pull is, in theory, almost unlimited.
However there are other, perhaps less obvious, factors that, individually
or in combination, may impose other limits on the cable length. These
might include:
159
The maximum length of cable that can be manufactured as a

single length
The maximum weight of cable that can be handled by the

factory
The maximum weight of cable that can be transported to site
The maximum diameter of drum that can be transported to site
Space available on site for accommodating the transport

vehicle, crane and the drum stands
The ability of the ground to support the drum stand and cable
drum
The power of the available winching equipment
The length of pulling wire available
The strength of the available pulling wire
The time required to set up the route and pulling equipment,

and actually pull the cable into position
References and Further Reading

1. Bartnikas, R. and Srivastava, K. D (2000) Power and
Communication Cables: Theory and application, , McGrawHill, New York, , ISBN 0-07-135385-2
2. Heinholdt, L. et al, (1990) Power Cables and their Application
(3rd Edition), Vol. I, Siemens Aktiengesellschaft, Berlin, ISBN 38008-1535-9
3. Moore, G. F. et al (1997) Electric Cables Handbook (Third
Edition), , BICC Cables, London, ISBN 0-632-04075-0
4. Peschke, E. F. and von Olshausen, R. (1999) Cable Systems for
High and Extra-High Voltages Development, Manufacture,
Testing, Installation and Operation of Cables and their
Accessories: Publicis MCD Verlag, Munich, , ISBN 3-89578-1185
For safety related information, visit the HSE website at:
http://www.hse.gov.uk
160

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S5: Cable Installation

state the main items of legislation that need to be considered

list key points for route preparation

describe cable installation methods

calculate pulling loads for cables in straight trenches and ducts

describe methods of minimising pulling loads

EEE8050 Power Cables

S5: Cable Installation

5.1 Excavation, Blinding, Backfilling & Reinstatement

Excavation obvious really, the digging of the hole!

Backfilling the placing and compaction of material to fill the

Blinding the placing and compaction of backfill material in

Reinstatement the placing and compaction of the sub-base,

EEE8050 Power Cables

S5: Cable Installation

Although not appropriate to deal in detail with the various items of

Liaison with local authorities, police forces, etc.

The rights and duties of the various parties involved it is

Signing and guarding of the works, traffic control, pedestrian

Technical requirements for backfilling and reinstatement of

EEE8050 Power Cables

S5: Cable Installation

riding on fairground rides whatever. The Act itself contains little of

EEE8050 Power Cables

S5: Cable Installation

5.3 Some Points Regarding Cable Installation

Trench sides stable, full or half timbered as necessary to

Spoil to be placed away from trench edge to avoid it falling

Walkway along at least one side of the trench workmen

Smooth bottom, with gradual transitions in level.

Soft material to be placed and compacted before pulling the

No stones, sharp objects or protrusions.

Ducts should be proved with mandrel and cleaned

A bellmouth should be installed in the start of the duct,

A sump should be dug beneath the start of the duct to

EEE8050 Power Cables

S5: Cable Installation

Rollers placed every metre, or more frequently for heavy

Rollers should actually roll (!) and have no sharp projections.

Skid plates installed at bends, NOT vertical rollers.

Rollers and skid plates to be adequately secured.

Rollers and skid plates to be properly greased.

5.3.2 Alternative excavation methods

guided boring/directional drilling

5.3.3 Installation equipment

in full working order

properly set up and properly applied.

S5: Cable Installation

Cable drum set up

EEE8050 Power Cables

S5: Cable Installation

The winch should be fitted with a dynamometer to monitor/measure the

EEE8050 Power Cables

S5: Cable Installation

5.3.4 Backfill & reinstatement

EEE8050 Power Cables

S5: Cable Installation

5.4 Cable Pulling Tensions

Figure 5.1 Calculating cable tension

Some typical coefficients of friction are given in the table below:

Lubricated plastic ducts

Ball bearing rollers

Table 5.1 - Coefficients of friction for different surfaces