FactorsThatInfluenceTheInstallation

PerformanceOfBlownCables&Fibres
RalphSutehall PrincipalInstallation&ApplicationsEngineer.

PrysmianGroup
Thursday8th December,17.25 18.25pm

Cable/FibreUnitDesigns

(4fibreversionshown)

(96fibreversionshown)

(144fibreversionshown)

BlownFibre

Minicables

ConventionalBlownCables

FibreCount

1 12f

24 218f

24 288f

Diameter
Range

1.0 1.4mm

5.7 8.8mm

12.8 15.1mm

Tube/DuctSize

3.5/5.0mm

8/10mm,10/12mm
12/16mm

20/25mm

DuctDesigns

BlownFibre

Minicables

ACTION

Max.TubeCount

Upto24

Upto7

Max.FibreCount

Upto288f

Upto1008f

288f

DiameterRange

11 34mm

12 45mm

25mm

TypicalBlowing
Distance

800 1000mts

1000 2500mts

Upto3000mts

Typicalblowingdistancesaregovernedbyroutedifficulty

FillFactors&FlowRates

BlownFibre

MiniCables

ACTION

FillFactor

8 16%

8mmBore 52 66%
10mmBore 42 77%

41 56%

AirflowRate
@10bar

18l/min

8mmBore 160l/min
10mmBore 280l/min

~1500l/min

TypicalBlowing
Distance

800 1000mts

1000 2500mts

Upto3000mts

FreeSpace

37mm2

250 290mm2

1077 1128mm2

Influences
CableDesign
MiniDuctDesign
RouteDesign
QualityOfMiniductInstallation
InstallationEquipment

CrashTest.

Inorderforthefindingsinthispresentationtobevalidwemustassume
thatpriortoanyinstallationcommencingtheinstallerhasundertaken
aCrashTest withthecable/fibreandduct.
Thiswilldeterminethemaximumlevelofpushforcethatcanbesafely
appliedtothecable/fibrebytheblowinghead.
Thiswillensurethatthecable/fibrewillbeinstalledinamannerthat
Willnotdamageit.

RouteConfiguration ForTheoreticalCalculations

25 m
15 m

Start
110 m
180 m

RouteConfigurations ForPracticalEvaluations

Multiple
Ducts
1m

100 m

Total route length 1100 m

As recommended by IEC 60794-1-2 Ed 3.0 draft

Mini-duct Design

Cable/Fibre Unit Design

Route Design

Installation Equipment

Installation Of
Mini-duct &
Cable/Fibre

CableDesign
CableDesign

Factors
CoefficientOfFrictionOfCableSheathMaterial
Diameter
Stiffness
Weight

F ill facto r (% )

CableDiameter FillFactor
90
80
70
60
50
40
30
20
10
0

8.0mm Bore

10.0mm Bore

5.2

5.4

5.6

5.8

6.2

Cable Diameter (mm)

6.4

6.6

6.8

CableDiameter Cable ReductionInAirFlowDuring

InstallationOfA6.5mm DiaCable

Air Flow (l/min)

450
400
350
300
250
200
150

14 bar/10mm bore

100
50

10 bar/10mm bore
14 bar/8mm bore
10 bar/8mm bore

0
0

200

400

600

800

1000

Distance (m)

Air flow

Installation performance for the cable

1200

CableDiameter AffectofPushForce
1600

Distance (m)

1400
1200
300N

1000

225N

800
150N

600
400
200
0
0.1

0.11

0.12

0.13

0.14

0.15

Coefficient of Friction

Push force

Installation performance of the cable

0.16

CableSheathFinish

Smooth

Reflective

Highly
Reflective

Smooth - Air flow

Highly Reflective - Viscous Drag of Air

CableDiameter AffectofPushForce
CoF0.1 Pitch20m
1600

6.5/10mm-300N

Distance (m)

1400
1200
1000

5.7/8mm-200N

800
600
400
200
0
0

0.05

0.1

0.15

0.2

0.25

0.3

Amplitude (m)

Cable diameter

Maximum push force

Blowing performance

Weight
1600

Distance (m)

1400
33 kgs/km

1200
1000

42 kgs/km

800
600
400
200
0
0.1

0.11

0.12

0.13

0.14

Coefficient of Friction
Weight

Blowing performance

0.15

0.16

MiniDuctDesign

Factors
CoefficientOfFrictionOfInnerBore
Diameter
MiniductConfiguration

AffectOfCoefficientOfFriction
1600

5.7mm Diameter Cable

Distance (m)

1400
1200
1000

6.5mm Diameter Cable

800
600
400
200
0
0.1

0.11

0.12

0.13

0.14

0.15

Coefficient of Friction
Coefficient of friction

Blowing performance

0.16

AffectOfMiniductBoreSize 6.5mmDiaCable
PushForceRequiredToKeepInstallationSpeedAt60m/min

Push Force (bar)

6
5
4

8mm Bore

3
10mm Bore

2
1
0
0

200

400

600

800

1000

Distance (m)
Fill factor

Installation speed

Blowing performance

1200

MiniductConfiguration
CableType

Stiffness(Nm2)

12

49

153

Trench Floor
The ability of the duct cable to follow undulations, horizontal or vertical, has a
significant affect on the blowing performance.

RouteDesign

Factors
Length
Length
QualityOfDesign
QualityOfDesign

Air F lo w (l/m in )

10 bar
12 bar
14 bar

AffectOfRouteDistance 10/8mmMiniduct

500
450
400
350
300
250
200
150
100
50
0
200

400

600
Route Length (m)

Route length

Air flow

800

1000

QualityOfMiniduct
Installation

Factors
Undulations

LackOfUnderstanding?

AffectOfInstallation 6.5mmCableInto8mmBore
Miniduct
1600
20 m Pitch
0.1 CoF

20 m Pitch
0.16 CoF

1400
Distance (m)

1200
1000
800
600

5 m Pitch
0.1 CoF

400
200

5 m Pitch
0.16 CoF

0
0

0.05

0.1

0.15

0.2

0.25

0.3

Amplitude (m)

Quality of installation of mini-duct

Blowing performance

AffectOfInstallation 6.5mmCableInto10mmBore
Miniduct
1600

Distance (m)

1400

20 m Pitch
0.1 CoF

20 m Pitch
0.16 CoF

1200
1000
800

5 m Pitch
0.1 CoF

600
400

5 m Pitch
0.16 CoF

200
0
0

0.05

0.1

0.15

0.2

0.25

0.3

Amplitude (m)
An approximate 10% improvement in blowing performance over
that of an 8mm bore mini-duct.

InstallationEquipment

Factors
BlowingHead
CablePayoff
Compressor
Lubricant

AffectOfPushForce 0.1CoF 5.7mm&6.5mmCable

Distance (m)

IntoA10mmBoreMiniduct.300NPushForce
1600
1400
1200
1000
800
600
400

6.5/20m Pitch

5.7/20m Pitch

5.7/5m Pitch
6.5/5m Pitch

200
0
0

0.05

0.1

0.15

0.2

0.25

0.3

Amplitude (m)
Assuming that the maximum push force can be applied to each cable
then the installation performance of the reduced diameter
cable will be the best.

AffectOfPushForce 0.1CoF 5.7mmCableIntoA8mm

D istance (m )

BoreMiniduct
1600
1400
1200
1000
800
600
400
200
0

300N/20m Pitch
200N/20m Pitch

300N/5m Pitch
200N/5m Pitch

0.05

0.1

0.15

0.2

0.25

0.3

Amplitude (m)
In order to gain the benefits from a reduction in cable diameter the maximum
push force that can be applied to the cable must remain
at a high level.

Compressor
Ashasbeenseenfromthepreviousgraphsitis
importanttomaximisetheairflowthroughthe
route.Inordertoachievethisthecompressormust
beabletodeliverairattypically14barminimum.
Thisairshouldbecleananddryandshouldbe
deliveredtotheblowinghead/miniductviaan
aftercooler.
Ifusingpneumaticallydrivenblowingheadsthen
considerationjustbegiventothelevelofairthatis
beingconsumedbytheairmotor.

AffectOfAftercooler
8
7

100% RH, No A/c

Water Flow Rate (l/hr)

6
5
4

50% RH, No A/c

3
2
1

Aftercooler

0
-20

-10

10

20

30

40

Ambient Temperature (C)

Use aftercooler: Moisture Level in Compressed Air

50

60

CableDrums

3kms Of Cable

Old vs New

Must be lightweight but strong enough to protect the cable.

Material must be smooth so that the cable sheath is not damaged if it
comes into contact with the flange.

CablePayoff

Spindle Roller Bearing

Axle Collar

These are important as you must be able to provide an even low tension
during the installation of the cable.

Lubricant
Ithasbeenshownthatthecoefficent offrictionbetween
thecableandtheminiductboreiscrucial.Itistherefore
recommendedthatadditionalwetlubricantisaddedto
theductpriortoinstallingthecableorlubricatingthe
cableduringtheinstallationprocess.Thiscanimprovethe
installationperformanceofthecablebyasmuchas20%.
Thiswetlubricantmustbespecificallydesignedforthe
installationofminicables.Usinglubricantdesignedfor
winchedcablesisnotrecommended.
Theuseofwetlubricantisnotrecommendedforusewith
blownfibre.

InlineLubricators

Suitable for mini-duct sizes up to 16mm.

Suitable for cable sizes up to 9mm

100
90
80
70
60

Sponge Application

Maximum Blowing Distance

%ageAffectOfLubricationMethod

50
40
30
20
10
0
HDPE Mini-duct Only

Low Friction Liner

Mini-duct

No Lubricator

Lubricator

Low Friction Liner

Mini-duct plus Field
Lubrication

Summary

Route Design

Conclusions
Theinstallationofminicables/fibresintomini
ductsisaninteractivesystem.
Primaryfactors:
thequalityoftheinstallationoftheminiductcable.
thecoefficientoffriction,betweentheminicableand
miniductbore.

Settinguptheinstallationequipmentcorrectly
byundertakingacrashtest