Deadending Standard quadrant-type bolted deadend clamps work well with the TransPowr T-2 B I C C B r a n d conductor.

. The clamp should T r a n s P o w r T - 2 be sized to allow the component conductors to lay horizontally side by side. When the TransPowr T-2 conductor is in line position, each of the component conductors will develop the proper share of line tension. Compression-type deadend connectors for the component conductors are also acceptable. These are attached to a small yoke that is attached to the deadend insulator string. The TransPowr T-2 conductor product has been in use since the mid 1970s. There are numerous fitting and deadend manufacturers who are available to assist in the correct selection of the accessory products. Clipping in Conductor TransPowr T-2 conductors should not be left in the stringing blocks for any appreciable time period. Good engineering practice would be to minimize the length of time that the conductor is left sitting idle. Since the conductor is installed in areas prone to wind, delays in the sagging and clipping operation could result in damaged conductor strands from aggressive movement within the blocks. There is a wide variety of different styles of conductor clamps and tie down products available in the industry. Always make sure to consult with the accessory manufacturer for the correct selection and installation procedure for the product. Line Taps Most accessory manufacturers have either hot line taps or parallel groove connectors that can be used for electrical connections. Splicing TransPowr T-2 conductors are joined by separately splicing each component conductor. First, overlap the two lengths of TransPowr T-2 conductor by approximately five feet. Cut one of the component conductors at one end of the overlap. Use a compression splice to join this component conductor to one of the component ends from the other length. When this compression splice is complete,

cut the other component conductor of the second length where it is aligned with the end of the other member of the first length. These two ends are then spliced. (An additional twist may be needed before the second splice is made to remove any looseness between the component conductors.) This procedure will result in the component conductor splices being separated by approximately five feet and each component conductor will carry its share of the line tension. Automatic-type splices can also be used. The procedure is similar to compression. Both splices must be made before tension is applied. After both splices are completed, tension is applied evenly to the TransPowr T-2 conductor thus causing the gripping jaws of both automatic splices to engage. Repairs Repairs to damaged component conductor can be made using the following procedure: 1. Attach two wire grips facing each other approximately 15 feet apart on the undamaged component conductor. 2. Attach a hoist to the grips and take up the tension. (As the tension increases, slack will appear in the damaged component conductor.) 3. Increase tension until there is enough slack to make the repairs. 4. If it is necessary to cut the damaged conductor to install a splice, a second set of grips and hoist must be installed on the damaged conductor before it is cut. Steps 1 and 2 should be followed to install this second set of grips. Helically applied rods may be used for repair of a damaged conductor, in accordance with utility policy, and given the nature and severity of damage. Assistance General Cable can provide additional information and assistance if desired. Please contact your General Cable Sales Representative.
The information contained herein or related hereto is intended for evaluation by technically skilled persons, with any use thereof to be at their independent discretion and risk. Such information is believed to be reliable, but General Cable shall have no responsibility or liability for results obtained or damages resulting from such use. GENERAL CABLE, BICC BRAND, TRANSPOWR and T-2 are trademarks of General Cable Technologies Corporation. 2001. General Cable Technologies Corporation. Highland Heights, KY 41076 All rights reserved. Form No. UT-0004-0201

TransPowr T-2 Conductor Installation Guide

This guide provides suggestions for methods, equipment and tools that have been found practical based on field experience during General Cables BICC Brand TransPowr T-2 conductor installation. The TransPowr T-2 conductor consists of two standard concentric stranded conductors twisted around each other. It may be installed using techniques and equipment similar to that used to install other concentric round wire conductors. However, a few special procedures must be used to maintain equal tension between the two component conductors. These guidelines, along with those suggested in the IEEE Guide to the Installation of Overhead Transmission Line Conductors (IEEE Standard 524), will help provide a high quality, trouble-free installation.

Tension The TransPowr T-2 conductor is pulled into position under tension by the use of a puller and a bullwheeltype tensioner. A rope is first strung through the travelers and used as a lead line to which the conductor is attached and by which it is pulled. The tension keeps the conductor clear of the earth and other obstructions that could cause damage. The back tension force is controlled by the tensioner and not the let-off reel. For the TransPowr T-2 conductor, the tension stringing method is the most preferred method. Semi-Tension This method is similar to tension stringing except the conductor is pulled directly off the let-off reel. Minimal ground clearance is maintained by applying gentle braking force to the let-off reel. It is important to recognize that the amount of back-tension must be kept to an absolute minimum level. Excessive line tension can not only damage the conductor remaining on the reel but also damage or collapse the reel itself. Slack The TransPowr T-2 conductor reel is mounted on strands or jacks and is free to rotate (with enough braking force to prevent over-run, backlash, or loops). A vehicle passes each structure and pulls out the conductor. At each structure the conductor is lifted into place in a traveler and the vehicle continues onwards. Layout This method is similar to the slack method except the lead end of the conductor is tied off and the reel is mounted onto a vehicle or trailer which travels down the line paying out the conductor as it goes. The conductor is then lifted into place into a traveler at each structure.

Shipping Reels The TransPowr T-2 conductor is shipped on reels large enough to accommodate the length ordered. The conductor should never be rewound in the field from the shipping reel to another reel. The rewinding action can result in uneven tension balance between the twisted components and can cause major problems when stringing the conductor. Reels containing TransPowr T-2 conductor should always be stored upright resting on the rims. Never lay the reel on its side. TransPowr T-2 Conductor Stringing Methods All methods of installation used for standard round conductors have been used satisfactorily to install TransPowr T-2 conductors. These conductor stringing methods include Tension, Slack, Layout, and Semitension. The following is a brief description of each.

B I C C

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One Crosfield Avenue West Nyack, NY 10994-2209 845.353.4000 800.237.2726 fax 845.353.4045 www.generalcable.com

T r a n s P o w r

Tensioner Machines There are several designs of puller/tensioner machines that have been used to install TransPowr T-2 conductors. Figure 1 illustrates one type of multi-groove bullwheel tensioner. With this design of tensioner the front and back bullwheels are offset by 1/2 the groove spaces. It is important that the bottom groove curvature (i.e. radius) of the tensioner bullwheel is large enough to enable the TransPowr T-2 conductor to lay flat. If an improperly sized tensioner is used there is the possibility that the ridge alignment between the grooves of the front and the rear bullwheels may catch and separate the individual members of the twisted conductor. The minimum bottom side-to-side groove radius, and the minimum diameter of the bottom groove must be sized correctly.
Pul l t o Towe r P ull t o To we r

Tensioners & Sheaves Dimensions When selecting the correct size of tensioner bullwheel and stringing sheave or traveler there are a number of important dimensions to check. The two most important dimensions are the side-to-side radius and the diameter of the bottom of the groove. Using smaller than recommended sheaves and/or with high stringing tension may cause a build-up of torsional stress in the conductor. As the conductor string is pulled in, this stress is cumulative and will work its way backward to result in looping of one of the conductors and/or birdcaging problems. Improper sheave application may also cause the twist length of the TransPowr T-2 conductor to push back and shorten. This builds a torque into the conductor that may not be released until the end of the length or a swivel is encountered. Figure 3 is an example of the correctly sized sheave being used. The recommended minimum side to side radius (Rg) for the bottom of the tensioner wheel or sheave groove is 0.55 x the maximum diameter (Dc) of the TransPowr T-2 conductor. The groove radius must be wide enough to allow the twisted pair conductor to pass through the tensioner wheel or sheave with the two component conductors lying flat and parallel while being supported in the lower 1/3 of the groove (see Figure 4). For the tensioner bullwheels the recommended minimum diameter (Ds) for the bottom groove should not be less than 28 times the maximum diameter of the TransPowr T-2 conductor. For the

the diameter of one of the component conductors. The IEEE 524 installation guide should also be referenced for additional dimensional criteria. If smaller than recommended sheaves are necessary, tensions must be reduced to avoid conductor damage (crushing) or redistribution of the twist length. It will also be necessary to shorten the pull length, thereby reducing the number of travelers, since the effect is cumulative. Smaller sheaves should only be used as a last resort. Stringing Each shipping length of TransPowr T-2 conductor has three metal bands applied at the factory around both component conductors one band at each end and one approximately 10 feet from the leading end. It is recommended that these bands not be removed for the stringing procedure. These bands will help maintain the component conductor length relationship when splicing and deadending. A single woven wire grip sized to fit over both component conductors and a swivel link should be used for tension stringing. Double band the open end of the grip to prevent it from accidentally coming off. Apply tape over the bands to protect the string sheave surface. The bottom conductor end on the reel is secured to the reel to provide a stationary attachment point during manufacture, and then paying out the conductor. The end attachment, in combination with several wraps of conductor around the drum of the reel enable higher leading tension to be maintained on the conductor string. When paying out the conductor, before the reel completely empties the installation procedure must be stopped and any required back tension be transferred off the conductor on the reel to some other anchor point. The end attachment must never be considered as a brake or end stop able to withstand a conductor run out situation. There should be sufficient distance between the payoff reel and the tensioner so that the TransPowr T-2 conductor is virtually in line with the tensioner groove (e.g. 30 to 50 ft). The tension on the payoff reel should be set only high enough to prevent over-run when pulled into the tensioner. High payoff tension can distort the twist as the conductor enters the tensioner. Wherever possible, the use of travelers to provide clearance from a front reel for a conductor leaving a reel placed in back of another should be avoided. The traveler can cause twist distortion if the tension or traveler size and position is not correct. The tensioner should be aligned with the section of

the line to be strung. The angle of the TransPowr T-2 conductor between the ground and sheave at the first structure should not exceed 15 degrees. This practice will limit the vertical load on the structure and also the pressure of the first sheave on the conductor. For example if the first sheave is 25 feet up, the tensioner should be set back 100 feet from the structure (i.e. four times the vertical height). The distance also allows the tension on the component conductors to equalize. Uneven tension between the adjacent components can cause the conductors to separate resulting in loops. Any sheave that touches or supports the TransPowr T-2 conductor between the payoff reel and the tensioner, or between the tensioner and the first structure, and at the first structure, should have a minimum bottom groove diameter (Ds) of 14 times the maximum diameter of the TransPowr T-2 conductor being installed. Small rollers can distort the twist and cause looping. The two component conductors of the TransPowr T-2 conductor are twisted during manufacturing with a machine that establishes a twist length of 9 feet. This twist may vary in the field because the torsional stiffness will depend on a) the tension in each component conductor, b) the distance between vertical supports, and c) the conductor size. Research has shown that the variation in twist length of the installed conductor is not a critical factor in the performance of the TransPowr T-2 product. Tensioning TransPowr T-2 conductor is tensioned by placing a separate grip on each component conductor. The two grips are connected through a snatch block with a sling. Tension is applied to the snatch block with a hoist or other appropriate tensioning device. This arrangement will apply even tension to the component conductors (see Figure 6).
con du cto r hoist

O ffs e t Wheels Pa y off fr om R e e l

Tilt ed

P ull f r o m R eel

Fig. 1

Fig. 2

Figure 2 illustrates another common tensioner where the two wheels are in line but one is tilted at a small angle to the vertical. This design of bullwheel tensioner has been used successfully and is the preferred type of tensioner to use with the TransPowr T-2 conductor. Again, it is important that the side-to-side radius, and the diameter of the bottom groove be sized correctly. The third type of tensioning device consists of two single groove bullwheels in the same plane employing an S wrap on the wheels. Such a simple unit, and when sized properly may be used satisfactorily. The V-Groove style of tensioner cannot be used. The snubbing action on the twisted pair will result in the rapid development of uneven tension between the twisted components.

Fig. 4
Rg

sheave groove radius

Rg = Bottom of Groove Radius minimum Rg = 0.55 x (maximum diameter of the T-2) Dc = maximum diameter of the T-2 conductor Dc = 2x diameter of single component Dc

Fig. 5 sheave bottom diameter

Ds = Diameter of Bottom of Groove for Bullwheels minimum Ds = 28 x (maximum diameter of the T-2) for Sheaves + Travelers minimum Ds = 14 x (maximum diameter of the T-2)

Ds

Fig. 6

g ri p

s l in g

stringing sheaves or travelers the recommended minimum diameter of the bottom groove should not be less than 14 times the maximum diameter of the TransPowr T-2 conductor (see Figure 5). The maximum diameter is twice the diameter of one of the component conductors. The dimensions are similar to those established in the IEEE 524 installation guide. For the TransPowr T-2 conductor type IEEE Dc term would also be twice

Sagging The sagging of TransPowr T-2 conductor can be completed using any of the existing methods that are used for the conventional round conductors. Use the sag chart values supplied by the Utility or by General Cable. Tension should be applied to the conductors as previously described by gripping both component conductors separately and using the snatch block / double grip arrangement to ensure even tension is applied to the conductor pair.

Fig. 3