Section 9

WIRE AND CABLE

GENERAL CONDUCTORS

Insulated wires and cables of all types, sizes and Conductor material is usually soft drawn or annealed
descriptions are used for equipment internal wiring copper, stranded. Solid conductors and hard drawn
and for field wiring between items of equipment, copper are only used for special applications. Soft
devices, components and instruments. Some wire drawn, or annealed, stranded wire provides the
and cable may be located in potentially hostile flexibility required to facilitate pulling of cables in
environments and will have special conductor, raceways or cable tray, and for training them in
insulation or jacket requirements. equipment. Conductor strands are usually tin-coated
to preclude copper oxidation which increases
Wire and cable for field installation will be resistance at terminations.
purchased by engineering per project specification
which usually states the requirements relative to Special alloy conductor materials are used for
service (power, control or instrumentation). For thermocouple extention leads. Common materials
each service type the specification will state such are iron-constantan (type J), copper-constantan (type
requirements as the performance characteristics of T), and chromel-alumel (type K). These are usually
the insulation and jacket materials and thickness, small, solid conductors #20 to #16 AWG.
voltage class, operating temperature, conductor
material and size, stranding, conductor coating, Aluminum conductors are sometimes used for the
shielding, color coding, jacket marking, make-up or larger sizes (1500 MCM - 2000 MCM) in special
multi-conductor cables, armor make-up, testing, applications such as in underground or cable bus
applicable industry standards, required certifications, installations. Construction power is often installed
and related documentation. with direct burial aluminum conductors. For equal
ampacity, the aluminum conductors are 120% to
Hi or Medium Voltage Power cables in the larger 130% the size of equivalent copper conductors.
sizes are usually single-conductor, shielded or non- Aluminum terminations must be made with
shielded with ground conductor(s). Power cables compatible terminals, aluminum or tinned copper, to
associated with the 480v power system is usually avoid corrosion problems. An oxide inhibitor paste
multi-conductor. Control cables also are usually is also used. The choice of aluminum is an
multi-conductor. Instrumentation cables are usually economic one, balancing the lower material costs
multi-conductor paired and shielded either 300v or against higher costs of installation.
600v. Lighting, fire, and freeze protection wiring is
usually single conductor stranded. Cathodic CONDUCTOR SIZES
Protection and communication wiring is usually
“vendor” recommended, preferred, or provided. Conductor sizes are stated in AWG (American Wire
Gage) for conductor sizes ranging from #18--4/0.
Equipment wiring is furnished and installed by the The term kcmil is often used in place of MCM for
equipment supplier and is generally specified by conductor sizes ranging from 250 to 2000. Most
insulation type (industry standard) with additional international projects conductor sizes are stated in
requirements relative to flame resistance. square millimeters (mm2). Solid colored wire ranges
#22--#16 are also used for “solder” or “solderless”
Small wiring for control (or used as jumpers) is connections for most 24v (ac or dc) systems.
usually single-conductor, type SIS, stranded
switchboard wire with synthetic, heat resistant Note: AWG is a number gage where the largest gage
insulation. number is the smallest size with diameters
increasing as the gage number decreases (e.g. #12
Grounding cable is identified in Section 6 of this AWG is smaller in diameter than #10).
Handbook.

Rev. 0 Electrical Handbook 9-1

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

A circular mil is the area of a circle, 1 mil (0.001”) rope stranding may be specified. Class K bunch
in diameter. Conductor size expressed in stranding is often used for the Type SIS wire used in
MCM/kcmil is the cross-sectional area in thousands equipment such as switchgear and control panels.
of circular mils. The area of a circle in circular mils Typical are AWG #14 with 41 strands, and AWG
is the square of its diameter, in mils. A one (1) inch #10 with 105 strands. This type of stranding
diameter solid conductor is 1000 MCM in cross- provides the flexibility required for wiring in close
sectional area (1” = 1000mils, 10002 = 1000 MCM). spaces. Bunch stranding has the strands twisted
together without regard to the geometrical
The AWG gage number (or MCM size) applies to arrangement.
stranded as well as solid conductors of the same
cross-sectional area. The diameter of a stranded Concentric stranding may be used where it is desired
conductor will be somewhat greater than a solid to reduce the overall diameter and thus require less
conductor of the same AWG or MCM size. The insulation and jacketing material. Stiffness,
amount of increase in diameter is a function of the however, is increased. Sector stranding may be used
type of standing. The most common stranding is in three conductor cables to reduce overall diameter.
concentric which increases the conductor diameter to Compact conductors are first laid up with round
about 115% that of the equivalent solid conductor. strands and then rolled to compress and provide the
final shape.
Conductors smaller than AWG #20 are seldom
encountered except for the winding of small coils in INSULATION AND JACKETING MATERIALS
relays, specialized “pin connectors”, or plugs, etc.
Although all sizes are available, the most common Electrical insulation is applied over the bare
are the even numbers of AWG, and 50 MCM conductors to provide the appropriate dielectric
increments from 250 MCM through 500 MCM, and strength to withstand the voltage between conductors
increments of 100 to 250 MCM for cables larger and from conductor to ground. Jackets are often
than 500 MCM. Conductors larger than 2000 MCM applied over the insulated conductors to provide a
are seldom used because of difficulties in handling mechanical protection against crushing, cutting,
and installing. It is preferred to keep cable sizes abrasion, and other physical damage. Jackets may
below 750 MCM because of the ratio of ampacity to also provide flame-retardance or protection against
material and installation costs. moisture and/or chemicals. Insulation and jacket
thickness for various voltage classes, insulation types
CONDUCTOR STRANDING and types of service are prescribed by industry
standards, particularly those of the Insulated Cable
There are many types of stranding available. The Engineers Association (ICEA).
choice is dependent on the degree of flexibility
desired, shape and overall diameter. The most The most commonly used insulating and jacketing
common is concentric stranding with one strand materials are synthetic thermoplastic or thermo-
forming the core and the other strands in one or setting compounds of the desired properties.
more helically laid layers. Class B standing is the
most common for power cables. Additional types of overall protection which may be
used are interlocked armor made from steel,
NOTE: Sizes smaller than AWG #20 are usually aluminum or bronze, spirally wound, corrugated
solid. metal armor, etc., usually with a synthetic plastic
jacket. Oil impregnated paper insulation is
Class C and Class D concentric stranding have sometimes used for high voltage applications, in
greater numbers of strands respectively and are more which case it is usually jacketed with lead or
flexible. Where extreme flexibility is required, for installed in an oil filled pipe. Of the synthetic
example, trailing cables to mobile electric shovels, materials, the most common are:

Rev. 0 Electrical Handbook 9-2

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

• 8 kV - Used for 7.2 kV power.

• Cross-linked polyethylene (XLP). • 15 kV - Used for 13.2 kV power.
• Ethylene propylene (EPR). • 35 kV - Used for 34.5 kV power
• Butyl rubber.
• Silicone rubber. CABLE CONSTRUCTIONS
• Neoprene (jacket).
• Hypalon (jacket). There are many types of constructions available for
• Nylon. specific applications. The more common are:
• Teflon.
Power Cables
Polyvinyl chloride (PVC) and unmodified
polyethylene were formerly used to a great extent but • Single-Conductor or Three-Conductor Non-
are usually prohibited by most Engineering Shielded usually rated for power at 600 volts or
specifications because of their flammability or less. Individually insulated conductors, usually
production of corrosive gasses when involved in a AWG 4/0 to 12.
fire. Asbestos is also usually prohibited because of
its hazards. • Single-Conductor or Three-Conductor Shielded
is usually rated for power at 5000 volts and
Flame retardancy of insulating, jacketing and filler greater. Shielded power cables are for the
materials has become a very important characteristic. purpose of preventing corona at the higher
Most procurements require testing to specified voltages. Corona is a low energy electrical
industry or project standards. discharge caused by ionization of air in a
relatively high electric field. Ionization of air
Most insulating materials are rated for continuous produces ozone which is detrimental to
operation with a conductor temperature of 900C. insulating materials. The shield placed over the
Some must be operated at lower temperatures while insulation results in a uniform electric field so
others may be operated at higher temperatures. that the insulation is not overstressed where it is
closest to other conductors or ground. Shields
Insulation and jacketing materials are usually may be thin metallic tapes spirally wound or a
compounded by the cable manufacturer from raw plastic jacket specially formulated to be
materials supplied by chemical manufacturers. The somewhat conductive and into which are
generic or basic materials may be mixed with fillers, embedded a number of corrugated copper drain
plasticizers, pigments, etc., and processed in various wires. The latter is less likely to be damaged
manners such as vulcanization to produce the when bent to a short radius than tape shields.
desired properties. Some of the compounds are Shields are grounded after installation. In
proprietary and many suppliers use trade names to addition to the insulation shields, cables have a
identify their materials and products. stranded shield which is a conducting layer
applied directly over the conductor and in
VOLTAGE CLASSIFICATIONS intimate contact with insulation to produce a
controlled and uniform electric field at the
Common voltage classifications used are: conductor surface.

• 300 V - Generally only used for instrumentation. For shielded medium voltage power cables, the
• 600 V - Generally used for 480 or 240Vac phase-to-phase voltage rating of the cable is
power, 120 Vac control or instrumentation, and specified along with an insulation level category
125 or 250 Vdc. - 100% Insulation Level or 133% Insulation
• 3000 V - Used for 2400 V power. Level. The insulation level category is used to
• 5 kV - Used for 4.16 kV power. define what happens to a cable during failure

Rev. 0 Electrical Handbook 9-3

 Bechtel Corporation 1997. 11/26/97
 Section 9
WIRE AND CABLE

conditions and determines the proper insulation usually single paired or multi-paired insulated
thickness for the cable. conductors with a braid or metallized foil shield
over the conductors and under the jacket. A
100% Insulation Level common conductor size is AWG #16. With the
Cables in this category are used on electrical systems foil shields a bare copper drain wire is placed
with relay protection such that ground faults under the shield. The shield is grounded and
(cable failure) will be cleared within one (1) serves to minimize noise pickup by electro-static
minute (i.e., fault current is transmitted to induction. Noise pickup, from nearby power
circuit breaker which opens, removing all three circuits by electro-magnetic induction, is
phases from the circuit). A normal insulation minimized by twisting the signal pairs in the
thickness can be used for these cables because cables.
no exposure to over-voltages occurs during the • Thermocouple extention leads are in the
failure. instrument cable category.

133% Insulation Level • Coaxial Cable. These have a single center

Cables in this category are used on electrical systems conductor, solid or stranded, which is concentric
where a ground fault (cable failure) cannot be with the insulation and a shield, which is often
cleared in one (1) minute but the faulted cables braided copper, with an overall jacket. They are
will be de-energized within one (1) hour. These used for radio frequencies of pulsed signals.
cables are often used on delta connected circuits
or ungrounded neutral circuits. When one phase
fails, the two remaining phases continue to
operate but with a higher than normal voltage
applied across the insulation. A greater
insulation thickness is required on some cables
to withstand this higher voltage.

• Triplexed Cable. This is basically three single

conductor cables assembled together in a helical
lay and placed on reels as a unit. They are used
to reduce installation costs as compared to
handling and pulling three separate cables. • Interlocked Armored Cables. An interlocked
armored cable is a factory assembly of two or
Control and Instrumentation Cable more insulated conductors cabled together with
a grounding conductor and fillers and then
Multi-Conductor Control Cable. These are used for covered with a shaped interlocking tope of
control circuits operating at 600 volts or less. aluminum or galvanized steel armor. A PVC
Individually insulated conductors, usually AWG jacket is usually provided over the interlocked
#12 or smaller, are laid up with appropriate armor to provide additional corrosion protection.
fillers, a binder tape, and an overall jacket
applied. Some control cables may be rated for Interlocked armored cable is available with 600 volt,
1000 volts, though uncommon. 5 kV and 15 kV rated insulation and is a
popular wiring system in industrial plants.
Caution: 300v cable should not be used unless specified
and approved by the Project Engineer.
• Tray Cable. Type TC tray cable is a factory
• Shielded Instrumentation Cable. These are used assembly of two or more insulated conductors
for low level instrumentation circuits and are cabled together with a nonmetallic jacket

Rev. 0 Electrical Handbook 9-4

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

overall. The cable is rated 600 volts and has gallium-arsenide photodiodes are used as electro-
temperature ratings of 90°C dry, 75°C wet. The optic receivers. Information is encoded into light
most popular designs of TC tray cable have pulses by amplitude, frequency, frequency shift
color-coded conductors in sizes AWG #14 - keyed, pulse shift keyed, or pulse code modulation
#10 and black conductors with surface printed techniques.
numbers (1,2,3) for larger sizes. Three-
conductor AWG #8 - MCM #1000 cables Advantages of Fiber Optics
normally are supplied with a bare copper
equipment grounding conductor in the cable Fiber optics communication offers several
assembly. Polyvinyl Chloride (PVC) is the most advantages over metallic systems.
commonly used overall jacket.
• The transmitted signals are not distorted by any
Type TC tray cables can be used in numerous form of outside electronic, magnetic, or radio
installation conditions such as cable tray, frequency interference. Therefore, optical cables
conduit or raceway, aerially supported by are completely immune to lightning or high
messenger, underground ducts and direct earth voltage interference.
burial.
• Because optical signals do not require grounding
Note: In industrial installations the use of Type TC connections, the transmitter and receiver are
tray cables installed in cable tray can result in electrically isolated and free from ground loop
significant cost savings in comparison with problems. With no chance of terminal-to-
installing many parallel runs of conduit and terminal ground potential shifts, plus safety
then pulling single conductors into the conduits. from sparking and shock, fiber optics is
increasingly the choice where safe operation in
hazardous or flammable environments is a
FIBER OPTIC CABLE requirement.
• Compared to conventional coaxial cables with
Fiber Optic Cable employs a technology in which the same signal carrying ability, the smaller
light is transmitted along the inside of a thin glass or diameter and lighter weight of fiber optic cables
plastic fiber. The basic design is a central core glass means relatively easier installation. A single
which conducts the light and an outer clad glass conductor fiber optic cable weighs about six (6)
which minimizes light leakage out of the core pounds per 1,000 feet, compared to coaxial cable
material. The effect is due to index of refraction which weighs about 80 pounds per 1,000 feet.
differences in the two materials.
Disadvantages in the use of Fiber optics are commonly
Fiber Technology associated with:

There are two materials used to make the fiber optic • Tray use limitations.
cables, plastic and glass. Plastic fibers are not • Raceway use limitations or a dedicated system.
suitable for distribution applications since their high • Terminal box restrictions.
loss, limited operational temperature range, low • Significantly greater cable bend radius’.
strength and low bandwidth limit their use to • Installation of an interduct may be necessary.
distances of 50 to 200 meters (165 to 650 feet). • Specialized termination tools, training.
Glass fibers transmit most efficiently in the near and • Requires delicate cable pulling to avoid damage.
far infrared portion of the spectrum (800 to 1550
nm), so light emitting diodes (LED’s) and Basic Elements of Optical Fiber
semiconductor lasers are used as electro-optic
transmitters, and silicon, germanium, and indium-

Rev. 0 Electrical Handbook 9-5

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

• Core. This is the light transmission area of the name from the sharp steplike difference in the
fiber. The larger the core, the more light that refractive index of the core and cladding.
will be transmitted into the fiber.
• Cladding. The function of the cladding is to In the more common graded index multimode fiber
provide a lower refractive index at the core the light rays are also guided down the fiber in
interface in order to cause reflection within the multiple pathways. But unlike step index fiber, a
core so that lightwaves are transmitted through graded index core contains many layers of glass,
the fiber. each with a lower index of refraction as you go
• Coating. Coatings are usually multi-layers of outward from the axis. The effect of this grading is
plastic applied to preserve fiber strength, absorb that light rays are speeded up in the outer layers, to
shock and provide extra fiber protection. These match those rays going the shorter pathway directly
buffer coatings are available from 250 microns down the fiber axis. The result is that a graded
to 900 microns. index fiber equalizes the propagation times of the
various modes so that data can be sent over a much
longer distance and at higher rates before light
pulses start to overlap and become less
distinguishable at the received end.

The single mode fiber allows only a single light ray

or mode to be transmitted down the core. This
Fiber Size virtually eliminates any distortion due to the light
pulses overlapping. The core of a single mode fiber
The size of an optical fiber is commonly referred to is extremely small, approximately five to ten
by the outer diameter of its core, cladding and microns. The single mode fiber has a higher
coating. (Example: 50/125/250 indicates a fiber capacity and capability than either of the two
with a core of 50 microns, cladding of 125 microns, multimode types.
and a coating of 250 microns.) The coating is
always removed when joining or connecting fibers. Fiber Optic System Design Considerations

Fiber Types When selecting components for a fiber optic system,

there are two optical fiber factors that affect
Fiber can be identified by the type of paths that the transmission performance: bandwidth and
light rays, or modes, travel within the fiber core. attenuation.
There are two basic types of fiber: multimode and
single mode. • Bandwidth. Bandwidth is the measure of the
data carrying capacity of the fiber. The greater
the bandwidth, the greater the information
capacity.

Bandwidth is expressed in a frequency-distance

form (Mhz-km). (Example: A 200MHz-km
fiber can move 200Mhz of data up to one
kilometer or 100MHz of data as far as two
kilometers.)

Multimode fiber cores may be either step index or • Attenuation. In addition to physical changes to
graded index. Step index multimode fiber derives its the light pulse which results from frequency or
bandwidth limitations, there are also reductions

Rev. 0 Electrical Handbook 9-6

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

in the level of optical power as the light pulse

travels to and through the fiber. This optical • First Level of Fiber Protection. The optical
power loss, or attenuation, is expressed in cable is a very small waveguide. In an
dB/km (decibels per kilometer) at a specified environment free from stress and external
wavelength. forces, this waveguide will transmit the light
• Intrinsic Optical Fiber Loss. Light is an launched into it with minimal loss, or
electromagnetic wave of vibrating nature. Short attenuation.
wavelengths are in the ultraviolet spectrum. To isolate the fiber from these external forces,
Microwaves, radar, television and radio operate two first level protections of fiber have been
in the longest wavelength areas. In between the developed: loose buffer and tight buffer.
ultraviolet and the microwave spectrums, are the
infrared optic wavelengths.

Just as the speed of light slows when traveling

in transparent materials, each infrared
wavelength is transmitted differently within the
fiber. Therefore optical power loss (attenuation)
must be measured in specific wavelengths for
each fiber type.

Wavelengths are measured in nonometers (nm) -

billionths of meter - which represent the
distance between two cycles of the same wave.

Losses of optical power at the different In loose buffer construction, the fiber is
wavelengths occur in the fiber due to absorption, contained in a plastic tube that has an inner
reflection, and scattering. These occur over diameter considerably larger than the fiber itself.
distance depending on the specific fiber, its size, The interior of the plastic tube is usually filled
purity, and refraction indexes. with a gel material. The loose tube isolates the
fiber from the exterior mechanical forces action
• Microbending Loss. Without protection, an on a cable. For multiple-fiber cables, a number
optical fiber is subject to losses of optical power or these tubes, each containing single or
caused by microbending. Microbends are multiple fibers, are combined with strength
minute fiber deviations caused by lateral forces members to keep the fibers free of stress, and to
which cause optical power loss from the core. minimize elongation and contraction. By
Different types of protection for the fiber are varying the amount of fiber inside the tube
available to minimize microbending. during the cabling process, the degree of
shrinkage due to temperature variation can be
Step index fibers are relatively more resistant to controlled, and therefore the degree of
microbending losses than graded index. attenuation over a temperature range is
minimized.
Cable Design Considerations
The other fiber protection technique, tight
Considerations of tensile strength, ruggedness, buffer, uses a direct extrusion of plastic over the
durability, flexibility, size, resistance to basic fiber coating. Tight buffer constructions
environment, flammability, temperature range and are able to withstand much greater crush and
appearance are important in constructing optical impact forces without fiber breakage. This
fiber cable. design, however, results in lower isolation for

Rev. 0 Electrical Handbook 9-7

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

the fiber from the stresses of temperature

variations. While relatively more flexible than Strength members which are typically used in fiber
loose buffer, if the tight buffer is deployed with optic cable include aramid yarn, fiberglass epoxy
sharp bends or twists, optical losses are likely to rods (FGE), and steel wire. Pound for pound,
exceed normal specifications due to aramid yarn is five times stronger than steel. It and
microbending. fiberglass epoxy rods are often the choice when all-
dielectric construction is required. Steel or FGE
A refined form of tight buffer construction is should be chosen when extreme cold temperature
breakout cable. In breakout cable, a tightly performance is required, since they can offer better
buffered fiber is surrounded by aramid yarn and temperature stability.
a jacket, typically PVC. These single-fiber
subunit elements are then covered by a common Vendor or Subcontractor Wiring/Cables
sheath to form the breakout cable. This “cable
within a cable” offers the advantage of direct, Vendor supplied or subcontractor installed wiring
simplified connector attachment and and cabling requirements are similiar in nature to
installation. the parameters established by codes and standards,
project design considerations, client specifics, and
Each construction has inherent advantages. The their own design standards and criteria. Associated
loose buffer tube offers lower cable attenuation from documents, drawings, specifications, standards,
microbending in any given fiber, plus a high level of test(s) results, and cable descriptions are all required
isolation from external forces. Under continuous to be available to the Field Engineer in the
mechanical stress, the loose tube permits more stable supporting of installation, procurement, testing,
transmission characteristics. checkout, and problem resolution. Typically, this
data information is available as a part of the
The tight buffer construction permits smaller, light- vendor/subcontractor purchase order documentation.
weight designs for similar fiber configuration, and
generally yields a more flexible, crush-resistant CABLE MANUFACTURING SPECIFICS
cable.
The exterior of each cable is indelibly marked
Mechanical Protection periodically by ink or embossing with some or all of
the following information:
Normal cable loads sustained during installation may
ultimately place the fiber in a state of tensile • Manufacturer name.
strength. The levels of stress may cause • Cable type (NEC and/or trade name).
microbending losses which result in an attenuation • Conductors (number and size).
increase and possible fatigue effects. To transfer • Voltage and operating temperature rating.
these stress loads in short term installation and long- • Conductor material ( if other than copper).
term application, various internal strength members • (UL) if listed by Underwriters Laboratory.
are added to the optical cable structure. Such • Footage Marks.
strength members provide the tensile load properties
similar to electronic cables, and keep the fibers free
from stress by minimizing elongation and CABLE INSTALLATION
contraction. In some cases, they also act as
temperature stabilization elements. Many failures of power cables have their roots in
damage incurred during installation. This damage
Optical fiber stretches very little before breaking, so can usually be attributed to improper cable handling
the strength members must have low elongation at procedures, pulling, or improper installation of the
the expected tensile loads. raceway system. The damage is often not

Rev. 0 Electrical Handbook 9-8

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

immediately apparent, but usually results in cable

failure in months or years after installation. At that If, reels are stored outdoors, they must be supported
point, replacement is difficult and costly. off the ground in an area which is secure and is
isolated from construction activities. Exposed cable
A cable’s insulation, jacketing, and even the ends should be as a minimum taped or sealed with a
conductor can be damaged during installation. protective boot to prohibit the intrusion of water or
Punctures and tears to cable coverings are usually moisture.
produced by blows from foreign objects, while
abrasion is usually the result of excessive friction As a precursor to installation, the medium/hi-voltage
from dragging. Also, conductors are frequently and power cables should be meggered on the reel
twisted, or stretched by applying excessive force upon receipt. Cable suppliers typically perform this
during bending. activity in advance of shipment, though, shipping or
unloading damage to the cables could happen after
Any insulation disruption produces a localized the supplier test was performed.
weakening of the cable’s dielectric strength,
reducing the cables ability to withstand operating Proper cable inventory controls must be established
stresses. Disruption of the cable’s covering makes it early, maintained, recorded, and updated which as a
susceptible to moisture intrusion and consequent minimum identify:
failure. Reduced insulation resistance at points of
damage can also provide convenient paths for • Cable manufacturer.
leakage current, while not necessarily resulting in • Cable type, class, rating, operating temperature.
total, catastrophic failure. • Restrictive uses.
• Laydown or area stored and storage
These problems are readily avoidable. The key lies requirements.
in proper design and installation of the raceway • Total available or received footage “on hand”.
system, planning and execution of the cable • Conductor Size.
installation process, and proper techniques for • Certification, testing data and test results.
storing, handling, and installing the cable. • Cable diameter, area.
• Bending/forming/training radius’ criteria.
Cable Receipt and Storage.

It is not infrequent for cable to be delivered to the Cable Pulling Equipment, Set Up, Approach
jobsite well in advance of its required use. Cable
installation begins with receipt inspection and proper Proper cable pulling techniques begin prior to the
storage when it is received. Upon delivery, all cable installation of the first piece of equipment, tray, duct
should be carefully off loaded, verified that it is the bank, or conduit. It begins with the review of cable
proper type, class, length requested, and inspected to pulling equipment needs, tools, and a coordinated
ensure the manufacturer’s protective packaging has plan. The Field Engineer and Supervision identify
not been damaged or disturbed. what specialized equipment is needed and establish
the overall cable pulling plan. As a minimum the
If possible, cable reels should be stored indoors by following cable pulling equipment and tools will be
classification (power, control, instrumentation) to aid required to support all the various types of 600v and
inventory controls, minimize environmental most medium-voltage cables that will be pulled:
deterioration, possible ingress of moisture, and
susceptibility to accidental physical damage, or • Reel Jacks.
intentional vandalism. Cables with moisture
• Sheaves, cable wheels, and slings.
sensitive coverings must be stored indoors or in
• Cable Pulley’s Rollers.
tented areas.
• Pull Rope (various sizes and strength’s).

Rev. 0 Electrical Handbook 9-9

 Bechtel Corporation 1997. 11/26/97
 Section 9
WIRE AND CABLE

• Pull String, Fish Tapes (vinyl and steel). • Cable “in the area” ready for “pull down” to
• Lubricant, Soap, Rags, and Pulling Gloves. final destination.
• Tugger. • Is an effective use of manpower.
• Jet Line (Power Fish Tape). • Effectively reduces overall installation schedule.
• Com-a-longs, chain fall. • Enables an early start on terminations.
• Dynamometer. Multimeter, voltage testers. • Establishes raceway installation priorities.
• Current Tracer, Amprobe, Megger, Hi-Pot.
• Label Maker or printer for (cable id tags). Raceway Preparations Prior to Cable Pulling.
• Cable baskets, pulling eyes, mesh cord grips.
• Cable Cutters, hacksaw, cable skinning knife. Commensurate with the cable pulling plan and the overall
• Spool Caddies, roll up reel(s), re-reeler. pulling approach is the preparation of “cable pull
packages”, verification of raceway or tray completion
Considerations to cable pulling approach factor in or equipment installation, reviewing cable routes for
systems, start-up sequencing, energization schedules, “gaps” in the raceway design (when cables utilize
equipment deliveries and setting, cable quantities, SETROUTE), and review cable pulls for potential
bulk pulling, manpower, weather, equipment safety hazards, scaffolds, additional pull points,
resources, tray and duct bank installations. boxes, equipment entrances or energized components
that the cable may be pulled into.
Ironically, the least significant is the conduit
installation, instruments, and minor electrical Preparation of the raceway or tray system must also be
devices. Cable installation only requires the raceway considered prior to any cable pulling. Specific areas
“to finish or complete” the cable pulling activities. of preparation include:
When pulling activities begin in advance (or are
concurrent) with the raceway completion, the • “Blowing out or Swabbing Conduits” to remove
cable(s) are pulled and coiled, this practice is normal debris, water, condensation that may have
though not encouraged. Pulling and coiling, by accumulated inside the raceway or duct bank.
definition, means cables are literally coiled at • Deburring of the conduit.
locations in the tray system pending the raceway • Filing smooth or covering any jagged edges.
completion to the “to or from end” device or • Installation of tray edge guard, dropouts, or
component. removal of any installed tray, box, or condulet
covers.
Disadvantages associated with pulling and coiling • Verify equipment entrance(s), plates removed,
are: location of “energized” sources or components.
• Installation of pull strings, pull ropes, tray cable
• Increased cable usage, waste, or excess. rollers.
• Possibility of physical damage to coiled cables • Raceway, tray, wall, floor, or equipment seals
greatly increased. are not installed or will require “breaching”.
• Probability of cable being “pulled short” • Verify or walkdown cable route for “true
increased. length” actual pull measurements. When utilizing
• Increased use of cable slings and rope tie offs. SETROUTE’s cable pull cards lengths should
• Double pulling of same cable(s). always be verified by actual lengths between the
• Increased use or probability of scaffolds, ladders, “pull from and the pull to” prior to releasing the
manlifts. Or, same will have to remain up to cable(s) to be cut or pulled especially for long
avoid reinstallation to complete cable pull. distance pulls.

Advantages to pulling and coiling are: Note: To assist this effort consider installing “true tape”
for underground or above ground raceways which
• Early start on systems schedules or bulk pulls. provide more reliable actual raceway footages.

Rev. 0 Electrical Handbook 9-10

 Bechtel Corporation 1997. 11/26/97
 Section 9
WIRE AND CABLE

drammatically when delays, problems, or hold ups

Note: For cable pulls that will utilize raceways within are encountered during the pull(s) requiring shutting
hazardous classified areas the field engineer and or the pull down and redirecting/setting up for another.
supervision should verify that appropriate raceway Understanding that, these potential cable pulling
sealing fittings (boxes/instruments etc) are installed concerns should be given serious forethought:
to prevent potential rework to the raceway (cable too)
to install these fittings later to satisfy the • Preplan with Safety in mind and acquire all
requirements of the hazardous area. necessary permits equipment, materials, and tools.
• Develop a “fall back” cable pulling plan in the
Cable Pulling Preparations. event the present pull “goes south”. Or, anticipate
where potential problems may be encountered and
Inclusive, with raceway preparation, is cable preparation remedy them beforehand.
activities which also must be considered prior to • Avoid “pull byes”. A pull bye by definition is
cable pulling they include: the pulling of cables into a raceway that already has
existing cables pulled into it. If, a pull bye is
• Tugger requirements or placement. necessary ensure pull ropes or strings exist or remain
• Are measuring and test equipment required that will aid in the pulling of the new cable(s).
(M&TE) or “witnessing” by an inspector? • Never use “steel” fish tapes where the potential
• Is Pull Card, cable labels available or needed? for energized devices or sources may exist. Also,
• Reel(s) set up, floor space available, cable slings avoid use in PVC or aluminum where the potential
in place? for gouging into the conduit could cause jagged or
• Are cable sheaves or wheels etc. required? sharp burrs.
• Are scaffolds, manlifts, ladders needed? • Use a Wire pulling compound, liberally, and one
• Are additional manpower or specialized that does not degrade the cable or hardens inside the
equipment resources required? conduit.
• Are communications required (radio’s)? • All “pull ropes” are not the same ensure the
• Ample soap, rags, equipment or floor area proper rope (preferred manila hemp or synthetic
covered or available. fiber) are used. Avoid nylon as they are elastic and
• Prepare cable end with pulling eyes, or baskets. exert uneven pulling tensions.
• Cable separation or maintained spaced cable • Be mindful of “cold weather” pulls. Cable
requirements. insulation and jacketing lose flexibility and become
• Are the cables energized (pull and coil brittle in cold weather. Consult cable manufacturer,
situations) or is the equipment, cabinet, panel, store in warmer area, or consult cable guidelines on
device, compartment energized? suitable ambient temperatures requirements.
• Is the pull in a confined space? Are safety • Figure eight cable on covered floor surfaces
permits required? when cable is removed off reels or during pulling.
• Mount reels on “reel jacks” and “hand feed” off
Cable Pulling Guidelines. the reel in the same direction as the cable was placed
on the reel.
Common problems encountered during cable pulling can • Optimum pulling speed should not exceed 50’
be avoided if identified prior to pulling, are (feet) per minute. Nor should pre-calculated
anticipated before experienced, and solutions are sidewall pressures or tensions be exceeded.
readily given. • “Training Radius and Minimum Bending
Radius” are not the same. Training radius is the in-
Time is money and schedule and never more true than position installed cable radius, whereas minimum
during cable pulling. Given that it frequently bending radius (radii) is the allowable bending radii
requires “crews” of electricians to pull the vast to which an insulated cable may be bent.
majority of cables; manhour costs increase

Rev. 0 Electrical Handbook 9-11

 Bechtel Corporation 1997. 11/26/97
 Section 9
WIRE AND CABLE

• Install cable grips to relieve stress or to aid as a The tension on the cable should never deform the
cable support when larger cables are pulled in a jacket and should be “faced” outward from the tray
vertical plane. to avoid “ripping” adjacent or future pulled cables.
• Figure eight cables in boxes where “training Commonly used in vertical (riser) trays in short
radius” violations may be a concern or due to distance spans and less frequently in horizontal trays
raceway installation. (this information is usually identified in the Cable
• Determine where the pull will start. From end, installation General Notes).
to end, mid point or location.
• For multiple cable (bundles) types and conductor Other means used to secure cables include:
pulls do not exceed the pulling requirements of
the smallest conductor/cable type in the bundle. • Cable grips or cord connectors.
• Consider the raceway and tray layout/complexity • Conduit clamps or pipe straps.
the pull will be utilizing. • Strain relief connectors.

Review and become familiar with the requirements of the Cable Reworks
sites or designs cable pulling General Notes,
procedures, and guidelines. Invariably during cable pulling and installation their
will be rework or the potential for cable rework due
Consult, request, or perform Cable pulling calculations possibly to design or vendor modifications and/or
for the more complicated or hi-medium voltage cable changes, installation problems and/or interferences,
pulls. raceway or equipment changes and modifications,
SETROUTE cable pull revision cards, or cable field
Cable Pulls and SETROUTE installation error.

In supporting either “bulk cable pulling” or selective Most potential reworks to cables can be avoided if
cables requiring pulling the Field Engineer generates notification to supervision or the craft is not delayed
a cable pulling card(s). These “pull” cards provide when initially identified either by design engineering
the field craftsman with the cable installation route or the field engineer.
(vias), “equipment/device from and to end”, cable
type, cable code, bend radius, general notes, and For cable situations or problems that involve design
other relevant information to support the cable pull engineering resolution or assistance the field
installation activities. Additionally, these cards engineer should consult with the designers.
contain system information, reel numbers, pull
package number, and estimated or actual cable Note: design revisions to “issued to the field” cable
length. What is not generally provided on the pull cards where SETROUTE is utilized should always
card(s) is how to support the cable(s). include a general note to the cable card explaining
the reason for the cable card revision.

Cable Supporting Cable Installation Tests

The most common support utilized to secure cables is the Cable insulation resistance (and/or a hi-pot) test should
cable tie (tyrap). Types, colors, sizes, and width’s be performed on all cables that are classified as
vary. Typically, they are sized based on the cable od. ≥480vAC or ≥125vDC power. Specific test ranges,
(outside diameter) or by the cable “bundle”. Their cable, and expected test results are normally
use is generally applied, cut, and tensioned by the governed by site procedures or by client specifics.
use of a “tyrap gun” though other methods are used.

Rev. 0 Electrical Handbook 9-12

 Bechtel Corporation 1997. 11/26/97
 Section 9
WIRE AND CABLE

Continuity checks on the installed cable(s) (power,

control, instrumentation) are performed either prior
to termination, during termination, or prior to
testing. Continuity checks are performed either
audibly or visually or both. Methods used include:

• Use of M&TE (fluke, multimeter) make or break

method to ground or by conductor.
• Phoning the cable/conductors out (headsets,
battery operated phones).
• Battery (bells, tone, or light).

Applications requiring continuity on multiple/single

conductor power cables ensure correct phasing is
maintained.

Caution: Prior to performing continuity on a potentially

energized circuit/cable requires de-termination at the
from or originating end of the cable/conductor,
power supply, or source. Alternate methods include
deenergization or lifting and isolating. It is sound
construction practice to always verify no AC or DC
voltages exist prior to performing any cable test.
The craft or field engineer should also be cognizant
of what voltages are expected (e.g. 24, 48, 120, 480).
As a minimum loop drawings, wiring diagrams or
drawings, SETROUTE termination cards,
interconnection drawings, or schematics should be
included as a part of the cable or circuit under test.

Performance of continuity checks may require a witness

or inspector on some projects (nuclear).

Rev. 0 Electrical Handbook 9-13

 Bechtel Corporation 1997. 11/26/97
 Section 9
WIRE AND CABLE

Pulling Hazards.

Inherit to any cable pull are the effects on the cable by

the raceway system it is utlilizing they include:

• Jamming or Twisting - experienced generally

when Three (3) cables are aligned side-by-side.
• Side Wall Pressure - crush force exerted on the
cable when it is being pulled through conduit bends
or sheave. Pressure is defined as pounds of force per
foot of radius of bend.
• Pulling Tension - the tension cable(s) will be
subjected to during pulling.
• Clearance - the distance between the topmost
cable and the inside top wall of the conduit.
Minimal clearances should be 1/2” to 1”.

Rev. 0 Electrical Handbook 9-14

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

600v Power Cable Examples

Rev. 0 Electrical Handbook 9-15

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

Medium-Voltage Power Cable Examples

Rev. 0 Electrical Handbook 9-16

 Bechtel Corporation 1997. 11/26/97
Section 9
WIRE AND CABLE

600v Control Cable Example

Rev. 0 Electrical Handbook 9-17

 Bechtel Corporation 1997. 11/26/97