Users Guide

Electrical Distribution and Transmission

Systems Analyses and Design Programs

Cable Pulling Tensions

Power Analytics Corporation

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San Diego, California 92127
U.S.A.
U.S. Toll Free Phone: 800-362-0603
Fax: 858-675-9724
www.PowerAnalytics.com

©Copyright Power Analytics Corporation 2012

All rights reserved

Version 4.10.00 August 2007

Cable Pulling Tensions

IMPORTANT NOTE: Power Analytics Corporation’s software products are tools intended to be
used by trained professionals only. They are not substitutes for your professional judgment or for
independent verification and testing of results as they pertain to your specific application. Use of all
Power Analytics Corporation software products is governed by the terms and conditions of the End-
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request, read, and understand a copy of your EULA before proceeding.

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Power Analytics Corporation.

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 Cable Pulling Tensions

Table of Contents

I. FOREWORD ....................................................................................................................................................1

II. CABLE PULLING CAPABILITIES, FUNCTIONS AND FEATURES .........................................................1

III. INTRODUCTION ............................................................................................................................................1

III. CABLE PULLING TENSIONS AND SIDEWALL PRESSURES ..................................................................2

IV. CABLE CONFIGURATIONS ..........................................................................................................................2

V. CABLE DATA..................................................................................................................................................2

VI. DESIGN CRITERIA .........................................................................................................................................3

VII. COEFFICIENT OF FRICTION ........................................................................................................................3

VIII. PROFILES ........................................................................................................................................................3

IX. USE OF THE KEYBOARD .............................................................................................................................3

X. LIBRARIES ......................................................................................................................................................3

XI. CABLE REEL BACK PRESSURE ..................................................................................................................4

XII. METHOD OF CALCULATION ......................................................................................................................4

XIII. TECHNICAL PARAMETERS .........................................................................................................................4

XIV. 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. REFERENCES................................................................................................................................................21

XVI. GLOSSARY OF TERMS AND DEFINITIONS ............................................................................................ 21

XVII. ADDITIONAL NOTES ..................................................................................................................................23

APPENDIX A: Cable Pulling Tutorial .......................................................................................................................24

A 24

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Cable Pulling Tensions

Table of Figures

Figure 1 ..........................................................................................................................................................................2
Figure 2 ..........................................................................................................................................................................2
Figure 3 ..........................................................................................................................................................................2
Figure 4 ..........................................................................................................................................................................2
Figure 5 ..........................................................................................................................................................................7
Figure 6 ..........................................................................................................................................................................8
Figure 7 ..........................................................................................................................................................................9
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 ..........................................................................................................................................25

Table B: Recommended Maximum Sidewall Bearing Pressures .................................................................................25

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 Cable Pulling Tensions

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,
DESIGNBASE 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
DESIGNBASE's attention.

II. CABLE PULLING CAPABILITIES, FUNCTIONS AND FEATURES

 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;
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Cable Pulling Tensions

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.

IV. CABLE PULLING TENSIONS AND SIDEWALL PRESSURES

This program has been written for professional design engineers. DESIGNBASE 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.

V. 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

VI. 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.

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 Cable Pulling Tensions

VII. 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.

VIII. 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.

IX. PROFILES

DESIGNBASE 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.

X. USE OF THE KEYBOARD

This program makes use of FUNCTION KEYS 1-10 and ESC.

XI. 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.

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Cable Pulling Tensions

XII. CABLE REEL BACK PRESSURE

The cable reel backpressure is a common value expressing the estimated reel back tensions of
100 lbs.

XIII. 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.

XIV. 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 = conduit inside diameter in inches;

d =  1.05  nominal cable outside diameter in inches;

C = clearances in inches;

 1.05 Safety factor for manufacturer tolerance.

For single conductor cable pull

C = D-d (1)

For three-conductor cable pull:

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 Cable Pulling Tensions

D   d 
2 
C = - 1.366d + 0.5 ( D - d ) 1-    (2)
d   D - d 
For four-conductor cable pull:

2 d2
C = (D- d) - (3)
D- d
4: JAM RATIO

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: D = conduit inside diameter in inches,

and dn = nominal cable outside diameter in inches, (4)

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 = 1 (5)

For 3-single cables in triangular configuration:

1
Wc = (6)
  d  
2
 1 -   
  D - d 


For 3-single cables in cradled configuration:

2
4  d 
Wc = 1+   (7)
3  (D - d) 

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Cable Pulling Tensions

For 4-single cables in diamond configuration:

2
 d 
Wc = 1 + 2  (8)
 D- d 

Note that:

D = inside diameter of conduit in inches;

d = nominal outside diameter of a single cable in inches;

Wc = weight correction factor, no dimensions.

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 = basic coefficient of friction

Wc = weight correction factor

K = effective coefficient of friction

K = 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:

1
(Rc - D)
Ri = 2 (9)
12

where:

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 Cable Pulling Tensions

Ri = inside radius of bend in feet;

Rc = centerline radius of bend in inches;

D = diameter of duct in inches.

For single cable:

T
SWBP = (10)
R

For 3-cable cradled formation:

(3Wc - 2)T
SWBP = (11)
3R

For 3-cable triangular formation:

WcT
SWBP = (12)
2R

For 4-cable in diamond formation:

(Wc - 1)T
SWBP = (13)
R

Cable Sections

Figure 5

STRAIGHT OR HORIZONTAL PULL

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Cable Pulling Tensions

T2 = T1 + WKL (14)

L = actual length of the section of cable in feet

K = effective coefficient of friction

W = total weight of cable in conduit in pounds/foot

T1 = the tension at the beginning of pull in pounds

T2 = the tension at the end of pull in pounds

Figure 6

HORIZONTAL BEND

T2 = T1 Cosh(K )  FSin h(K )

F = T12  (WR) 2

 = bend angle from horizontal

R = inside radius of conduit bend

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 Cable Pulling Tensions

Figure 7
SLOPE UP PULL

T2 = T1 + LWX (15)

X = SIN  KCOS (16)

 measured from horizontal axis

Figure 8
SLOPE DOWN PULL

T2 = T1 - LWY (17)

Y = SIN   KCOS (18)

 measured from horizontal axis

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Cable Pulling Tensions

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

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
2
 L
 
4 D’  2
 = and R = (20)
L 4 D’

Use coefficient of friction  f for SWBP  150 lbs/ft

For T  RW

T2 = T1 + WKL (21)

For T  RW

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 Cable Pulling Tensions

T2 = T1 e4 K + RW[e4 K - 2 e3K + 2 eK - 1] (22)

D' = Depth of Dip from horizontal axis

1
S = length of the Dip Section
2

Figure 10

CONVEX DOWNWARD BEND

 measured from vertical axis

WR
T2 = T1 eK + Z (23)
1+ k 2

Z = 2KSIN   ( 1  K 2 ) ( e K  COS ) (24)

Figure 10A

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Cable Pulling Tensions

 = offset angle from vertical axis

 measured from vertical axis by angle 

WR
Ta = T1eK a + Z1 (25)
1+ K2

Z1 = 2 K SIN  a - (1- K2)(eK a - COS b ) (26)

WR
Tb = T1 eK b + Z2 (27)
1+ K2

Z2 = 2 K SIN  b - (1- K2)(eK b - COS b ) (28)

 =  b  a (29)

b = total angle from vertical axis

and T2 = Tb  Ta  T1 (30)

Figure 11
CONVEX UPWARD BEND

 measured from vertical axis

WR
T2 = T1 eK + Y1 (31)
1+ K2

Y1 = 2 K eK SIN  + (1 - K2)(1 - eK COS ) (32)

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 Cable Pulling Tensions

Figure 11A

 measured from vertical axis by

b  a

WR
Tb - Y2
1+ K2
T2 = (33)
eK a

Y2 = 2 K eK a SIN  a + (1 - K2)(1 - eK a COS a) (34)

WR
Tb = T1 eK b + Y3 (35)
1 + K2

Y3 = 2 K eK b SIN  b + (1 - K2)(1 - eK b COS b ) (36)

 =  b  a (37)

Figure 12
CONCAVE UPWARD BEND

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Cable Pulling Tensions

 measured from vertical axis

WR
T2 = T1 eK - Z (38)
1+ K2

Z = 2 K SIN  - (1- K2)(eK - COS ) (39)

Figure 12A

 measured from vertical axis by angle  a

WR
Ta = T1 eK a - Z1 (40)
1+ K2

Z1 = 2 K SIN  a - (1 - K2)(eK a - COS a ) (41)

WR
Tb = T1 eK b - Z2 (42)
1+ K2

Z2 = 2 K SIN  b - (1- K2)(eK b - COS b ) (43)

where

 =  b  a (44)

and

T2 = Tb  Ta  T1 (45)

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 Cable Pulling Tensions

Figure 13

CONCAVE DOWNWARD BEND

 measured from vertical axis

WR
T2 = T1 eK - Y1 (46)
1+ K2

Y1 = 2 K eK SIN  + (1 - K2)(1 - eK COS ) (47)

Figure 13A

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Cable Pulling Tensions

 measured from vertical axis by angle  a

WR
Tb + Y2
1 + K2
T2 = (48)
e K a

Y2 = 2 K eK a SIN  a + (1 - K2)(1 - eK a COS a ) (49)

WR
Tb = T1 eK b - Y3 (50)
1 + K2

Y3 = 2 K eK b SIN  b + (1 - K2)(1 - eK b COS b ) (51)

 =  b  a (52)

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.

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 Cable Pulling Tensions

- Provides graphic display of raceway sections in front, side, top and perspective views.

- 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.

15.1 USING THE PROGRAM'S BUILT-IN HELP FACILITY

“Help” menu consists of Contents, Using Help, and About….

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Cable Pulling Tensions

15.2 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 Edit the current job file. If no job is currently loaded, the program will automatically
generate a list from which to choose.

Analyze 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.

Tools This entry will get you into the program's general editors. Once there, you can edit
any of the program reference library data files.

Help Enter the system online help facility.

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 Cable Pulling Tensions

15.3 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.

Open… Load an existing job file for editing, viewing, or running an analysis.

Close Close the job file.

Save Save the file under the same name.

Save As… Save the file under a different name.

Print Print the results to a printer.

Print Setup… Setup the document print characteristics.

Exit Exit from the program

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

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Cable Pulling Tensions

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 Access the cable parameters library editor.

Compound Library Access the cable lubricating compounds library editor.

Raceway Library Access the cable raceway library editor.

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 Cable Pulling Tensions

XVI. 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.

2: Mehta, Yash, "Design and Installation of Large Feeders", Electrical Systems Design, pp.
32 - 36, June 1987.

3: 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.

4: 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.

XVII. GLOSSARY OF TERMS AND DEFINITIONS

1. Cable Area Enter the cable area, 0.001 - 99.999.

2. Cable Code Word Use up to 16 characters to uniquely describe or label the entry.

3. Cable Configuration Use either one of the +/- keys, or the <F2> key, to select the cable
configuration (e.g. single, triangular, etc.).

4. Cable Diameter Enter the cable diameter, 0.001 - 99.999.

5. Cable Insulation Enter up to 4 characters to describe the type insulation used in the
cable (e.g. "XPC").

6. Cable Material 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).

7. Cable Size Enter up to 4 characters to describe the cable size (e.g. "1/0").

8. Cable Weight Enter the cable weight per unit length, 0.001 - 99.999.

9. Coefficient of Friction Enter the coefficients of friction for the compound corresponding to
low and high sidewall bearing pressure, 0.001 - 99.999.

10. Compound Description Use up to 20 characters to describe or label the entry.

11. Job Description This field provides you with an area to describe the analysis or note
important characteristics of the analysis. (Optional, but
recommended).

12. Maximum Allowed SWP Enter the maximum allowed side wall bearing pressure, 0 - 9999.

13. Maximum Allowed Tension Enter the maximum allowed tension, 0 - 9999.

14. Nominal Raceway Size Enter the nominal size of the raceway, 0.001 - 99.999.

15. Output File Choices 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.

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Cable Pulling Tensions

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.

18. Raceway Diameter Enter the actual diameter of the raceway, 0.001 - 99.999.

19. Reel Back Tension Enter the reel back tension, 0 - 9999.9

20. Section Arc 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).

21. Section Length Enter the length of the section, 0.001 - 9999.999.

22. Section Offset 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.

23. Section Radius 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.

24. Section Type Use either one of the +/- keys, or the <F2> key, to select the section
type (e.g. horizontal pull, vertical dip, etc.).

25. System 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.

26. Theta In the perspective view, the angle of rotation about the y-axis.

27. View 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.

28. Voltage Enter the voltage, 0 - 99999.

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 Cable Pulling Tensions

XVIII. ADDITIONAL NOTES

Limitations/Caveats

Program Limitations:

Item Maximum

- Sections/Job 100

- Cables types in library 100

- Raceway sizes in library 100

- Lubricating compounds in library 100

Abbreviations Used:

Metric U.S. Customary

Mass kg - Kilogram = 2.205 lb - pound mass

Length m - meter = 3.281 ft - feet

cm - centimeter = 0.394 in - inches

Area sq cm - square cm = 0.155 sq in - square inch

Force N - Newton = 0.225 lb - pound force

Pressure kPa - 1000 Pascals = 0.145 psi - pounds/sq in

Files Used:

File Description
------------ -----------------------

* cpl Cable pull project file

cablpull hlp Help file

cables cbl Cable type library file

compound cml Lubricating compound library file

raceways rwl Raceway library file

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Cable Pulling Tensions

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: The cables will lay in a Triangular Configuration

2.5 < D/d < 3.0: The cables may lay in a Triangular or Cradled Configuration

D/d > 3.0: 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

24
 Cable Pulling Tensions

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.
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 Configuration SWBP equation
1 Single SWBP=T  R (eq.5.)
3 Cradled SWBP=[(3W-2) x2T]  3R(eq.6)
3 Triangular SWBP=WT  2R (eq.7)
4 Diamond 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 Maximum
1
Construction type SWBP (lbs./ft)
XLPE Insulation/Jacket-600V 1200
EPR, Neoprene-600V cable 1000
PE & XLPE insulation concentric wire shield:
Without jacket 2
1200
With encapsulating jacket 2000
PE and XLPE insulation,
LC shield LDPE jacket 1500
PE, XLPE, EPR insulation,
Concentric wire or tape shield,
LDPE and PVC sleeved jackets. 3
2000
Lead sheathed cable, with and without jackets:
XLPE insulation 2000
EPR insulation 2000
XLPE insulation, copper ribbon
Shield, MDPE sleeved jacket 2000

1
Note 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.
2
Note For pull of three single-conductor cables in parallel, a maximum SWBP of 750
lbs./ft is recommended.
3
Note The recommended SWBP limit should be reduced to 1500 lbs./ft when the jacket
is not applied tightly to the cable core.

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Cable Pulling Tensions

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 multi-
conductor 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
DESIGNBASE'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.

Plan View

11 10 9 8 765 4 3 2

Profile View

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

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 Cable Pulling Tensions

The following table describes each of the sections shown in Figure A-1. The order of the sections
indicates the forward pulling direction:

Length Arc Deg Off Radius

Sec Description Comments
(ft) (Deg) Vertical (ft)
F.I. Concave bend down 10.0 90.0 0.0 6.0 Feed-in section
1 Horizontal pull 80.0 0.0 0.0 0.0
2 Horizontal bend 25.0 90.0 0.0 12.5
3 Vertical dip 110.0 0.0 0.0 3.0
4 Horizontal pull 30.0 0.0 0.0 0.0
5 Convex bend down 7.0 45.0 0.0 6.5
6 Slope down 15.0 45.0 0.0 0.0
7 Concave bend down 7.0 45.0 0.0 6.5
8 Concave bend up 7.0 45.0 0.0 6.5
9 Slope up 30.0 45.0 0.0 0.0
10 Convex bend up 7.0 45.0 0.0 6.5
11 Horizontal pull 55.0 0.0 0.0 0.0

The cable data are as follows:

Type of pull: 3 cables in duct

Cable Description: 1000 kcmil 15kV shielded aluminum conductor.
Insulation: XLPE; PE jacket
Cable Diameter: 1.86 inches
2
Conductor area: 0.7854 inches
Weight of 3 cables: 5.05 LB/ft.
Diameter of Conduit: 6.065 inches
Conduit Material: PVC
Type of Lubricant: Soap and Water
Low SWBP: 0.45
High SWBP: 0.20
Reel back tension: 100 lbs.

Before using DESIGNBASE'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.

2. 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.

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Cable Pulling Tensions

Step 1.
From the main DesignBase
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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 Cable Pulling Tensions

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.

29
Cable Pulling Tensions

This screen capture

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

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 Cable Pulling Tensions

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.

Length Arc Deg Off Radius

Sec Description Comments
(ft) (Deg) Vertical (ft)
F.I. Concave bend down 10.0 90.0 0.0 6.0 Feed-in section
1 Horizontal pull 80.0 0.0 0.0 0.0
2 Horizontal bend 25.0 90.0 0.0 12.5
3 Vertical dip 110.0 0.0 0.0 3.0
4 Horizontal pull 30.0 0.0 0.0 0.0
5 Convex bend down 7.0 45.0 0.0 6.5
6 Slope down 15.0 45.0 0.0 0.0
7 Concave bend down 7.0 45.0 0.0 6.5
8 Concave bend up 7.0 45.0 0.0 6.5
9 Slope up 30.0 45.0 0.0 0.0
10 Convex bend up 7.0 45.0 0.0 6.5
11 Horizontal pull 55.0 0.0 0.0 0.0

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Cable Pulling Tensions

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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 Cable Pulling Tensions

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.

33
Cable Pulling Tensions

Section 1

Section 2

Section 3

Section 4

34
 Cable Pulling Tensions

Section 5

Section 6

Section 7

Section 8

35
Cable Pulling Tensions

Section 9

Section 10

Section 11

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 Cable Pulling Tensions

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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Cable Pulling Tensions

The output report can also

be generated as described
in step 16 of this tutorial.

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 Cable Pulling Tensions

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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Cable Pulling Tensions

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

40
 Cable Pulling Tensions

The Complete report follows:

DESIGNBASE 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 Cradled (3)

Reel back tension on cables 100.0 lb

Pulling Compound SOAP
Basic coefficient of friction
Low Sidewall bearing pressure 0.450
High Sidewall bearing pressure 0.200
Design maximum allowed tension 4000 lb
Design maximum allowed SWP 400 lb/ft

Raceway Data:

Size 6.000 in
Inner diameter of duct 6.065 in
Area 28.89 sq in
Percent fill 28.22

Cable Data: Library Name : DesignBase Standard

Size 1000 Type Aluminum Insulation XLP

Voltage 15000
Diameter of single cable 1.860 in
Area 0.785 sq in
Weight 1.683 lb/ft
Total area 2.356 sq in
Total weight 5.050 lb/ft

General Information:

Cable clearance in conduit with no tolerance 2.606 in

with 5% tolerance 2.247 in

Jam ratio with 3% tolerance on cable 3.166

with 5% tolerance on conduit 3.424

Feed-in Conduit Description

Concave bend down

Length 10.0 ft
Radius 6.0 ft
Tension 164.9 lb
Sidewall Bearing Presure 16.3 lb/ft
Arc 90.0
Angle off vertical axis 0.0

Forward Pull
Length Arc Deg Off Radius Actual Tension SWP
Sec Description (ft) (Deg) Vertical (ft) (ft) (lb) (lb/ft)

1 Horizontal pull 80.0 0.0 0.0 0.0 90.0 394 0.0

2 Horizontal bend 25.0 90.0 0.0 12.5 115.0 966 45.9
3 Vertical dip 110.0 0.0 0.0 3.0 225.0 1281 0.0
4 Horizontal pull 30.0 0.0 0.0 0.0 255.0 1367 0.0
5 Convex bend down 7.0 45.0 0.0 6.5 262.0 1663 152.0
6 Slop down 15.0 45.0 0.0 0.0 277.0 1640 0.0
7 Concave bend down 7.0 45.0 0.0 6.5 284.0 1981 181.1
8 Concave bend up 7.0 45.0 0.0 6.5 291.0 2419 221.1
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Cable Pulling Tensions

9 Slop up 30.0 45.0 0.0 0.0 321.0 2587 0.0

10 Convex bend up 7.0 45.0 0.0 6.5 328.0 3171 289.9
11 Horizontal pull 55.0 0.0 0.0 0.0 383.0 3329 0.0

All tension distributed on 2 cables 1664 lb/Conductor

2119 psi

All tension distributed on 3 cables 1110 lb/Conductor

1413 psi

Reverse Pull
Length Arc Deg Off Radius Actual Tension SWP
Sec Description (ft) (Deg) Vertical (ft) (ft) (lb) (lb/ft)

11 Horizontal pull 55.0 0.0 0.0 0.0 65.0 322 0.0

10 Convex bend down 7.0 45.0 0.0 6.5 72.0 509 46.5
9 Slop down 30.0 45.0 0.0 0.0 102.0 463 0.0
8 Concave bend down 7.0 45.0 0.0 6.5 109.0 693 63.4
7 Concave bend up 7.0 45.0 0.0 6.5 116.0 1077 98.4
6 Slop up 15.0 45.0 0.0 0.0 131.0 1161 0.0
5 Convex bend up 7.0 45.0 0.0 6.5 138.0 1842 168.4
4 Horizontal pull 30.0 0.0 0.0 0.0 168.0 1928 0.0
3 Vertical dip 110.0 0.0 0.0 3.0 278.0 2470 5.8
2 Horizontal bend 25.0 90.0 0.0 12.5 303.0 3671 174.5
1 Horizontal pull 80.0 0.0 0.0 0.0 383.0 3900 0.0

All tension distributed on 2 cables 1950 lb/Conductor

2483 psi

All tension distributed on 3 cables 1300 lb/Conductor

1655 psi

42
 Cable Pulling Tensions

Step 17.
To edit the program’s 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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Cable Pulling Tensions

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.

44
 Cable Pulling Tensions

45