Professional Documents
Culture Documents
Simple Calculations For Pulling Cable
Simple Calculations For Pulling Cable
Simple Calculations For Pulling Cable
November 1, 2001 12:00 PM, By John DeDad, Editorial Director EC&M http://ecmweb.com/mag/electric_simple_calculations_cable/
You can keep from damaging cables during the cable pulling process by paying attention to installation
parameters and correctly sizing bends.
Even if your crew has taken all the necessary precautions in paying out cable and handling the 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.
Area = 3 x (pi ÷ 4) x d2
Area = 3 x .785 x 1.602
Area = 6.03 sq. in.
In this situation, Table 4 (Rigid Metal Conduit) in Chapter 9 of the NEC calls for a 5-in. conduit. This conduit size will
allow you to slip under the allowable percentage of conductor fill by 10%.
Position makes a difference. It may not seem important, but each cable's
geometric position (Fig. 2 right) has a unique effect on the amount of
frictional force, or drag, the conductors endure during the pull. In addition, the
positioning affects the weight factor. By using the ratio of the raceway's inside
diameter (D) to the conductor's outside diameter (d), you can find what
geometric position you can expect to see.
Although the position of one cable is easy to predict (Fig. 2A at the top of
page 41), other positions are not as obvious:
Triangular (Fig. 2B): 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 (Fig. 2C): 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 (Fig. 2D): 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:
D÷d
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.
Conductors “weigh” more than you think. Now that you know the cable positioning, it's necessary to determine
how the conductors' weight will affect the pull.
Weight correction factor is important because when you pull two or more conductors in a raceway, the sum of the
forces developed between the conductors and the raceway is always greater than the sum of the individual conductor
weights.
W = 1 + {(4 ÷ 3) x [d ÷ (D-d)2}
W = 1 + {(4 ÷ 3) x [160 ÷ (3.47)2}
W = 1.28
Don't jam those cables. When sizing your raceway system, you should always consider the possibility of cables
jamming or wedging. This usually occurs when you have three or more individual conductors lying side by side in a
single plane. As you pull the conductors through a bend, the curvature of the bend tends to squeeze the conductors
together.
However, if you're pulling one or two conductor cables, a multiconductor cable with an overall jacket, or a
nonjacketed multiconductor cable made of a triplexed or quadruplexed conductor assembly, you probably don't have
to worry about jamming.
Use the following formula to determine the likelihood of jamming. Use the inside diameter of the raceway and the
outside diameter of the individual conductor:
1.05 x (D ÷ d)
The constant 1.05 factor is a reflection of the fact that bends are actually oval in the sectional view.
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.
Conductors need headroom, too. Don't forget you must also have adequate clearance between the uppermost
conductor and the top of the raceway to ensure a safe and easy pull. For straight pulls, you can have a clearance as
small as ¼ in. and still be safe. For more
complex pulls, you should have between ½ in.
and 1 in.
Use the equations in Table 2 (right) on page 42
(which are based on worst-case scenarios) to
find the clearance distance for a given raceway
and cable sitting position. Note that these
equations include a 5% increase (a factor 1.05)
to compensate for variations in cable and
raceway diameters and the oval shape of the
raceway sections at bends. However, because the conductors in the current example will sit in the cradle position,
you will not need to check for clearance.
T=LxwxfxW
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.
Cables are sensitive to pressure on their walls. The final step in the cable-pulling process is determining whether
the pulling tension will compromise the conductor's sidewall bearing pressure limit. When you pull a cable or
individual conductors through a raceway bend or around a sheave, sidewall bearing pressure (SWBP) develops
between the cable or conductor wall and the bend or sheave.
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.
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.