Guidelines for the Installation of Cable in Cable Trays

Authors:

Bob Finke, Member The Okonite Company

1600 Parkwood Circle, Suite 603 Atlanta, Georgia 30339

Sid Ticker, Member Southwire Company One Southwire Drive Carrollton, Georgia 301 19

Abstract

The use of ladder type trays as raceways for insulated cables is becoming more prevalent These raceways are being more heavily loaded with increasing number and size of cables being installed With this growth in the use of tray, it is increasingly important that the tray and cable be installed within ipdustry recognized practices Discussed are the installation in tray of single and multi-conductoi insulated cables with design limitations, example calculations, equipment and equipment usage snd its limitations
Introduction

For pulling eyes and bolts the maximum tension is expressed as Tmax = 008'N'A E.q. (1) (For copper conductors and full hard drawn aluminum ) Tmax= .006 * N * A (For soft aluminum) Eq. (2)

For over thim years the use of ladder-type tray as a rigid structural systern for support of cables has grown dramatically Accompanying this increase, is the need for larger and longer cables to be installed Designers and installers are continually faced with difficult challenges in the layout and installation of cable in tray It is incumbent that pre-planning of an orderly sequence of events takes place to ensure that a successful installation occurs within recognized limits Cable installed in tray is subject to many of the same considerations as cable being installed in conduit systems Correctly calculated data and adherence to the design limits of the cables being installed with respect to tensions, sidewall pressures, and minimum bending radii increases the probability for a successfJl installation Damage occurs more frequently as a result of improper handling during installation, or inadequate protection after installation, Cable tray layout must take rnt 3 consideration the design Iimqts of the cable

Where Tmax = Maximum allowable pulling tension in Ibs/(kg) N = Number of conductors A = Conductor area in circular Mils

(mm2)
,006 or ,008 = Allowable stress per circular Mil (mm') area for referenced metals.

For pulling eyes and bolts, the tension ganerated in a straight section o f cable tray is expressed as: T= Lxwxf Where L

Eq. (3)

w
f

= The length of the cable trav section in feet (m) = The total weight of the cable being pulled in pounds (kg). = The coefficient of friction

A range of 15 to 25 is recommended f i r the coefficient of friction This coefficient is a fun( tion of the condition and alignment of sheaves

Installation Design Considerations and Formulas

. Tensions
The maximum allowable pulling tension that can be applied safely to a cable varies with the size and material of the conductor, the number of cables, and the method of attachment between the pulling line and cable

For basket grips the limit is 1000 Ibs (45 i 6 kglm) per grip or the value calculated in equatiJn (1) whichever is smaller This limit applies tcr a single conductor cable, a multi-conductor cable with a common overall Jacket,two or three twisted cables, or paralleled caoles using one giip It IS desirable to pull the cable by the conduc tors if this cho ce can be made rather than other @Degrips For conductor wedge type corripressior grips, the grip manufacturer should be consulted for design limits of these devices The same limits apply to the>,e devices as pblling eyes and bolts

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0-7803-2418-8-6/95 $4.00 0 1995 IEEE

Sidewall Pressures Sidewall pressure is defined as the pressure or force per unit length that is exerted on a cable when it is pulled around a sheave in a cabte tray. Darnage to cable while being installed in tray may occur if the maximum pressures are exceeded Where change in the direction of the cable pull is made, conveyor sheaves are employed Conveyor sheaves are multi-sheave devices bound together by a rigid meVal frame to form an arc of various degrees Rue to the small diameter of individual sheaves, it is recommended that each conveyo. sheave have a minimum of one sheave for every 20 degrees of bend (See Fig 1) The conveyor sheaves must be properly sized with radii sufficiently large to satisfy the maximum allowable sidewall Pressure limits and minimum bending radii requirevents

Typically, the tension out of the sheave is considered to be the same as the tension into the sheave. Many believe this to be true because the sheaves are considered to be frictionless. However, a moment of force is generated by the cable in its effort to conform to the shape of the sheaves. From practical experience, this force or tension is found to be 100 to 150 pounds (45.3-68.0kg)for larger cables This should be added to the total tension calculations. Calculation of the sidewall pressure out of the sheave can be obtained by using the following formula.
For single conductor cables or multi-conductor cable urider a common jacket the formula:

SWP = To/R

Eq. (4)

Where SWP = Sidewall Pressure in IbRt (kg/m) To = Tension out of sheave in pounds (kg) R = Radius of sheave in feet (m) When installing new cable in existing trays with existing cable, these existing cables need to be protected By placing a sheet of plywood or other rigid flat surfaced material over the tray in a bend, the sheave can be placed on top of the plywood and over the existing cable This surface not only protects the existing :able but provides support to the sheave
Reel Back Tension

.-

Cable

Cable

Proper

Improper

Fig. 1 -SHEAVE CONFIGURATION

Alignment of the conveyor sheaves to accept the cable should be made prior to the actual pull by applying tension to the pulling rope and aligning the rope in the center of the sheaves Slight adjustments during the pull may be required The sheaves and the individual sheaves of conveyor sheaves should be free turning and well lubricated The following table is recommended when considering maximuqt sidewall pressures

Reel back tension ISgenerated when removing the cable from the cable reel To further assure proper pulling of the cable, a reel drive mechanism or adequate manpower should be provided as the cable is being renoved from the cable reel An effort should be made to prevent free-wheeling of the reel during the pull Thc. drive mechanism (equipped with braking ability) works best in controlling cable payoff Some installers choose to use a fulcrum and wedge device to prevent free- wheeling This works well as lorig as the reel is nct elevated to a height where employment of such a rig is impossible This tension must be considered when calculating the total tensior developed during the installation The recormended tension io calculated by the equation Tr = 25 * W

TABLE I Maximum Sidewall Pressure PMAX (Lbslft or kglm) Power Cables Conductor Size <8AWG > 8AWG Lbslft kglm Lbslft kglm One Single Cable 300 136 500 2268 Two or More (parallel or plex) 500 226 E 1000 453 6

Eel

(5)

Where T r = Tension in pounds (kg) at the reel W = Weight per foot of cable in pounds (kg/m).

Multi Conductor Power & Control Cable One Cable Two or Msre Cables Instrument Cable Single Par Multipair

All Sizes Lhslft kglm 500 226 8 1000 4 5 3 6

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Pulling Device The common method of pulling cable into tray is with the use of an electric winch or tugger, or a truck-mounted winch. Pullers are generally rated between 4000 and 6500 pounds and provide a direct tension readout as the pull progresses. A truck- mounted winch has a very high tension limit, and the pulling tension is generally read by a inline dynamometer or a tensiometer. Some tuggers are equipped with control devices to allow for a preset tension to be programmed. If this preset tension is exceeded, the tugger will stop the pull. The route should be inspected foot by foot for faulty equipment, alignment of equipment, or other obstructions, since pre-installation calculations did not predict this situation The tension must be read constantly during the pull On extremely long pulls, the maximum pulling tension or sidewall pressure limits can often limit the distance a cable can be pulled. When using conventional pulling techniquets (i.e. one cable puller), the installation of splices should be consil3ered. Though not considered reliable by some, splices done ccvectly provide long reliable service. If an nstaller IS faced with a design calling tor a long length of cable to be installed without splices, and back feeding ISnot a consideration, a second, or assist puller can be used The risk of damage to the cable is increased when back feeding a significant portion of the cable and should be the last alternative employed The assist puller method is accornplished by strategically placing an additional puller and pulling line in d straight section of the pull T'iis puller is used to pull slack to the point of the assist puller By Dulling slack, the pulling tension and sidewall pressure from that point are reduced The lead or main puller will have a lesser load to pull, thereby reducincj philling tensiorls and sidewall pressures (See Fig 2)
Good communication between the main puller and the assist puller must be established The pi.rlling line of the assist puller is attached to the cable by using a "mare's tail " A swivel joint must be placed between the mare's tail or grip The mare's tail, or grip is made of high-strength fibers and IS woven around the cable to form a "Chinese finger" type grip that spreads the pulling tension over several feet of the cable surface The mare's tail must be sized prcperly to evenly distribute the pulling force over a sufficient amount of cable length The maximum allowable tension of the "mare's tail" is 3000 pounds (1360 8kg) for armored cable and 1000 pourids (453 6kg) for non-armored cable

In Fig 2, the assist puller (P2) is installed in a straight section of cable tray. The cable is pulled to the assist puller, but not around Bend No. 2. The assist puller rope is attached to the cable with a "mare's tail" at point P2'. When the pull is restarted, the main puller (PI) is now pulling only that cable from the "mare's tail" to point B. The assist puller (P2) is pulling the cable from the reel located at point A to the "mares tail", P2'. As the mare's tail approaches the assist puller, the sidewall pressure in Bend No. 2 is reduced as less cable is pulled from P2' to the bend by puller P I . The tension at puller P I remains fairly constant during the pull, but increases each time the "mare's tail" is reconnected to complete the pull. The tension at P2' increases as more cable is pulled from the reel Roller Mounting and SDacing Spacing of the rollers must be adequate to prevent the movfng cable from touching or rubbing the tray The iollers must be placed to keep the cdble in a fairly level position As the cable approaches t?e end of the pull the tension is significantly greater 3t this point, allowing for rnore distance between rollers Field experience shows that 15' (4 57m) apart is gcod but 10' (3 04) spacing is better The Objective is tn reduce drag and tension The following equation can be used to calculate spacing

s=,,6HT/ W

Where S = Distance between rollers in feet (neters) H = Height of top of rollers above tray surface in feet (meters) T = Tension in pounds (kg) W = Weight per foot of cable in Ibslft, (kglm) Use of this equation requires an estimate of tensions along the tray route Field experienc ? demonstrates it is not practical to establish varying numbers of different roller spacings The inst,iller should have excess rollers in place to prevenl excess sag and drag Armor LockinqlPinning

Field experience has shown that several layers of friction tape over the surface of the cable armor or jacket and beneath the "mare's tail" provide a better gripping surface The friction tape also serves as a bedding layer -- important when installing thermoplastic jacketed cable in Wdrm temperatures

I' "

Field experience has shown that the melallrc sheath of an interlocked or continuous corrugated armored cable will most likely sleeve if the armor is not adequately secured to the cable core conductors This can be accomplished by one of three methods 1 Drill two holes 90 degrees apart, within two feet from the pulling eye or bolt and inserting flat head bolts or solid wire rht?diameter of the bolts should be no smaller than 1/4' in diameter 2 Nail the armor by inserting nails through the armor 90 degrees apart to E depth into the cable core sufficient to allow them to not be easily removed 5 Use a compression grip ir conjunct on with the pulling eye or bolt

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Pulling LinelRope The pulling rope should be a high-strength, low- stretch, abrasion resistant rope. Its strength should exceed the maximum tension to be encountered during the cable pull. A safety factor of We is recommended. Double-braided ropes made of aramid and some polyester fibers are good. Manila hem&ine is also acceptable. Unstressed nylon or polyethylene is not recommended due to their high stretch characteristics. Lubrication Though not normally considered when installing cable in tray, field experience has shown that friction can be reduced if the cable is lubricated during the pulling process. This can be done by simply swabbing the cable as it pays off the reel. A lubricant compatible with cable outer covering should be considered. Roller and sheave bearings should be lubricated prior to the pull as well. Any rollers and sheaves with sharp protrusions and not free spinning should be repaired or replaced. Pulling Eves. Bolts and Swivels Pulting eyes or b o b can be factory or field installed. Factoryinstalled eyes or bolts are done under "ideal" conditions using presses adequate for crimping. Eyes and bob are madefor single and multi-conductor cable configurations. Some installers rig a pulling eye by using the bare conductor formed into an eye shape. If this method is chosen, the client or cable manufacturer should be contac:tedto ensure that the pulling tensions are not exceeded, and the strand cross-section is not reduced for convenience on large conductors. (See Fig. 3)

Cable Trav Lavout Whether installing cable in existing trays or newly installed trays, it is incumbent that the tray layout be considered when designing a cable pull. Cable tray bends must accommodate the minimum bending radius required during pulling so that the maximum sidewall pressure is not violated. (Tables 11,111 give minimum training radius for various cable construction.) The location of the tray determines if the proper pulling equipment can be used to complete the pull in one section. Location of the reel with respect to the tray entry point is critical as a large tension can be created at this point if the reel is a substantial distance from or below the tray entry point. These and other considerations must be addressed in the early stages of planning the installation. Design, planning, and coordination between the designer, installer, and end user is imperative.

l55 and Lm 170 310 3ZSandOvcr

TABLEID

Cables With Metallic Shieldine or Armor

Pmcrcontd
M u u "Bending h & u s as a Multipk dCabkDb t c r
COMPRESSION AR E A

Flr. J

- C0MPRBSSIO)V BrWCOMUPRBSSJON BOLT

A m v e l device should be used at the point where the pulling eye or bolt is attached to the pulling line. This serves to reduce the twist that normally occurs when pulling caMb during installation.

... U .... t i Armored, Comgated sheath o r intcrlockcd lypc .. 7 ..-. .7 WithrhicMedsingleconductor................ U .... U Withchieldcdmulti-awductor ................. 7 ..... 7
Nooanmorcd, Oat or mrmgated .... l2 Tapc s h i e d multicoodudor ................. 7 ..... 7 Uswith W C jackct .................... 15 .... 15 Nooarmortd, k t shapshieldcd ............... 8 ....... Non-od, wirc shicldcd ................... I2 .......

Anoored,Oattapcorwirctype ............. U Armored,sal& aluminum rhea* up t o 0-75 hrher cabk diamettr .................... 10' 0.76 t o I 5 inches cable diameter .............. 12 Ovcr 15 inches cablc diamctcr ................ 15

....

12

.... 10'

T a p c shielded single conductor ................ U

PUUlUGBiWBOLTGRIP / TO CABLE

m m
Y

SR'lVIL

ROPE TO

I -

7 1 1

With shiddcd conductorsl2

Us = Longitudinally applied mrrugatcdshield

Fig. I SIIYEI. INSTALLATION

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Other Considerations TemDerature Considerations Prior to making the pull, the cable temperature should be warm enough to prevent cracking of all the various non metallic components. The cable should be kept in a heated indoor storage area for 48 hours prior to installation in extreme low temperature cases.

Number of Bends Every bend whether vertical or horizontal increases the tensions and complicates the cable pull. Where design allows, these bends need to be minimized. The layout should not be looked at as trying to get cable from point A to point E. but rather what design limits are inherent with regard to the cable being installed. Decisions can then be made about splices and at what point should the splice be made. The worst case is to actually get into a cable pull where design calculation limits are at maximum and be forced to splice at a point in the cable pull that was not given good forethought and planning. Cable tray configurations that contain numerous horizontal and vertical bends may satisfy the maximum calculation limits for tension, sidewall pressuie, and bending radii. However, the practicality of pulling cable through the tray system should be judged after site visits and inspections. Interim steps during installation may be considered such as spanning or bridging cable near bends prior to final training of cables into the cable tray configuration. Maximum Cable Lenaths Maximum cable lengths are driven by two variables. At the factory, the mwknum length is related to production and testing capabilities. At the job site, the logistics of the site conditions andor installation equipment dictates cable lengths. The gross weight and overall dimensions of the reel should always be considered at the planning stage.

rypC or insulation
or Jacket
PVC

Table IV Minimum Temperature for Installation

-10C . . . . . . . . . 14F 4 C . . . . . . . . 40F -40C . . . . . . . . 40F
4C

EP R PE
XLPE
PVC (Arctic)

. . . . . . . . 4YiF

-40C CSP(Hypa1on)ORCPE -20C:

........

.AO"J

. . . . . . . 4F

Trav Height Height of the tray should be minimized where possible so that l icranes and elevated platforms do not become necessary to position reels of cable (See Fig.5) If this is not possible, the installer should make necessary equipment or platform arrangements to reduce the tension applied to the cable when originatvng the pull.. In some cases, cable can be installed by loading the cable reel on a crane, l i n g the cable above the tray and then moving the reel parallel to the tray and placing the cable in its tray position. In rare cases, the cable reel can be l i e d by helicopter, lifting the cable reel above the tray, then moving along the tray route and placing the cable in the tray Reliable breaking of the reels is recommended when using these methods.

7 oday, the splice designs for low and medium voltage cable constructions are sound, easy to install, and reliable. Splicing is a viable option when planning and defining an installation scope of work that responds to the best cost- effective cable tray installation.
Pull Preparation The dynamic and mechanical forces that exist during cable movement should be recognized and respected. The installation crew, inspectors, and visitors to the jobsite should be trained and briefed on the planned operations. Tray Obstacles Where design allows, trays should be installed so that obstacles do not exist to inhibit installation of sheaves and rollers. In addition, thought should be given to support structure. Many times an installation requires that the sheavelroller apparatus be attached and suspended. The support structure must have adequate mechanical strength to handle the tensions applied to the cable when making the pull Cable tray is not designed for support structure of sheaves. Confirm the direction of the pull derived from tension, and sidewall pressure calculabons, and if pulling equipment can be set up (See examples below ) Two-way communications and adeqdate manpower should be provided at both feeding and pulling ends of the cable pull Manpower should be placed strategically (at bend locations) along the pull route to ensure the cable maintains alignment in the rollers and sheaves. Twoway communications at the sheaves should be prowled

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Establish that the pulling equipment is adequate for the anticipated tensions and can provide a smooth uninterrupted pull and speed control. Variations in speed will cause "galloping." Establish adequate tension monitoring. Lubricate all rollers and sheaves and coifirm they are all freeturning Consideration should be given to the last piece of cable coming off the reel. This section of cable is generally not secured to the reel drum by a tether: personnel safety must be addressed. Pullina the Cable The start of the pull should be slowly accelerated to be sure damage is not incurred while the cable is being fed into the cable tray fron the reel. After entry into the tray, the pull should be accelerated to a constant pulling speed in the range of 15 feet per minute (4 5 7 m V " ) to 50 feet per minute (15 2 4 m l m i ~ ) The pull should be contiriuous without stopping

Maximum Sidewall Pressure: 1000 Ib (453.6kg) per foot of bend radius for three conductor cable. With a radius of 3 feet for all sheaves the maximum pulling tension is 3000 Ibs. (1360.8kg) A precise calculation of the effective distance between cable reel and sheave shown in Fig 6 may be made at the start of the pull, (if reel and sheave dimensions, A-frame or reel jack details are known and if the mounting height of rollers on the cable tray is established). The actual height will change as successive layers are removed from the reel. In general, it is sufficiently accurate to treat the cable tray elevation above the floor as the reel elevation, unless the cable reel is elevated above normal floor mounting height. Ths following calculations assume that properly sized st-eaves are installed securely to accommodate changes in direction along the cable tray route
3 f t (0.9 ' m ) for all sheaver ihe maximum pulling lenston is
3000 Ib (81 4 4 8 k d

Ret ord pulling tension reading at frequent intervals particula ly after exiting conveyor sheaves
Summary As inore cable tray installabons are being utilized it is imperative that installation guidelines be employed so that reliable, trouble free service ltfe is obtained Limits of pulling tension, sidewall pressure, and minimum bending radii have been described showing that installation calculaticns are the basis of avoiding violations of these limits. Frequently, these calculations are ignored resulting in cable damage which can ultimately reduce the service life of the cable For a successful cable tray installation to rake place, equipme i t must be properly sized and utilized From calculations, the size lating, and location of the equipment with respect to the cable alii1 cable tray layout can be made In l a w cable tray design, the cable to be installed should be considert-d with regard to its installation limits Proper pre-design can alleviate most field installation problems C oordination between Dwner, designer, and installer is paramount for a successf 11 installation Example

._ m.&.&lAhL

Case A Tr=25w=25x8.67 lb=217 Ib. (98.43kg) This assumes that cable is removed from the reel under tension from the pulling end. Ta=125 bs (56 7kg) Assumed tension adder for bends Tw=wt/ft of cable times height T1=Tr+Tw+Ta=217+30 x 8 67+125 = 602 Ib (273.06kg) T2=T1+ 3OOx 1 3+ Ta = 602 + 390 + 125 = 1,117 Ib (506 6kg) T3=T2+Tw+Ta= 1,117 + 30 x 867 + 125 = 1,502 ih (681 3kg) T4=T3+ 230 x 1 3 = 1,502 + 260 = 1,762(799 2kg\

Calculations Cable in Tray See Fig. 6

A 3/C-531 kcmrl copper 15KV-133% level armared cable (Type MV-90 0 1 MC approved for cable tray use per NEC)
Approximate OD=3 60 inches (91.4") Net Weight Per Foot = 8.67 Ib ( 3 9 . 3 ~ g ) Minimurn Bend Radius is equal to 7xOD (during installation) 01 larger to satisfy the maximum allowable sidewall pressure limit Minimum bend radius =7 X 3 6 in = 25 2 ' (640 08") Effective :able Weight wt = 8 67 X 15 = 1 30 Ib

Use pulling eye on conductors and install basket grip over metal sheath securely attached to pulling line

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Case B Tr=25w = 217 Ib. (98 43kg) T4=Tr+yw+Ta = 217 + 60 x 8.67 + 125 = 862 Ib (391 Okg) T3=T4+ 200 x 1.3 + 125 = 1,247 Ib (565.6kg) T2=T3-Tw+Ta = 1,247 - 30 x 8.67 + 125 = 1,112 Ib. (504.4kg) Tl=T2 + 300 x 1.3 = 1,502 Ib. (681 30kg) Use pulling eyes on conductors and install basket grip over metal sheath securely attached to pulling line. Difference in tension =1762-1502 = 260 Ib. (1 17 9kg) Even though the bends are not treated as tension multipliers the direction of pull affects the total tension. In CASE A the cable is raised 60 ft vertically. In CASE R the cable ISraised a net height of only 30 ft with respect to pulling tension. Acknowledgment
The authors would like to acknowledge Robert Cotton (Southirvire Company) for his help in the preparation, editing, contributions, and support in the writing of this paper

References 1. T 4. Kommers, Electric Cable Installation in Raceways, Technical Paper, June 1980, Pulp & Paper Conference Portland, Oregon. T P. Arnold and C D Mercier, Power Cable Manual, Southwire Company, 1991 The Okonite Company, Installation Practices for Cable

2.
3.

Raceway Systems, 1988.

Biography

Bob H. Finke (M'65) received the B.S.E.E degree from Texas A & I College, Kingsville, Texas in 1964. He joined PPG A in 1964 with Industries, Chemical Division, Lake Charles, L assignnients in plant engineering, project design and construction, and maintenance. In 1971, he joined The Okonite Company in their sales department He joined Okonite's applications engineering department in 1992. tie is a member of Power Engineering Society and Industry Applications Society of IEEE and the P E : ; Insulated Conductor Committee and the IAS Pulp & Paper Technical Committee.
Sid Ticker - A graduate of New York Institute of Applied Arts & Sciences, began his career as a military instructor at Fort Monmouth, NJ, Microwave Radio School, Signal Corp. In 1960, he joined Phelps Dodge Wire 8 Cable Company, working as a senior lab technician in the area of UL and GovernmentfMilitary Specifications. In 1973, he became Quality assurance manager for Phe ps Dodge Cable & Wire, responsible for four manufacturing plants and providing technical assistance in the area of installation, splicing and terminations. IP 1978, he became Assistaiit Plant Manager, Pape! Insulated Cable Plant, Yonkers. NY, ressonsible for operations. In 1983, he became District Sales Managttr. Direct Sales New York, New Jersey, Pennsylvania and Connecticut, In 1984, he joined Hi.Tech Cable in Starkville, MS, as an Applications Engineer and QA Manager. In 1989, he was promoted to Senior Applicatiovs Engineer at Southwire Company in Carrollton, GA, responsible fcir providing technical support to sales ai id engineering

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