PULL CALCS USER GUIDE

What are Pull calculations and why do they need to be performed?

Prior to the installation of cables, it is of upmost importance to perform tension and sidewall
pressures calculations. The tensions and sidewall pressures should not exceed the manufacturer’s
specified limits to avoid damage to the cables.
Accurate prediction of cable pulling tension is essential for the proper design of cable
systems. This knowledge makes it possible to avoid under-estimated and/or over conservative
design practices to achieve substantial capital savings during construction.

It helps in the following important aspects:

1) Test feasibility of the running cables through conduit.
2) Verifies current alignment or determines changes to alignment.
3) Helps maintaining safer operating conditions and minimize the risk of electrical
accidents for the underground electrical Transmission and distribution cables.

Factors affecting the cable pull calculations are as follows:

1) Maximum Tension

2) Maximum Sidewall Pressure

3) Coefficient of Friction

4) Jam/Fill Ratio

5) Reel Back Tension

Key Definitions:
1) Sidewall Pressure: Sidewall Pressure is the radial force exerted on the cable at a Bend. It
is inversely proportional to the radius of the bend. It also depends on the number of
cables being pulled, the configuration of those cables, and the resulting weight correction
factor.
It is measured in lbs/ft.
As a component of the pulling tension calculation, sidewall bearing pressure is a marker
indicating potential mechanical damage.

2) Tension: Tension refers to the pulling force transmitted axially by the means of a string,
cable, chain, or similar one-dimensional continuous objects, or by each end.
The tension in a cable is measured in lbs.
3) Jam Fill Ratio: The ratio which determines how much space the cables take up within a
conduit and the ability to make bends without jams.
When multiple cables are run through the conduit since they are not bundled, they may
become oriented in a way that cause a Jam.

4) Coefficient of Friction: The material of each object affects the coefficient of

friction. In this case, conduit material and jacket material of cable.
Coefficient of Friction is a dimensionless variable that measures the frictional resistance
to movement.
Below list shows the coefficient of friction for the conduit material and Jacket of cable.
5) Reel Back Tension: The pulling force to free the cable has counteracting force of the
reel. Basically, it is the force required to initially free the cable from the reel.

6) Type of Cable Pull: The way the cables are oriented in a conduit. Following are some of
the examples for the cable orientation:
i) Single
ii) Triangular
iii) Cradled
iv) Diamond
Types of Curves:
Following are some of the standard curves:
1) Straight Section

2) Slope Up

3) Slope Down

4) Horizontal Bend

Vertical Bends:
Getting Started with the Pull Planner 4.0 Software:
1. To start a new calculation open Pull Planner software and click the new icon
2. This will prompt a new window to appear that asks for a folder location for you to save the
Pull file.
It is recommended you save the file in the project folder location on DFS in the Civil folder
under the Design/Underground/Elec location.
Name the file something that is easily recognizable such as "Sub Term to SV1" if you are
running/creating the pull calculation for the duct bank alignment from the substation termination
to the first splice vault.

3. Next another window will appear asking you where to save your pull directory, you can save it
in the same location as you did above in step 2.

4. Then a series of Project specific input windows will appear asking for your design criteria:
4a. Conduit Inner Diameter, note this is project specific and can be found on the typical cross
section drawing or within the project design basis criteria memo. Depicted on the right-hand side
is a Schedule 40 PVC Pipe dimension table which is a common conduit material used in
underground transmission installations. Note we are looking for the Inner diameter of the conduit
to input into the software.
4b. Cable Information: Can be found on the cable cut sheet. The software does have a database
of template cables to use but for transmission class it is standard practice to select manual entry
and populate the cells per the cable cut sheet. After you input your first cable it will ask you if
you would like to add another table, this is not typically used, and you can select no.
4c. Coefficent of Friction (COF): Default entry should be "Manual" as this is project specific
based on cable construction and the type of conduit being installed for the project.
The contributing factors to determining the coefficient of friction are as follows: Is the
installation lubricated or unlubricated?
All transmission class installation should be lubricated. What is the material of the conduit that
houses the transmission cable? This is project specific but in most applications, we see PVC,
HDPE or steel. What is the jacket material of the transmission cable being installed?
This information is subject to the construction of the cable and can be found on the cable cut
sheet Now with those questions answered you can determine the COF using the table depicted
below taken from the EPRI Green book, typical values for a PE cable jacket and a PVC conduit
range from 0.15 to 0.22.

4d. Back Tension: Back tension is the tension required to unspool the cable off a reel. It is the
starting tension in which the pulling of the cable must overcome to be pulled off the reel and
installed. For transmission class XLPE cables a typical value used is 500lbs.
5. Now the software will bring you to the main input screen, it should look like the image below.
The next two inputs will be the maximum sidewall pressure and maximum tension, simply click
on the icons to open a pop-up window to input.

5a. Maximum sidewall pressure: Is the allowable force that should not be exceeded in order to
not damage the cable. When the cable is being pulled through the conduit bends it undergoes
pressures that if exceeded could damage the cable deeming it unusable. Sidewall pressure is
defined as tension (lbs/ft)
For transmission class cables this value is determined by the cable manufacturer and is specific
to your project. Typical values range from 1000lb/ft to 1500lb/ft.
5b. Maximum Tension: Is the force required to pull the cables into the conduit and should not be
exceeded in order to not damage the cable. The force to pull the cable is applied to the conductor,
allowable pulling levels are based on the conductor material.
For cables this value is determined by the cable manufacturer and is specific to your project. To
calculate the maximum pulling tension, we use a rule of thumb of 6lb/kcmil for Aluminum
conductor cables and 8lb/kcmil for copper conductor cables. 5000 kcmil Copper cable maximum
pulling tension = 5000kcmil x 8 lb/kcmil = 40,000 lb 5000 kcmil Aluminum cable maximum
pulling tension = 5000kcmil x 6 lb/kcmil = 30,000 lb
6. You are now ready to input your pull segments! This software reads left to right starting with
the straight segments then having you input bends next. These inputs should be taken directly
from your project files, the CAD (1 to 1 scale) or pdf drawings.

6a. Add Section segment: Select the slope of your member.

6b. Add Section segment: Input the member length, then hit enter, your member should be input
now with the COF and Tension automatically calculated for you.
6c. Add Bend segment: Select the bend type, horizontal is for the plan view elements with the
vertical up and vertical down selections for your profile elements.

6d. Add Bend segment: Input your bend radius and bend angle (can be measured directly from
drawings or CAD file or provided in drawing curve table). Hit enter and the following columns
will auto populate.
6e. Add Bend segment: If you are adding a vertical bend type select the appropriate bend and
then the software will prompt you to enter in bend direction. This will be dictated by the
direction in which the cable is being pulled. Enter your bend radius and bend angles respectively
and hit enter.

7. You now can run through the alignment for each specific segment (termination to vault, vault
to vault, etc...). Once you have inputted all your segments into the program, save the program
and then click Pull Report. A table should appear with your design criteria and results. You
should be able to print the pull calculation report to pdf for review.
8. The next step is to verify both pulling directions (forward and reverse) to determine the
preferred direction in which the cable will be pulled. Sidewall pressures and pulling tensions can
drastically change based on the direction of the pull. On the drawings we will denote the pulling
direction in which the contractor shall install the cable.

The next step is to run both (forward and reverse) pulling direction calculations to determine the
preferred direction in which the cable will be pulled. Sidewall pressures and pulling tensions can
drastically change based on the direction of the pull. On the drawings we will denote the pulling
direction in which the contractor shall install the cable. To do so navigate to the bottom left
corner of the software and click "Reverse Segment." Note no inputs need to be modified as you
have already input all your values on the "Segment Input/Edit" Tab.
Likewise, to step 7, click the pull report icon on the top bar and then print to pdf for review.

Ways to identify the type of bend:

i) Using the PDF
ii) Using the CAD file
We can identify different types of bends by viewing the Plan and Profile PDF and mark the same
in the Bluebeam. The snip below shows different bends marked in the profile view:

We need to identify the bend type, bend radius and Slope of the section and can give callouts for
the same.
Identifying the bends using the CAD.
i) Open Civil-3D and open the plan and Profile drawing for the required file.

ii) Go to model space and zoom into the Profile view.

iii) Select the alignment and select Edit Profile labels.

iv) Go to Edit Profile label Groups and edit profile label style
v) Go to contents and add the required marker text.

vi) Add the correct marker text format and hit apply

vii) The profile labels will be generated after doing the above steps.
Links for the Pull Cals Training Videos:
Engineering - Intro to Pull Calculations