FactorsThatInfluenceTheInstallationPerformanceOfBlownCables&Fibres

RalphSutehall PrincipalInstallation&ApplicationsEngineer.

PrysmianGroupThursday8th December,17.25 18.25pm

Cable/FibreUnitDesigns

BlownFibre Minicables ConventionalBlownCables

FibreCount 1 12f 24 218f 24 288f

DiameterRange

1.0 1.4mm 5.7 8.8mm 12.8 15.1mm

Tube/DuctSize 3.5/5.0mm 8/10mm,10/12mm

12/16mm

20/25mm

(144fibreversionshown)

(96fibreversionshown)

(4fibreversionshown)

DuctDesigns

BlownFibre Minicables ACTION

Max.TubeCount Upto24 Upto7 1

Max.FibreCount Upto288f Upto1008f 288f

DiameterRange 11 34mm 12 45mm 25mm

TypicalBlowingDistance

800 1000mts 1000 2500mts Upto3000mts

Typicalblowingdistancesaregovernedbyroutedifficulty

FillFactors&FlowRates

Upto3000mts1000 2500mts800 1000mtsTypicalBlowingDistance

BlownFibre MiniCables ACTION

FillFactor 8 16% 8mmBore 52 66%

10mmBore 42 77%

41 56%

AirflowRate

@10bar

18l/min 8mmBore 160l/min

10mmBore 280l/min

~1500l/min

FreeSpace 37mm2 250 290mm2 1077 1128mm2

Influences

CableDesign

MiniDuctDesign

RouteDesign

QualityOfMiniductInstallation

InstallationEquipment

CrashTest.

InorderforthefindingsinthispresentationtobevalidwemustassumethatpriortoanyinstallationcommencingtheinstallerhasundertakenaCrashTest withthecable/fibreandduct.Thiswilldeterminethemaximumlevelofpushforcethatcanbesafelyappliedtothecable/fibrebytheblowinghead.

Thiswillensurethatthecable/fibrewillbeinstalledinamannerthatWillnotdamageit.

RouteConfiguration ForTheoreticalCalculations

25 m

15 m

180 m110 m

Start

RouteConfigurations ForPracticalEvaluations

100 m

Multiple Ducts

Total route length 1100 m

As recommended by IEC 60794-1-2 Ed 3.0 draft

1 m

Route Design

Cable/Fibre Unit Design

Installation Equipment

Mini-duct Design

Installation OfMini-duct & Cable/Fibre

CableDesignCableDesign

Factors

CoefficientOfFrictionOfCableSheathMaterial

Diameter

Stiffness

Weight

0102030405060708090

5 5.2 5.4 5.6 5.8 6 6.2 6.4 6.6 6.8 7

Cable Diameter (mm)

F

i

l

l

f

a

c

t

o

r

(

%

)

CableDiameter FillFactor

8.0mm Bore

10.0mm Bore

050

100150200250300350400450

0 200 400 600 800 1000 1200

Distance (m)

A

i

r

F

l

o

w

(

l

/

m

i

n

)

CableDiameter Cable ReductionInAirFlowDuringInstallationOfA6.5mm DiaCable

Air flow Installation performance for the cable

14 bar/10mm bore

10 bar/10mm bore14 bar/8mm bore10 bar/8mm bore

0200

400600

8001000

12001400

1600

0.1 0.11 0.12 0.13 0.14 0.15 0.16

Coefficient of Friction

D

i

s

t

a

n

c

e

(

m

)

CableDiameter AffectofPushForce

Push force Installation performance of the cable

300N

225N

150N

CableSheathFinish

Smooth Reflective HighlyReflective

Smooth - Air flowHighly Reflective - Viscous Drag of Air

0200400600800

1000120014001600

0 0.05 0.1 0.15 0.2 0.25 0.3

Amplitude (m)

D

i

s

t

a

n

c

e

(

m

)

CableDiameter AffectofPushForceCoF0.1 Pitch20m

6.5/10mm-300N

5.7/8mm-200N

Cable diameter Maximum push force Blowing performance

0200400600800

1000120014001600

0.1 0.11 0.12 0.13 0.14 0.15 0.16

Coefficient of Friction

D

i

s

t

a

n

c

e

(

m

)

Weight

42 kgs/km

Weight Blowing performance

33 kgs/km

MiniDuctDesign

Factors

CoefficientOfFrictionOfInnerBore

Diameter

MiniductConfiguration

0200400600800

1000120014001600

0.1 0.11 0.12 0.13 0.14 0.15 0.16

Coefficient of Friction

D

i

s

t

a

n

c

e

(

m

)

AffectOfCoefficientOfFriction

6.5mm Diameter Cable

5.7mm Diameter Cable

Coefficient of friction Blowing performance

01

2

3

4

5

6

0 200 400 600 800 1000 1200

Distance (m)

P

u

s

h

F

o

r

c

e

(

b

a

r

)

AffectOfMiniductBoreSize 6.5mmDiaCablePushForceRequiredToKeepInstallationSpeedAt60m/min

10mm Bore

8mm Bore

Fill factor Installation speed Blowing performance

MiniductConfiguration

CableType

15349122Stiffness(Nm2)

Trench FloorThe ability of the duct cable to follow undulations, horizontal or vertical, has a

significant affect on the blowing performance.

RouteDesign

Factors

Length

QualityOfDesign

Length

QualityOfDesign

050

100150200250300350400450500

A

i

r

F

l

o

w

(

l

/

m

i

n

)

200 400 600 800 1000Route Length (m)

AffectOfRouteDistance 10/8mmMiniduct

1

0

b

a

r

1

2

b

a

r

1

4

b

a

r

Route length Air flow

QualityOfMiniductInstallation

Factors

Undulations

LackOfUnderstanding?

0200

400

600

800

1000

1200

1400

1600

0 0.05 0.1 0.15 0.2 0.25 0.3

Amplitude (m)

D

i

s

t

a

n

c

e

(

m

)

AffectOfInstallation 6.5mmCableInto8mmBoreMiniduct

20 m Pitch0.16 CoF

20 m Pitch0.1 CoF

5 m Pitch0.1 CoF

5 m Pitch0.16 CoF

Quality of installation of mini-duct Blowing performance .

0200400600800

1000120014001600

0 0.05 0.1 0.15 0.2 0.25 0.3

Amplitude (m)

D

i

s

t

a

n

c

e

(

m

)

20 m Pitch0.1 CoF

20 m Pitch0.16 CoF

5 m Pitch0.16 CoF

5 m Pitch0.1 CoF

AffectOfInstallation 6.5mmCableInto10mmBoreMiniduct

An approximate 10% improvement in blowing performance overthat of an 8mm bore mini-duct.

InstallationEquipment

Factors

BlowingHead

CablePayoff

Compressor

Lubricant

0200400600800

1000120014001600

0 0.05 0.1 0.15 0.2 0.25 0.3Amplitude (m)

D

i

s

t

a

n

c

e

(

m

)

AffectOfPushForce 0.1CoF 5.7mm&6.5mmCableIntoA10mmBoreMiniduct.300NPushForce

5.7/5m Pitch6.5/5m Pitch

6.5/20m Pitch5.7/20m Pitch

Assuming that the maximum push force can be applied to each cable then the installation performance of the reduced diameter

cable will be the best.

0200400600800

1000120014001600

0 0.05 0.1 0.15 0.2 0.25 0.3Amplitude (m)

D

i

s

t

a

n

c

e

(

m

)

AffectOfPushForce 0.1CoF 5.7mmCableIntoA8mmBoreMiniduct

300N/5m Pitch

200N/5m Pitch

200N/20m Pitch

300N/20m Pitch

In order to gain the benefits from a reduction in cable diameter the maximum push force that can be applied to the cable must remain

at a high level.

Compressor

Ashasbeenseenfromthepreviousgraphsitisimportanttomaximisetheairflowthroughtheroute.Inordertoachievethisthecompressormustbeabletodeliverairattypically14barminimum.

Thisairshouldbecleananddryandshouldbedeliveredtotheblowinghead/miniductviaanaftercooler.

Ifusingpneumaticallydrivenblowingheadsthenconsiderationjustbegiventothelevelofairthatisbeingconsumedbytheairmotor.

AffectOfAftercooler

0

1

2

3

4

5

6

7

8

-20 -10 0 10 20 30 40 50 60

Ambient Temperature (C)

W

a

t

e

r

F

l

o

w

R

a

t

e

(

l

/

h

r

)

100% RH, No A/c

50% RH, No A/c

Aftercooler

Use aftercooler: Moisture Level in Compressed Air

CableDrums

3kms Of Cable Old vs New

Must be lightweight but strong enough to protect the cable.Material must be smooth so that the cable sheath is not damaged if it

comes into contact with the flange.

CablePayoff

Spindle Roller Bearing Axle Collar

These are important as you must be able to provide an even low tension during the installation of the cable.

Lubricant

Ithasbeenshownthatthecoefficent offrictionbetweenthecableandtheminiductboreiscrucial.Itisthereforerecommendedthatadditionalwetlubricantisaddedtotheductpriortoinstallingthecableorlubricatingthecableduringtheinstallationprocess.Thiscanimprovetheinstallationperformanceofthecablebyasmuchas20%.

Thiswetlubricantmustbespecificallydesignedfortheinstallationofminicables.Usinglubricantdesignedforwinchedcablesisnotrecommended.

Theuseofwetlubricantisnotrecommendedforusewithblownfibre.

InlineLubricators

Suitable for mini-duct sizes up to 16mm.Suitable for cable sizes up to 9mm

%ageAffectOfLubricationMethod

0

10

2030

40

50

6070

80

90

100

HDPE Mini-duct Only Low Friction LinerMini-duct

Low Friction LinerMini-duct plus Field

Lubrication

No Lubricator Lubricator

M

a

x

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m

u

m

B

l

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D

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S

p

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n

g

e

A

p

p

l

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Route Design

Summary

Conclusions

Theinstallationofminicables/fibresintominiductsisaninteractivesystem. Primaryfactors:

thequalityoftheinstallationoftheminiductcable. thecoefficientoffriction,betweentheminicableandminiductbore.

Settinguptheinstallationequipmentcorrectlybyundertakingacrashtest