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International Wire & Cable Symposium 169 Proceedings of the 58th IWCS/IICIT
For all ducted systems preparation is the same: the ducts sector. Worldwide adopted is the jetting method, especially for
segments are laid in a trench and joined together before the the installation of optical cable, where air is used as propelling
cable installation. The trench is typically opened and closed in fluid. In some countries, like Hungary, Denmark, Sweden and
sections, thus reducing additional or exhaustive disturbances to France, water is used as the propelling fluid, this method is
the neighbourhood and traffic. In the same time the jointing commonly known as cable floating. One could wonder why the
chambers are built. After completion of the duct route between jetting method was never used for energy cable installation?
each jointing chamber, including filling the trench, rehabilitating This is due to the fact that the amount of air needed to install
for traffic the actual cable placement can start. A thin steel wire large cables in large ducts exceeds the capacity (volume flow)
or P-line is blown trough the duct. Typically a stronger rope or of field compressors available on the market. Thanks to the
winch-line is then pulled trough the duct. The winch-line is then much higher viscosity of water compared to that of air the
connected to the cable end and the cable is pulled with winch. volume flow for floating is much less. Furthermore, the
Quite often also lubricant is used to reduce the friction between Archimedes uplift of the water acting on the cable makes the
the cable and the duct. The method requires operators on both lengths reached by floating generally longer compared to jetting
ends of the duct to operate the winch and the cable drum. The by air.
installation lengths achieved by this method are limited by The system to float the cable is shown in figure 4. The cable is
friction and the number of curves and the undulation. The fed into the pre-installed duct with a cable pusher, typically
method is typically used for distances up to 1 km. The method is driven by caterpillars or belts. Immediately after the cable
presented in figure 2. pusher a water inlet chamber attached to the duct. The role of
the water is, next to providing uplift to the cable, to reduce and
stabilise by cooling the friction between cable and duct, thus
enabling to reach greater lengths. Quite often a small amount of
environment friendly additive is introduced in the water to
reduce the friction. Another benefit provided by this system
when compared to the cable pull or the cable push-pull methods
is that the floating method is a one step process, avoiding steps
like P-line and winch-line installation. Also control of the whole
process is done from one side only, i.e. the drum side. This
Figure 2. Pulling method remarkably reduces the required manpower and it also makes it
easier to control the cable feeding process. For installations in
ducts having an outer diameter of up to 60 mm the floating
2.3 Push-pull method
method has been used successfully for the insertion of single
To increase the installation length achieved with pulling, in
phase power cables 240 mm2 of up to 20 kV over 2 km in a
particular in the projects where the cable has to pass several
50/42 mm HDPE duct in one step (see figure 5). This method is
curves, the idea to push the cable simultaneously with pulling
not applicable for floating in ducts of over 60 mm outer
was introduced years ago. At first sight the method is equivalent
diameter due to excessive water consumption, causing water
to the pulling method. Indeed preparation and equipment are the
logistics problems.
same, except for a pusher placed between cable drum and duct
inlet. Typically the pusher is a two or three belt caterpillar
synchronised with the cable winch located at the other end of
the duct. Also in this case lubricant is generally used to reduce
the friction between the cable and the duct. The system is shown
in figure 3.
International Wire & Cable Symposium 170 Proceedings of the 58th IWCS/IICIT
2.5 Watucab method 3.1 Reference cables
The patented Watucab method [1] is combining the benefits of Two reference cables are considered. Their respective
the push-pull and the floating methods. According to this characteristics are shown on Table 1. These cables are currently
method a cable is fed into the pre-installed duct via a water inlet available and have been successfully installed with the new
chamber attached to said duct. A watertight pig [2] is attached to Watucab method [3]. The associated ducts are commonly used
the end of the cable. Pressurized water is fed into the duct via and fulfill conditions according to (1) and (2)
the water inlet chamber, the pressure difference over the
watertight pig exerting a mechanical thrust, resulting in a pulling
force at the cable foremost end. In addition to this pulling force Cable # Voltage Conductor Screen
a pushing force is exerted on the cable by means of a [kV] [mm2]
mechanical pusher located between cable drum and water inlet 1 225 1200 Al Al
chamber. Similar to floating the cable is subjected to
Archimedes uplift and friction can be reduced by environmental 2 63 630 Al Al
friendly additives in the water. The method is shown in the Cable # Outer dia Dc Lin. weight Stiffness
figure 6. [mm] [N/ m] [N/ m2]
1 109 111 6000
2 66 43 1800
Cable # Max pull Duct ID Diduct Ampl/ Period
allowed [N] [mm] [mm] / [m]
1 48000 192 200 / 28
2 25200 102 125 / 17.5
International Wire & Cable Symposium 171 Proceedings of the 58th IWCS/IICIT
3.3.1 General observations 3.3.2 Forces exerted on the cable
From table 2 and 3 the performances achieved using the Pulling 3.3.2.1 Pulling force:
, Push-pull and Watucab method, one will note the significant The pulling force F [N] needed for achieving the installation
performance increase of 35 to 60% brought by the push-pull lengths shown on figure 2 are identical for the pull and push-
method, respectively 87 to 95% by the Watucab method when pull methods and correspond to the maximum allowable pulling
compared to conventional pulling . The coefficient of friction forces Fadm applicable for cable 1 & 2. These forces F are equal
Mu has a similar impact on all above mentioned installation to:
methods. This means that lubrication remains a key element
F = Fadm = σadm x Scond [N]
Where: σadm is the max admissible tensile load on the conductor
given by the cable manufacturer and S is the cable conductor
Mu = 0.1
metallic cross section [mm2]. For reference cables 1 and 2
Cable # Pulling Push-pull Watucab
σadm = 40 [N/mm2]
1 0.00% 40.00% 90.00%
2 0.00% 60.00% 100.00% Scond = 1200 resp 630 [mm2]
With Watucab the pulling forces F correspond to the force
Mu = 0.125 exerted by the water tight pig. They are equal to
Cable # Pulling Push-pull Watucab
F = P x Sduct [N]
1 0.00% 37.50% 87.50%
2 0.00% 62.50% 100.00% Where P is the water pressure [N/mm2] and Sduct is the duct
inner cross area [mm2]
Mu = 0.15
Cable # Pulling Push-pull Watucab
3.3.2.2 Pushing forces:
The pushing force Fs [N] applied in our case is 10000 [N]. This
1 0.00% 34.87% 94.81% corresponds to the push exerted by available pushing
2 0.00% 63.85% 93.64% mechanism which is common for both methods, i.e. Push-pull
and Watucab. This value satisfies the cable manufacturer
Mu = 0.2
requirements.
Cable # Pulling Push-pull Watucab
For the above described performance comparison, the pushing
1 0.00% 40.00% 93.87%
forces Fs [N] is identical for the Push-pull and Watucab method.
2 0.00% 60.00% 100.00% our case i.e.10000 [N] for cable 1 and 2. see table 5
From table 4 below one notes the considerably lower pulling
Table 2. Relative length increase per method forces exerted on cable 1 and 2 when compared to the pulling
having a direct impact on the installation length, from Table 2 force applied with the pulling or push-pull method. This
one can note that, for 0.1 < Mu < 0.2, the installation length is contributes to enhance the service reliability of the cable
more or less inversely proportional to the coefficient of friction
Mu.
Push-pull
F / Fadm
Watucab
(Fadm)
(Fadm)
Pulling
Mu = 0.1 (F)
Cable # Pulling Push-pull Watucab
cable#
1 1500 2100 2850
2 1500 2400 3000 1 48000 48000 17370 36.19%
2 25200 25200 6120 24.29%
Mu = 0.125
Cable # Pulling Push-pull Watucab
Table 4. Pulling forces comparison
1 1200 1650 2250
2 1200 1950 2400
Mu = 0.15
Fs Push-pull
Fs Watucab
Fs Push-pull
Fs Pulling
Fs Watucab/
[N]
[N]
International Wire & Cable Symposium 172 Proceedings of the 58th IWCS/IICIT
4. Cost comparison of methods This buried duct route, made of 160/152 mm PVC includes a
Although it is very difficult to compare the methods in specific total of fourteen 90° bends and 3 siphons evenly spread over
countries in real monetary terms we have made an analysis of 976 m. This represents a cumulated angular deflection of 1620°.
the cost factors based on man-hours and number of splice This is more severe than most urban duct routes.
chambers required for the construction of a typical 21 km long For validation purpose 1 km of 90 kV, 1000 mm² Al, with ext.
underground power line cases. Manpower needed for duct diameter 82 mm, 68 N/m has been successfully placed in the
placement and cable drum logistic is not taken into account here above described test circuit. Furthermore said cable has been
as it remains more or less equivalent with all installation placed and removed several times (for tests and demonstration
methods analyzed here . The results are shown in table 5. purpose) To remove the cable the Watucab process is reversed
i.e. water is injected from the opposite duct end after having
pivoted the pig in order to make it act on the cable extremity as
a pusher instead of a puller. The pusher is also reversed and
becomes a puller. In this way the cable is removed from the duct
and recoiled on the drum at a very low load. This demonstrates
that Watucab is a reversible process allowing for an efficient
upgrading of power-lines as the removed cable can be replaced
by an other with larger capacity.
Installation forces exerted on the cable : 6000 N for pulling
respectively 7000 N for pushing.
Figure 9 : Neuchâtel
International Wire & Cable Symposium 173 Proceedings of the 58th IWCS/IICIT
diameter 160/132 mm. Average section length 2.03 km, longest 5) Faster and less costly installation
section: 2.3 km 6) reversible process allowing network upgrade
The high voltage cables are installed in increasing amounts under
ground for several reasons. The main drivers are better protection
of the cable against weather hazards and public acceptance than
for aerial cables. The main limiting factor for underground cables
has been the higher installation cost than for aerial cable
networks. Watucab offers an efficient solution to install high
voltage cable under ground at lower cost compared to any other
underground cable installation method. The system has proved to
be viable and offering important benefits to the cable companies,
installers and the end customers
7. Acknowledgements
Special thanks to Willem Griffioen for his precious support and
advice during the preparation of this paper.
8. References
[1] EP 1456923. “Method for Installing a High or Medium
Voltage Power Cable in the Ground.” Plumettaz SA
[2] EP 1518307 « Pig for installing a cable in a conduit »
Plumettaz SA
[3] M. Le STUM & Al., “Report on the Use of Extruded Cables
on the French Grid”.Chap. 4 B1-204, CIGRE 2006,
www.cigre.org
[4] W. Griffioen, «Installation of Cables in Ducts”, Plumettaz
Figure 10 : Normandy
SA Bex (CH) (1993) ISBN 9072125 37 1
In Brittany, France (see Figure 11), installation over a 19 km
long route, 3 x 63 kV, 800 mm2 Al single phase cable, ext
diameter 68 mm, linear weight 51 N/m. Duct used: 3 x HDPE
The Authors
Gerard Plumettaz received a MS degree
125/102 mm The average section length is 3.17 km, longest
in mechanical engineering at the Swiss
section: 3.31 km..
Federal Institute of Technology, Zürich,
in 1970 with an emphasis on machine
tool techniques. Joined his family
business, Plumettaz SA, Bex, Switzer-
land, in 1971 and became instrumental in
product design, development and
marketing. Initial task was to design
and develop winching concepts for
military tank retrieval. Here specialized
winching techniques led to the design of underground placement
methods. Until 2009, CEO of Plumettaz SA. Today Chairman of
Plumettaz Holding SA, he is continuing to be active in the pursuit
of advanced methods in underground placement technology.
Jouni Heinonen holds a MS degree in
mechanical engineering from the
Tampere University of Technology, in
Finland. He began his career in 1986 as
Product manager at Falcon Chemicals
Figure 11 : Brittany in Finland and then joined Nokia Cable
Machinery in Finland as Product
6. Conclusions Development Engineer. In 1988
A new method for installation of high voltage energy cables in he joined Nokia-Maillefer Oy as
pre-installed ducts has been developed and successfully applied. Product Development Manager and
The method is applicable for ducts with an outer diameter superior moved to Switzerland to join Nokia-
to 60 mm. The main benefits gained from this innovation are Maillefer SA, initially as Project leader
1) longer installation lengths in one step saving expensive joints to finally become Managing Director in 1996. From 1998 he held
2) one step process the role of Executive VP of Business Group Plastics of Nextrom
3) process control from drum side only enabling easy visual and became CEO of Nextrom Holding SA from 1999. From 2005
communication between active parties thus avoiding hazards to 2008, he held the role of CEO of Gurit Holding AG. Today, he is
4) Increased protection of cable integrity acting as CEO of Plumettaz Holding SA in Switzerland, a leading
manufacturer of cable laying equipment.
International Wire & Cable Symposium 174 Proceedings of the 58th IWCS/IICIT