Cable HandlingInstallation

POWER CABLES INSTALLATION
IG01/1
GUIDELINES
POWER CABLES DIVISION Reception, handling and storage 05/01/2004
1. Introduction
To secure safe cables installation and assure their reliability, it has to be
confirmed that the selected cable is suitable for the application and no damage
occurred in transit or storage.
Proper cable inspection, handling and storage have to be carried out in order
to detect existing cable damage and prevent any further damage from occurring.
2. Cable inspection
Every cable reel has to be inspected for damage before accepting a
shipment. The following signs should draw the attention for possible cable damage:
A reel has been dropped: hidden damage likely!
The bobbin lagging is broken: the cable underneath may be harmed.
A reel flange is damaged.
A reel is lying flat on its side.
Extraneous load is stacked on a reel.
Several reels are stacked.
Nails have been driven into the reel flanges to fasten shipping blocks.
A cable covering is removed stained or damaged.
A cable end seal has been removed or damaged.
3. Reel unloading
DO NOT DROP!
Reels have to be carefully unloaded from a truck using a fork lift truck, a hoist or a
crane. NEVER DROP REELS. Unloading equipment should not come in contact
with the cable or it’s protective covering. Care should be taken not to loose nor
damage the reel identification labels.
Prepared by: E. Tanis Approved by: B. Fainaru

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IG01/1
GUIDELINES
4. Forklift truck lifting and transporting

When using a forklift truck, the forks must be applied across the flanges. The
forks must be long enough to accommodate both flanges. The distance between
forks should be sufficient to hold the reel steady during the truck movement.
Approach the reel from the flange side. Position the forks such that they lift the reel
by both reel flanges. Do not allow the lift forks to contact the cable. Reels must be
lowered gently, not dropped. The forklift operator must not make sudden turns or
stops.
DO NOT!
DO
5. Reel unloading with a crane

When using a crane to unload a cable reel, install a shaft through the reel
arbor holes and attach a sling. A spreader bar longer than the overall reel width
and placed between the sling ends just above the reel flanges must be employed.
Otherwise, bending of the reel flanges and mashing of the cable will occur.
DO DO NOT!
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GUIDELINES
6. Storing
6.1. Cable wound on wooden or metal reels may be stored outdoors.
6.2. For long term storage, keep the cable reels in relatively inactive areas.
6.3. Storage temperatures should be between –20 oC (-4 oF) and 50 oC
(120 oF). Even though some types of cables may be stored beyond the
given temperatures, special precautions should be taken immediately
before the cable installation.
6.4. Keep the cable dry, at a temperature that will not generate degradation
and protect the cable from damage. Do not store in sites where
standing water is likely.
6.5. Reels should be stored upright on their flanges and handled in such a
way as to prevent deterioration of, or physical damage to the reel or to
the cable. Multiple reels stacked on top of each other (“Pancake”
storage) is not recommended for medium voltage cable. A
concentration of stress on the bottom reel may cause its collapse and
subsequently damage the cable. Additionally, the inner cable end,
which normally protrudes through one of the flanges, will very likely be
damaged. Further damage will probably occur when the reel is flipped
for transit.
DO NOT!
6.6. During storage, the ends of the cables must be sealed against the
entrance of moisture or contamination. Electrical tape does not provide
sufficient seal. Rubber or plastic sealing caps should be used when
lengths are cut to protect the end of the cable. Maintain the cable ends
fixed to the reel flanges without puncturing the jackets of the end caps.
6.7. Reels should also be stored on solid ground to prevent the flanges
from sinking into the earth. Power poles or crossarms, conveniently
distanced, should cradle and raise the flange above the ground.
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GUIDELINES
Periodically change also the contact point between the reel flange and
its support. All this should protect the reels from decay and prevent
them from rolling.
6.8. Organize the storage in a way that will ease the application of the “first
in, first out” criteria.
6.9. Maintain a covering on the cable reels so that any damage on it will
draw the attention to a probable damage also on the cable underneath
it.
6.10. In zones of rodent infestation, the cable reels should be protected with
full lagging, steel plates over flange penetrations and / or other suitable
means.
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IG02/2
GUIDELINES
POWER CABLES DIVISION Installation 24/01/2005
1. Introduction
Cable installation comprises a series of operations that when carried out
carefully will result in a reliable cable system. Some of them are common to all the
types of installation: raceways, cable tray, trough, buried duct, direct burial,
tunnels, conduit, etc. Other – are specific of the type of installation. It is assumed
that the cable has been correctly selected for the application.
Proper cable inspection, handling and storage have to be carried out in order
to detect existing cable damage and prevent any further damage from occurring.
The cable routing should be thoroughly inspected to avoid bends and/or
pulling tensions that exceed specified limits.
2. Cable inspection, reel handling and storage

The recommendations presented in the guidelines IG 01/1 are also valid on
the referenced issues where applicable. In addition, nails and staples should be
removed from the reel flanges before moving a reel. Objects that could crush or
impact the cable during moving, should be avoided.
3. Preconditioning and installation temperatures

It must be assured that during the twenty four hour period preceding its
installation a XLPE (cross linked polyethylene) or EP (ethylene propylene rubber)
insulated cable has not been subjected to temperatures lower than –10 oC (26 oF)
when it has PVC fillers and / or PVC jacket. Moving the cable into a heated up
ambient at no less than 0 oC (32 oF) and keeping it there for at least 8 hours before
pulling, is recommended. Avoid also storing PVC jacketed cables prior to their
installation in direct sunlight when the ambient temperature exceeds 50 oC (122
o
F). The jacket will soften leading to physical damage during pulling. When the
cable insulated as above, has no PVC fillers and its jacket is made of PE
(polyethylene), the reel storage temperature before laying should not be lower than
-40 oC (-40 oF).
Handling and pulling cables in extremely low temperatures can cause
damage to the cable jackets or insulation. The following table summarizes the
temperatures below which cables should not be installed (IEEE Std 525-1992)
Cable insulation or jacket material Low temperature limits
EPR (ethylene propylene rubber) -40 oC -40 oF
CPE (chlorinated polyethylene) -35 oC -31 oF
PVC (polyvinyl chloride) -10 oC +14 oF
CSPE (chlorosulfonated polyethylene) -20 oC -4 oF
Neoprene (polychloroprene) -20 oC -4 oF
PE (polyethylene) / XLPE (cross-linked polyethylene) -40 oC -40 oF

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IG02/2
GUIDELINES
During cold weather installation, the cable should be pulled more slowly and
trained in place the same day it is removed from storage. Care should be taken not
to impact, drop, kink or bend the cable sharply in low temperatures.
4. Recommended minimum bending radius (ICEA S-97-682-2000)

The following limits apply to the cables during training. They may not be
suitable for conduit bends, sheaves, or other curved surfaces around which the
cable may be pulled under tension while being installed due to sidewall bearing
pressure limits of the cable. The minimum radius specified refers to the inner
radius of the cable bend and not to the axis of the cable. For pulling it is
recommended to use double radius values instead of the ones given next.
4.1. Tape shield
The minimum bending radius for tape shielded cables given below
applies to helically applied flat tape or longitudinally applied corrugated
tape or combination tape and wire shielded cables.
The minimum bend radius to which insulated cables may be bent for
permanent training during installation is twelve times the overall
diameter for single conductor cable. For multiplexed single conductor
cables, the minimum bending radius is twelve times the overall
diameter of the individual conductor cable or seven times the overall
diameter, whichever is greater.
4.2. Wire shield
The minimum bend radius to which insulated cables may be bent for
permanent training during installation is eight times the overall
diameter for single conductor cable. For multiplexed single conductor
cables, the minimum bending radius is eight times the overall diameter
of the individual conductor cable or five times the overall diameter,
whichever is greater.
4.3. In order to insure that the required minimum bending radius is always
followed, conveyor sheave assemblies with the adequate radius
should be employed along the whole cable route. Because of the small
diameter of each sheave, it is recommended that each conveyor
sheave have a minimum of one sheave every 20 degrees of bend.
4.4. Single sheaves with a correspondingly higher diameter may be used
only for guiding cables. Multiple sheaves should avoid polygon curves,
i.e. with sharp bends at some of them.
5. Cable pulling. Maximum pulling tension

5.1. Pulling winches and other necessary equipment should be of adequate
capacity to ensure a steady continuous pull on the cable.
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GUIDELINES
5.2. Cable reels should be supported so that the cable may be unreeled
and fed into the raceway without subjecting the cable to a reverse
bend as it is pulled from the reel. To further assure adequate pulling of
the cable, a reel drive mechanism or adequate manpower should be
provided as the cable is being removed from the cable reel.
Freewheeling should be avoided. The drive mechanism (equipped with
braking ability) works best in controlling cable payoff. A fulcrum and
wedge device may sometimes be used to prevent freewheeling.
5.3. A tension measuring device should be used on runs when pulling force
calculations indicate that allowable stresses may be approached.
5.4. Pulling tension will be increased when the cable is pulled off the reel.
Turning the reel and feeding slack cable to the duct entrance will
reduce the pulling tension.
5.5. The direction of pulling has a large influence on the pulling tension in
conduit runs containing bends. Whenever a choice is possible, the
cable should be pulled so that the bend or bends are closest to the
reel. The worst condition possible is to pull out of a bend at or near the
end of the run.
5.6. Sufficient cable slack should be left in each manhole and temporarily
supported so that the cable can be trained to its final location on racks,
hangers or trays along the sides of the manhole. Cable splices should
not be placed directly on racks or hangers.
5.7. For cable equipped with pulling eye or pulling bolt, i.e. pulling trough
the cable conductor, the formula shown below is used to calculate the
maximum allowable pulling tension on the cable for the entire routing:
Tm = K × n × CMA (1)
Where: Tm = maximum pulling tension (lbs.) (*)

K = constant
0.008 for copper conductors
0.006 for aluminum conductors
n = number of conductors < 3
CMA = circular mil area of one conductor
(*) This value is the maximum tension that can be placed on the cable or, if
pulling more than one conductor at a time, group of cables. In some cases this
could exceed the limitations of the pulling equipment being used. The
specifications set forth by the pulling equipment manufacturer should be compared
to this value, and the lower of the two should be considered.
If n (number of conductors) > 3, the formula (1) to use is modified as:
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GUIDELINES
Tm = K × n × CMA × 0.8 (1’)
5.8. In the next table are given the allowed tensions for the normal range of
circular mil areas:
MAXIMUM ALLOWABLE PULLING TENSIONS (LBS)
AREA Copper conductor Aluminum conductor
Number of conductors Number of conductors
kcmil
1 2 3 4 1 2 3 4
2 531 1,062 1,593 1,699 398 796 1,194 1,274
1 670 1,339 2,009 2,142 502 1,004 1,506 1,607
1/0 845 1,690 2,534 2,703 634 1,267 1,901 2,028
2/0 1,065 2,130 3,194 3,407 799 1,597 2,396 2,556
3/0 1,342 2,685 4,027 4,296 1,007 2,014 3,020 3,222
4/0 1,693 3,386 5,078 5,417 1,270 2,539 3,809 4,063
250 2,000 4,000 6,000 6,400 1,500 3,000 4,500 4,800
300 2,400 4,800 7,200 7,680 1,800 3,600 5,400 5,760
350 2,800 5,600 8,400 8,960 2,100 4,200 6,300 6,720
400 3,200 6,400 9,600 10,240 2,400 4,800 7,200 7,680
450 3,600 7,200 10,800 11,520 2,700 5,400 8,100 8,640
500 4,000 8,000 12,000 12,800 3,000 6,000 9,000 9,600
600 4,800 9,600 14,400 15,360 3,600 7,200 10,800 11,520
750 6,000 12,000 18,000 19,200 4,500 9,000 13,500 14,400
1000 8,000 16,000 24,000 25,600 6,000 12,000 18,000 19,200
5.9. Cable grip tension

When cable grip is used over non lead jacketed cable, the pulling
tension should not exceed 1,000 lbs or 1,000 lbs per grip (when used
with multi-conductor cables) and also the tension calculated in formula
(1).
6. Calculated pulling tensions
6.1. Straight section of conduit
Ts = L × W × f (2)
Where: Ts = pulling tension at end of straight section, lbs.

L = length of straight section, feet.
W = weight of cable, lbs./ft.
f = coefficient of friction
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GUIDELINES
6.2. Curved (bent) section of conduit
Tb = Tb × e fa (3)
Where: Tb = pulling tension at end of bend, lbs.

Ts = pulling tension at end of straight section entering the bend, lbs.
e = 2.718…, natural logarithm base.
f = coefficient of friction
a = angle of bend, radians
See the following table with efa values for common angles:
VALUES OF efa FOR COMMON ANGLES
BEND efa
ANGLE
f = 0.7 f = 0.6 f = 0.5 f = 0.4 f = 0.3 f = 0.15
(o)
15 1.20 1.17 1.14 1.11 1.08 1.04
30 1.44 1.37 1.30 1.23 1.17 1.08
45 1.73 1.60 1.48 1.37 1.27 1.13
60 2.08 1.87 1.69 1.52 1.37 1.17
75 2.50 2.19 1.92 1.69 1.48 1.22
90 3.00 2.57 2.19 1.87 1.60 1.27
7. Friction coefficients and lubrication

7.1. The coefficient of dynamic friction (μ) is a measure of the friction force
between a moving cable and the conduit. The coefficient of friction can
have a large impact on the tension calculation. It can vary from 0.1 to 1
with lubrication and can exceed 1.0 for unlubricated pulls. In the
following table are presented typical values for the coefficient of
friction:
TYPICAL COEFFICIENTS OF DYNAMIC FRICTION (μ)
ADEQUATE CABLE LUBRICATON DURING PULL (a)
Type of conduit (b)
External cable jacket
M PVC FIB ASB
PVC – Polyvinyl chloride 0.4 0.35 0.5 0.5
PE – Polyethylene 0.35 0.35 0.5 0.5
CSPE – Chlorosulfonated polyethylene 0.5 0.5 0.7 0.6
CPE – Chlorinated polyethylene 0.5 0.5 0.7 0.6
Nylon 0.4 0.35 0.5 0.5
(Two) Conservative values of coefficients
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GUIDELINES
(b) Conduit abbreviations:

M: metallic, steel or aluminum
PVC: polyvinyl chloride, thin wall or heavy schedule
FIB: fiber conduit – Orangeburg or Nocrete
ASB: asbestos cement – Transite or Korduct
Pulls should never be stopped and restarted, because the coefficient
of static friction will always be higher than the coefficient of dynamic friction.
7.2. The coefficient of friction between a cable exterior jacket and conduit
varies with the type of jacket, type and condition of conduit, type and
amount of pulling lubricant used, cable temperature and ambient
temperature. High ambient temperatures can increase the coefficient
of dynamic friction for cable with a non-metallic jacket.
7.3. From the formulae (1), (2) and (3) above, it follows that reducing the
pulling force by diminishing the coefficient of friction using a pulling
lubricant would be the primary consideration in its selection.
7.4. Not less important is that the lubricant should not contain ingredients
that will attack the cable materials: jackets and/or insulation. The effect
of the attack with time and at operating temperatures may be the
degradation of their physical and/or electrical properties. The material
may become brittle, or swollen, or loose its tensile strength and
elongation and/or suffer from a dangerous increase of the dielectric
losses.
7.5. Additionally, the lubricant and its residue should not propagate the
flame. A UL Listed pulling lubricant should be a must.
7.6. The cable jacket and/or conduit walls should be completely lubricated.
The lubricant application should be done before and during the pull.
For difficult pulling operations the quantity of lubricant to use may be
increased beyond the following estimation:
Q = 0.0015 x L x D gallons
Where: Q: quantity of lubricant in gallons
L: conduit length in feet
D: outside diameter of cable or inside diameter of conduit in
inches.
8. Maximum sidewall pressure at bends
8.1. Sidewall pressure is the radial pressure or force per unit length that is
exerted on a cable when in it is pulled around a conduit bend or
sheave. In vertical runs the cable weight should be also added.
Excessive sidewall pressure can crush a cable during its installation if
the pulling stress is too high or the bending radius too small.
8.2. The sidewall pressure is calculated with the following formula:
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GUIDELINES
P = Tb ÷ r (4)
Where: P: actual sidewall pressure on cable, lbs./ft.

Tb: pulling tension out of conduit bend or sheave, lbs.
r: conveyor sheave or conduit bend radius.
8.3. The sidewall pressure P should not exceed 500 lbs./ft. for single core
or multicore medium voltage non-armored cables.
9. Synchronized power drive rollers

In a complicated pulling operation, with many bends in a long cable route and
where splices are excluded, synchronized power drive rollers may be the only
feasible solution. The technique, well known in high voltage cables installation,
relies on the use of multiple powered rollers positioned at regular intervals along
the cable route to pull the cable. The frequency of rollers is dependent upon the
cable construction and the route itself.
Since each roller has to provide an equal force they require to be
synchronized to operate effectively and to avoid any damage to the cable due to
compressive forces.
Normally a winch is used to supplement the rollers but the tension on the
cable and the sidewall pressure are very low due to the effects of the powered
rollers.
10. Underground installations (the full NEC rules shall be used)

10.1. In accordance with the NEC, the depth of burial should be as per the
following table:
Rigid nonmetallic Rigid metal conduit
Direct-buried
Circuit conduit approved and intermediate
cables
voltage for direct burial metal conduit
in. in. in.
Over 600 V
30 18 6
up to 22 kV
Over 22 kV
36 24 6
up to 40 kV
Over 40 kV 42 30 6
10.2. In certain zones, where frost conditions could damage the cable,
greater burial depths should be adopted.
10.3. Where supplemental protection is provided, lesser depth may be used.
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GUIDELINES
10.4. If the earth surface is not to final grade, the cable should placed to
meet or exceed the requirements indicated above, at the time of
installation and when the surface is to final grade.
10.5. Trenching. The bottom of the trench should be smooth, well tamped
earth or sand. When excavation is in rock or rocky soil, the cable
should be laid on a protective layer of well-tamped backfill. Within four
inches of the cable, the backfill should be free of materials that may
damage the cable (large rocks, paving materials, large or sharply
angular substances, etc.). The backfill should be well compacted.
Within six inches of the cable no machine compaction should be
employed. A protective covering above the cable will serve as a
warning for excavators of the presence of an underlying cable.
Under pedestrian and vehicular traffic ways it is recommended to pull
the cables through a conduit.
11. Cable Tray installation
11.1. The NEC (ed. 2002) article 392 covers widely the cable tray system
installation.
11.2. Single-conductor cables shall be 1/0 AWG or larger and shall be of a
Listed type and marked on the surface for use in cable trays. Such
cables have a proven reduced fire propagation behavior.
11.3. Spacing of the rollers must be appropriate to prevent the moving cable
from touching or rubbing the tray. The rollers should be placed to keep
the cable in a fairly level position. As the cable approaches the end of
the pull, the tension is higher allowing for more distance between
rollers.
11.4. A high-strength, low-stretch abrasion resistance pulling rope should be
employed. Its strength should exceed the maximum tension to be
encountered during the pull by a factor of five. Double-braided
aramid/polyester ropes are recommended. Manila hempline is also
good.
11.5. The layout of the tray should be carried out in full consideration of the
future pulling operation. Reel location, pulling equipment and cable
tray bends should be facilitated at the cable tray planning stage.
12. Cable pulling stages
12.1. Preparation
12.1.1. Establish the direction of the pull based on safe pulling tensions and
sidewall pressure calculations.
12.1.2. Select the correct size pulling eyes, bolts or grips.
12.1.3. Locate feeder reels, spools, etc. such that the tension at the feeding
end is minimized.
12.1.4. Use pulling equipment that provides smooth speed control.
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GUIDELINES
12.1.5. Choose a pulling rope that has the required tensile strength.
12.1.6. Prior to pulling, make sure the conduit is clean and free of dirt, water,
scale, etc.
12.1.7. For long or heavy pulls, pre-lubricate the conduit and pull rope,
particularly when using PVC.
12.1.8. Install a dynamometer.
12.2. Cable pulling
12.2.1. Apply cable lubricant liberally during the installation.
12.2.2. If possible, use two-way communication at both ends of the run,
particularly on long runs.
12.2.3. Accelerate slowly and smoothly to a constant pulling speed.
12.2.4. Avoid letting the cable stop part way through the pull . The friction is
greatly increased when re-starting a pull.
12.3. After pulling:
12.3.1. Seal the ends of the installed cable to prevent moisture from getting
inside the cable.
12.3.2. High voltage testing is recommended after the installation.
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IG03/1
GUIDELINES
DC High Potential (Hipot) Field Testing of

POWER CABLES DIVISION 11/01/2004
Medium Voltage Power Cables
1. Introduction
Cables undergo thorough testing according to the applicable standards
before leaving the factory. Nevertheless, it is recommended to test the cable during
and after its installation. The purpose of these tests is to discover possible damage
caused by accidental mishandling of the cable during the pulling operations and/or
faulty mounting of the required accessories. As sooner the detection of such faults
is made, the better. Early corrective actions taken will diminish the delays in project
completion and additional expenditures will be avoided. It should be noted,
however, that these tests might not detect damage that may eventually lead to
cable failure in service, e.g., damage to the cable jacket or insulation shield.
After a cable system has been completely installed and placed in service
ICEA cable standards allow to make DC tests within the first five years. But, as
stated in the mentioned standards, “DC test voltages are applied to discover gross
problems such as improperly installed accessories or mechanical damage. DC
testing is not expected to reveal deterioration due to aging in service. There is
some evidence that DC testing of aged cross-linked polyethylene cables can lead
to early cable failures. Information on this subject is available in EPRI project report
TR-101245, “Effect of DC Testing on Extruded Cross-Linked Polyethylene
Insulated Cables”” (ICEA standards S-94-649-2000 and S-97-682-2000).
Consequently, maximum restraint should be exercised in front of the in service
testing of such cables. Maintenance DC hipot testing of such cable systems should
be avoided at all, or, at the most, limited only to those exceptional situations where
it would be imperative. Otherwise, cables good enough to operate fault free for
many years would unnecessarily been broken down.
The tests should be carried out according to the following guidelines.
2. Safety precautions
Only qualified personnel should run the DC high potential voltage tests. The
testing personnel should be familiar with IEEE Standard 400: “Guide for Making
High DC Voltage Tests on Cable Systems in the Field”.
The testing personnel should follow the instructions provided by the test
equipment manufacturer for the safe operation of the test equipment.
Before conducting tests on any cable system, it should be verified that the
cable system is de-energized. If the cable system has been previously energized,
the prescribed rules for conducting the switching required to de-energize, lockout,
tagging and grounding should be followed.
Adequate instructed personnel should guard or barricade the remote cable
end areas to prevent unauthorized access to the cable system under test.

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GUIDELINES

3. Preparation for testing

Non-cable system equipment and apparatus, like transformers, switch taps,
circuit breakers, surge arrestors, etc. should be disconnected from the cable
conductors to minimize the possibility of erroneous test results and prevent
damage to equipment and apparatus.
Adequate physical clearances should exist between the cable ends and other
equipment, other energized conductors or any electrically grounded objects.
Only the cable phase to be tested shall be disconnected from the ground. All
circuit conductors not under test as well as all the cable shields and nearby
equipment should be grounded.
When testing cable with already mounted accessories, the accessories
manufacturer should be consulted on maximum test voltages allowed and time
limitations.
4. Conducting test
4.1. During installation
At any time during installation, a DC proof test may be made at a voltage not
exceeding the DC test voltage specified in the following table under the
During/After Installation column, applied for five consecutive minutes.
DC Field Test Voltages
Rated Maximum DC Field Test
Nominal Insulation
Voltage Conductor Size Voltages [kV]
Thickness
Phase to [AWG or kcmil During/After First 5
[mils (mm)]
Phase (mm2)] Installation Years
[kV] A B A B A B
8-1000 (8.4-507) 90 (2.29) 115 (2.92)
5 28 36 9 11
Above 1000 (507) 140 (3.56) 140 (3.56)
6-1000 (13.3-507) 115 (2.92) 140 (3.56)
8 36 44 11 14
Above 1000 (507) 175 (4.45) 175 (4.45)
2-1000 (33.6-507) 175 (4.45) 220 (5.59)
15 56 64 18 20
Above 1000 (507) 220 (5.59) 220 (5.59)
25 1-2000 (42.4-1013) 260 (6.60) 320 (8.13) 80 96 25 30
28 1-2000 (42.4-1013) 280 (7.11) 345 (8.76) 84 100 26 31
35 1/0-2000 (53.5-1013) 345 (8.76) 420 (10.7) 100 124 31 39
46 4/0-2000 (107.2-1013) 445 (11.3) 580 (14.7) 132 172 41 54
Column A - 100% insulation level. Column B - 133% insulation level.
If it is intended to perform a hipot test on the cable on the reel, it should be

required at the time of ordering. A specially long and accessible inner cable end
will be provided that will enable to make such a test in the field.
A continuity test of the shield is recommended. If at this stage no final
terminations have been installed, the following DC testing ends may be used.
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GUIDELINES

CABLE END PREPARATION 1”
Remove jacket to dimension A = B + 4”.

Remove shield to within 2” of jacket.
Remove insulation semicon to within 1” of
shield: B Insulation
A
One. Score extruded semicon around
cable at point C-C.
Two. Score longitudinally 3/8” wide C C
around cable.
1” Semicon
Three. Grasp end with needle-nose
pliers and peel back. Shield
2”
Clean insulation with methylene chloride. tape/wires
Remove 1” insulation from cable end.
Jacket
B length as a function of test voltage
25
20
15
B [inch]
10
0
0 10 20 30 40 50 60 70 80 90 100 110
kV DC
4.2. After Installation

After installation and before the cable is placed in regular service, a high
voltage DC test may be made at a voltage not exceeding the DC test voltage in the
table above under the During/After Installation column, applied for 15 consecutive
minutes.
If the test voltage and/or the test time recommended by the manufacturer of
the on the cable installed accessories are respectively lower or shorter than the
ones given above, the test should be done with the lower voltages and/or shorter
times.
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If the installed cable is connected to an older network, the limitation given in

the next paragraph 4.3 must be considered. In such a situation the only possible
test to make may be sometimes on the new part of the network before connecting
it to the older one.
4.3. In service and maintenance

After the cable has been completely installed and placed in service, a DC
proof test may be made at any time within the first five years at a voltage not
exceeding the DC test voltage specified in the table above under the First 5 Years
column, applied for 5 consecutive minutes. After that time, DC testing is not
recommended.
The remarks given on this issue in paragraph 1, Introduction, are applicable.
4.4. Conclusion of testing

The grounding of all the conductors, shields and equipment should be kept
until the applied voltage was lowered to zero and the energized phase conductor
grounded with a grounding stick. The accumulation of a potentially dangerous
voltage can remain on the cable system if the conductors have not been grounded
for a sufficient time period after the completion of the test. A rough guide is to
maintain the ground connections of the just energized conductor for 1 to 4 times
the test time duration before they are removed and the cable conductors
reconnected into the circuit.
Page 4 of 4

Cable HandlingInstallation

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POWER CABLES INSTALLATION

POWER CABLES DIVISION Reception, handling and storage 05/01/2004

Prepared by: E. Tanis Approved by: B. Fainaru

U:\Installation instruction\IG01_1 Synergy 09_05_07.doc

POWER CABLES DIVISION Reception, handling and storage 05/01/2004

4. Forklift truck lifting and transporting

5. Reel unloading with a crane

POWER CABLES DIVISION Reception, handling and storage 05/01/2004

POWER CABLES DIVISION Reception, handling and storage 05/01/2004

POWER CABLES DIVISION Installation 24/01/2005

2. Cable inspection, reel handling and storage

3. Preconditioning and installation temperatures

Prepared by: E. Tanis Approved by: B. Fainaru

U:\Installation instruction\IG02_2 Synergy 09_05_07.doc

POWER CABLES DIVISION Installation 25/01/2005

4. Recommended minimum bending radius (ICEA S-97-682-2000)

5. Cable pulling. Maximum pulling tension

POWER CABLES DIVISION Installation 25/01/2005

Where: Tm = maximum pulling tension (lbs.) (*)

POWER CABLES DIVISION Installation 25/01/2005

Tm = K × n × CMA × 0.8 (1’)

5.9. Cable grip tension

Where: Ts = pulling tension at end of straight section, lbs.

POWER CABLES DIVISION Installation 25/01/2005

6.2. Curved (bent) section of conduit

Where: Tb = pulling tension at end of bend, lbs.

7. Friction coefficients and lubrication

POWER CABLES DIVISION Installation 25/01/2005

(b) Conduit abbreviations:

POWER CABLES DIVISION Installation 25/01/2005

Where: P: actual sidewall pressure on cable, lbs./ft.

9. Synchronized power drive rollers

10. Underground installations (the full NEC rules shall be used)

POWER CABLES DIVISION Installation 25/01/2005

POWER CABLES DIVISION Installation 25/01/2005

DC High Potential (Hipot) Field Testing of

Prepared by: E. Tanis Approved by: B. Fainaru

DC High Potential (Hipot) Field Testing of

3. Preparation for testing

If it is intended to perform a hipot test on the cable on the reel, it should be

DC High Potential (Hipot) Field Testing of

CABLE END PREPARATION 1”

Remove jacket to dimension A = B + 4”.

B length as a function of test voltage

4.2. After Installation

DC High Potential (Hipot) Field Testing of

If the installed cable is connected to an older network, the limitation given in

4.3. In service and maintenance

4.4. Conclusion of testing

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