00-Pzarea Cablurilor de Inalta Tensiune PRC0016 - R01 - Cable - Laying - GB

TECHNICAL Information
PROCEDURE
Laying of High-Voltage Cables
Dokument Nr. / Document No.: PRC0016

Datei / File: PRC0016_R01_cable_laying_gb.docx
erstellt von geprüft von genehmigt von

Rev.
created by checked by approved by
00 15.08.2013 K.-B.Tse 15.08.2013 H.-P. May 15.08.2013 H.-P. May
01 19.01.2014 H.-P. May 20.01.2014 K.-B. Tse 20.01.2014 H.-P. May
Anzahl Seiten / No. of pages: 11 Anlagen / Enclosures: 0
Düsseldorfer Straße 400

nkt cables GmbH Im Chempark
Engineering High Voltage Cables D – 51061 Köln / Cologne
PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012
17/1.0/16.07.14/PCPDOC-238-1411
CON TE N T
0 Modifications ........................................................................................................... 3
1 General ................................................................................................................... 4
2 Safety ...................................................................................................................... 4
3 Documentation ........................................................................................................ 4
4 Equipment ............................................................................................................... 5
5 Communication ....................................................................................................... 5
6 Preparation for Cable Laying................................................................................... 5
6.1 Advance Information ............................................................................................... 5
6.2 Position of Cable Drum ........................................................................................... 6
6.3 Pulling Winch and Rope .......................................................................................... 7
6.4 Calibration ............................................................................................................... 7
6.5 Pulling Head and Pulling Stocking .......................................................................... 8
6.6 Cable Pushing Device ............................................................................................. 8
6.7 Preparation of the Cable Route ............................................................................... 8
7 Cable Pulling ........................................................................................................... 9
8 Final Placing of the Cable ..................................................................................... 10
9 Sheath Testing after Cable Laying ........................................................................ 10
10 Summary of Important Points ................................................................................ 11
11 References ............................................................................................................ 11
12 Drawings ............................................................................................................... 11
17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 2

0 MODIFICATIONS
Rev.
00 first issue (German only)
01 additions and modifications in all sections
This document is the English translation of the original German version.

In case of discrepancies the German text prevails.

1 GENERAL
The purpose of this document is the provision of an overview concerning important
factors to be considered during cable pulling and laying.
The most common method for laying of high-voltage cables is the so-called "nose-
pulling" method. The pulling rope is fixed to the head of the cable. This can be
done at the pulling head which is directly installed on the cable conductor. More
often a pulling stocking is used to which the rope is connected.
The advantage of the pulling stocking is that it can be used again. During cable
pulling care shall be taken that pulling forces and sidewall pressures are kept to a
minimum. This is of special importance in the case of long cable lengths and high
cable weights.
Special laying techniques, for example laying of cables in deep tunnels or the
bond-pulling method, are not covered by this document.
2 SAFETY
Danger to persons and environment must be prevented under all circumstances.
Health and safety regulations must strictly be adhered to. The personnel involved
have to be instructed accordingly and shall dispose of the appropriate certificates.
Additional project-related requirements are to be observed as well. The cable
laying contractor is fully responsible for all activities in this respect. Any works
made in advance by third parties are to be carefully checked before making use of
it. Those are for example switched-off status of equipment, jointing pits, installation
scaffolds and the like.
3 DOCUMENTATION
Proper documentation is of high importance. Position and laying process of each
cable length shall be recorded in a cable laying report which shall comprise as a
minimum:
o name of cable connection and stations
o power cable type
o project or order number
o identification of cable section (location)
o phase identification
o cable identification by drum number or cable code number
o pulling direction
o cable length
o diameter of calibre (if used in pipes)
o date of cable laying

o protocol of maximum pulling force or preferably

complete diagram of pulling forces
o exact positions of cable pushing equipment, if used
(motorized rollers or caterpillar)
o Any abnormalities with respect to cable pulling, calibration of pipes, laying
of earthing conductors, positioning of components etc. are to be indicated
in the site report.
4 EQUIPMENT
It is essential that the cable laying company uses appropriate and reliable devices
to ensure laying works without problems and to avoid damage to personnel, to
cables or to equipment. Defective tools and equipment are to be replaced
immediately. The equipment to be employed has to be checked according to
relevant rules (VDE, TÜV ...). Labels on the equipment shall indicate the
compliance.
5 COMMUNICATION
During cable laying good communication is important. Usually this is done by radio
(walkie talkie). Communication facilities shall be used at all important locations.
These include the person at the drum, at the winch, at the cable head as well as at
other important places, e.g. road crossing, vertical section or the like. The laying
company has to provide a communication device to the Site Manager of nkt cables
in order to keep him informed during all stages of the cable pulling process.
6 PREPARATION FOR CABLE LAYING
6.1 Advance Information

Expected forces on the cables shall be calculated in advance. This includes pulling
forces and sidewall pressures in bends. The pulling force calculation provides
information on the pulling direction resulting in the smaller mechanical stresses for
the cables. The direction of pulling must only be changed after agreement with the
Project Manager of nkt cables.
Following information needs to be considered:
o minimum permissible ambient temperature
o cable weight
o maximum permissible pulling force
o maximum permissible sidewall pressure

o minimum permissible bending radii:

• during laying
• single bending
o cable overall diameter (to determine size of pulling stocking, minimum
bending radii)
o maps of the cable route including planned positions of joints and cable
pushing device (if used)
Limit values are to be respected in the calculations and, of course, during the
cable laying process. To prevent damage of the cables during pulling, following
bending radii must be respected as the absolute minimum:
o 25 x d for XLPE-insulated single-core cables with APL sheath, lead sheath
or corrugated aluminium sheath
o 25 x d for XLPE-insulated three-core cables with APL sheath on each core
(e.g. CityCable)
o The minimum permissible radius for the CityCable (pipe-type cable) is the
minimum radius of the appropriate steel pipe.
o d: cable diameter
Loading and transport of cable drums from store to site shall be done in
accordance with document No. BAE008.
6.2 Position of Cable Drum

Usually the drum is placed at the position which allows pulling in the direction
causing the lowest forces on the cable. The ground must be solid to carry the
weight of the drum. If necessary, steel plates for example are to be placed on the
ground surface. The drums shall be unloaded to an even surface to prevent
unintentional rolling. The ground surface shall be free from objects which may
damage the cable. Covering of the ground may be useful.
The drum must be positioned in such a way that the cable is pulled from the top.
This is achieved when the arrow indicating the rolling direction is contrary to the
rotation of the drum during cable pulling. Before pulling it shall be made sure that
the inner end of the cable is securely fixed to the drum.
As the drum must be able to rotate freely during cable laying, it is necessary to lift
the same from the ground by at least 50 mm. Therefore, the cable drum shall be
supported with an axle laid on drum stands or hydraulic jacks similar to what is
shown on drawing EHP 9695a. Bushings are fixed to the axle at both sides of the
drum to avoid sideways movement. It must be made sure that the drum stands are
placed on a solid base. If suitable, the drum can also remain on the cable drum
trailer.
When the drum is placed in the final position the wooden lagging, if present, can
be removed taking care not to damage the cable. After removal of the lagging final
inspection of the outer layer of the cable should be carried out before start of cable
laying. If required, testing of the oversheath can be performed. This test can be

made according to IEC 60229 with 10 kV DC for 1 minute. The cable ends must
be accessible for carrying out the test.
Before pulling the cable, it is to be checked and ensured that the cable ends are
properly sealed. Accordingly, the cable ends are always to be closed again when
the cable is cut, for example by using heat-shrinkable caps. The caps must have
glue inside to prevent ingress of water into the cable.
6.3 Pulling Winch and Rope

For pulling of high voltage power cables usually a motorized winch is used where
the maximum force can be adjusted. An example is shown on drawing
EHP 9697a. The capacity of the power winch and especially of the pulling rope
shall be twice as high as the expected maximum pulling force to provide a
sufficient safety margin. The winch shall be adjusted so that jerkily pulling is
prevented. It must be possible to continuously monitor the pulling force. A
corresponding protocol shall be printed.
After the pulling rope is checked for soundness, it is pulled out over the cable
route. It is connected with a swivel to the pulling eye of the cable. The swivel (see
drg EHP 8616/2b) is to compensate for twist and to reduce stress and damage to
the rope. Condition and direction of the pulling rope shall be such that damage to
cable protection pipes is avoided.
6.4 Calibration
In the case of pulling cables into protection pipes, the complete pipeline is to be
calibrated after backfilling and compaction of the ground. This is to ensure that
there are no obstructions, for example deformed pipes, which will cause problems
during pulling of the cables. The diameter of the calibre shall be such that
constrictions and damages are likely to be detected. The diameter of the calibre
shall be at least 85 % of the inner diameter of the pipe.
Furthermore, it shall be possible to blow auxiliary ropes into the pipe sections.
Pollution and debris must be removed by using appropriate brushes.

6.5 Pulling Head and Pulling Stocking

A pulling stocking must be at least 2 m long. For larger cables (220 kV and above)
the pulling stocking must be approximately 4 m long. It must be suitable for the
expected pulling forces with sufficient safety margin. The section of the cable
underneath the pulling stocking must not be used for jointing.
shrinkable sleeve
pulling eye conductor XLPE insulation
Figure 1: Construction of a pulling head
Usually a pulling head (Figure 1) is already installed in the factory. Before start of
cable pulling tightness of the pulling head is to be checked. In case of damages, a
newly installed pulling head may be required. The installation is to be done in
accordance with the installation instructions provided by nkt cables.
6.6 Cable Pushing Device

For heavy high-voltage cables of long length it is of special importance to keep
pulling forces as low as possible. This can be achieved by employing cable
pushers at suitable locations along the cable route.
Cable pushers are used to support the pulling winch during cable laying. In this
way the pulling force is reduced which is particularly beneficial in bends. The rise
in pulling force as well as radial forces can significantly be reduced. Care has to be
taken that the pushing rollers or belts do not brake the cable. Pushing devices
must properly be installed.
The cable pusher must be suitable with respect to the cable diameter. The
maximum permissible sidewall pressure of the cable must not be exceeded.
Appropriate locations for cable pushers are determined by cable pulling
calculations. When several cable pushers are used their speed must be
synchronized which applies also to the pulling winch.
6.7 Preparation of the Cable Route

For laying of cables in an open trench it must be ensured that the trench
dimensions and safety measures are in accordance with the requirements and
regulations. Depending on trench depth and soil conditions the trench walls must
be made with a slope or they are to be protected by timbering to prevent
deterioration.
The bottom of the trench shall be free from sharp stones and shall be covered with
a layer of sieved sand to avoid damage of the cable oversheath.

Pipes through which the cables shall be pulled must be clean and smooth and free
from any obstacles. The ends of the pipes shall be free over a distance of 50 cm.
This is to prevent ingress of stones and ground material which can block the cable
or damage its oversheath. On top of that the free end is advantageous for sealing
of the pipe.
The proper quality of the pipes must have been demonstrated by the installer
before cable laying. To protect the pipe it is recommended to install a bell mouth at
the pipe's entry and exit. An example is shown on drawing EHP 0784/2.
The pulling rope shall be guided in such a way that damage to the pipe is
prevented. The pulling rope shall be lubricated every time before use.
Cable lubricants can be used to reduce friction. The lubricant is evenly applied to
the cable sheath during pulling. A suitable lubricant is water soluble and
environmentally compatible.
When the cable is laid in an open trench sufficient numbers of cable rollers and
corner rollers shall be provided for guiding the cable along the route. For straight
sections normal cable rollers, e.g. according to drawing EHP 9704a, shall be used.
They are placed at intervals of maximum 3 m. For heavy cables the spacing may
be reduced to keep the friction load component lower.
For bends angle rollers (corner rollers) similar to what is shown on drawing
EHP 9690a are needed. Especially at the bends the rollers are to be securely
fixed, so they can withstand the pulling forces. Details of fixing and positioning of
rollers is to be decided on site to take into consideration the actual conditions
found there. For preparation of a bend several rollers are connected as shown on
drawing EHP 9690a. Care has to be taken that the rollers are evenly distributed
and that the cable is not overbent at the edges.
The minimum permissible bending radii of the cable shall be observed. The
minimum value should be considered as an exception and the bends shall be
made with the largest radius possible.
For exact guidance of cables during pulling, e.g. at the entrance in building or into
a pipe, guide rollers (drg. EHP 8636/2a) are used. One roller is removable so that
the cable can be taken out after pulling.
The roller close to the drum must be extra wide. This is because the cable is
wound over the width of the drum and its position will change during pulling
accordingly. This special roller is about 1.5 m wide. A construction with two rollers
is shown on drawing EHP 8637/2a.
7 CABLE PULLING
High-voltage cables must have a sufficiently high temperature before cable laying
to ensure the required flexibility. When the cable temperature is lower than the
minimum permissible value, the cable must be heated before laying. The minimum
permissible temperature depends on the cable type. Heating can be done by
keeping the complete cable drum warm under a tarpaulin using appropriate heater

or by storing the drum indoors. Under such circumstances the cable must be laid
as soon as possible to avoid undue cooling of the cable.
When pulling starts it shall be checked whether the pulling rope will have contact
with adjacent objects and may cause damage to them. If necessary, additional
guiding rollers shall be installed.
The minimum temperatures for cable laying are:
o -5°C for XLPE cables with PVC sheath
o -20°C for XLPE cables with PE sheath
A breaking device must be available at the cable drum to avoid over-running which
means that the drum must never run faster than the cable is being pulled out.
The cable should preferably be pulled continuously into its final position. Stop and
re-start results in higher stresses. A cable length should be pulled preferably
without interruption.
8 FINAL PLACING OF THE CABLE

Final positioning of the cable shall start from one end. Any slack is to be carried
forward. Distances and phase positions according to the given cable
arrangements are to be observed.
At the ends of the section the cable may require double handling as it may not be
possible to pull the cable directly in its final position. Therefore, a sufficient length
of cable must be over-pulled.
On top of that the over-length of the cable should also cater for the installation of
accessories. The part of the cable under the pulling stocking cannot be used for
jointing and is to be cut away. After cutting of the cable ends they shall
immediately be sealed to prevent ingress of moisture. Where the cables are laid
on air they shall be fixed according to the requirements.
9 SHEATH TESTING AFTER CABLE LAYING

When the cable has been laid in the final position the integrity of the oversheath is
to be checked by application of a DC voltage between metal screening of the
cable and outer conductive layer of the oversheath. When the oversheath of the
cable is not equipped with a conductive layer the optimum time for carrying out the
test is following the placing of the primary backfill. In this case the test voltage is
applied between metal screen and earth.
The oversheath test is performed in accordance with IEC 60229.

10 SUMMARY OF IMPORTANT POINTS

Independent from the laying method the following points are to be observed:
1. Adherence to relevant safety and environment protection regulations
2. Use of efficient braking device at the cable drum
3. Use of power winch adjusted to maximum pulling force
4. Measures to reduce friction
5. Preparation of cable trench with rollers etc., interior of trench, joint bay and
drum location in proper and clean condition
6. Permanent communication between personnel at important locations (winch,
cable head, cable drum, ...)
7. Sufficient over-length for jointing of accessories
8. Arrangement of cables with required distances and spacing
9. Marking of cable phases as required
10. Securing of cables against damage and sealing of cable ends
11. Successful performance of sheath tests
12. Completion of documentation
11 REFERENCES
BAE008 Handling of Cable Drums
IEC 60229 Tests on cable oversheaths which have a special protective
function and are applied by extrusion
12 DRAWINGS
EHP 9695a Cable Drum Hydraulic Jacks
EHP 9697a Capstan Winch for Cable Pulling
EHP 8616/2b Cable Pulling Grip with Swivel
EHP 9704a Cable Roller
EHP 9690a Cable Angle Roller
EHP 8636/2a Cable Guide Roller
EHP 8637/2a Cable Run-out Roller
EHP 0784/2 Lead-In Tube for Conduits

Für diese Zeichnung behalten wir uns alle Rechte vor. All rights reserved.
A4H3DE1 09.2002 Zeichnung wird bei Änderungen nicht eingezogen. Drawing will not be recalled in case of revisions.
Cable Drum Hydraulic Jacks

Kabelspulen-Hydraulikheber Maßst./Scale :
EHP 9695a
Gez. / Drawn : 21.01.2002 Hk
Änder. / Rev. : 02.01.2008 HPM

Gepr./Check. : 02.01.2008 HPM
Kabel-Spillwinde
Capstan Winch for Cable Pulling
Maßst./Scale :
EHP 9697a
Gez. / Drawn : 21.01.2002 Hk
Änder. / Rev. : 02.01.2008 HPM

with Swivel
Cable Pulling Grips Maßst./Scale :
Änder. / Rev. : 21.02.05

Gepr./Check. : 28.02.05
Gez. / Drawn : 22.02.98
EHP 8616/2b
Ah
Hk
Hü
Cable Rollers
Kabel-Verlegerolle Maßst./Scale :
Änder. / Rev. : 21.02.05

Gepr./Check. : 28.02.05
Gez. / Drawn : 21.01.02
EHP 9704a
Hk
Hk
Hü
Kabel-Eckrollen
Cable Angle Rollers
Maßst./Scale :
EHP 9690a
Gez. / Drawn : 21.01.2002 Hk
Änder. / Rev. : 02.01.2008 HPM

Cable Guide Roller

Maßst./Scale :
Änder. / Rev. : 21.02.05

Gepr./Check. : 28.02.05
Gez. / Drawn : 16.03.98
EHP 8636/2a
Ah
Hk
Hü
Cable Run-out Roller

Maßst./Scale :
Änder. / Rev. : 21.02.05

Gepr./Check. : 28.02.05
Gez. / Drawn : 16.03.98
EHP 8637/2a
Ah
Hk
Hü
Lead-In Tube for Conduits

Änder. / Rev. :
Maßst./Scale :
Gepr./Check. : 01.03.05
Gez. / Drawn : 01.03.05
EHP 0784/2
Hk
Hü

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TECHNICAL Information

Laying of High-Voltage Cables

Dokument Nr. / Document No.: PRC0016

erstellt von geprüft von genehmigt von

00 15.08.2013 K.-B.Tse 15.08.2013 H.-P. May 15.08.2013 H.-P. May

01 19.01.2014 H.-P. May 20.01.2014 K.-B. Tse 20.01.2014 H.-P. May

Anzahl Seiten / No. of pages: 11 Anlagen / Enclosures: 0

Düsseldorfer Straße 400

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 2

This document is the English translation of the original German version.

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 3

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 4

o protocol of maximum pulling force or preferably

6 PREPARATION FOR CABLE LAYING

6.1 Advance Information

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 5

o minimum permissible bending radii:

6.2 Position of Cable Drum

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 6

6.3 Pulling Winch and Rope

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 7

6.5 Pulling Head and Pulling Stocking

pulling eye conductor XLPE insulation

Figure 1: Construction of a pulling head

6.6 Cable Pushing Device

6.7 Preparation of the Cable Route

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

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PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 9

8 FINAL PLACING OF THE CABLE

9 SHEATH TESTING AFTER CABLE LAYING

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 10

10 SUMMARY OF IMPORTANT POINTS

PRC0016_R01_cable_laying_gb.docx ENG0000 R06 08.2012

17/1.0/16.07.14/PCPDOC-238-1411 Seite / Page 11

Cable Drum Hydraulic Jacks

Gez. / Drawn : 21.01.2002 Hk

Änder. / Rev. : 02.01.2008 HPM

Gez. / Drawn : 21.01.2002 Hk

Änder. / Rev. : 02.01.2008 HPM

Änder. / Rev. : 21.02.05

Änder. / Rev. : 21.02.05

Gez. / Drawn : 21.01.2002 Hk

Änder. / Rev. : 02.01.2008 HPM

Cable Guide Roller

Änder. / Rev. : 21.02.05

Cable Run-out Roller

Änder. / Rev. : 21.02.05

Lead-In Tube for Conduits

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