chapter 8 — sagging, terminations, suspending

7/26/2019 Chapter 8 Sagging, Terminations, Suspending

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ACCCConductor Installation Guidelines

Chapter 8 Sagging, Terminations,Suspensions, Ancillary Hardware

WI-750-077 Rev A Page 1of 12

Chapter 8 Sagging, Terminations, and Suspensions Table of Contents

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recommendations and requirements necessary to safely and successfully install the ACCC

composite-core bare overhead conductor and accessories. This document is an overviewand guideline covering what to do but not necessarily how to do it. It is not intended to

serve as a more intensive training manual or act as a substitute for proper training, requiredpersonnel skill sets, or industry experience.

2. SCOPE

2.1. These guidelines apply to equipment and techniques required to successfully install allsizes of ACCCconductor.

2.2. These guidelines include additional equipment and techniques that are required for Ultra-Low Sag (ULS) ACCC

conductor sizes.

3. DEFINITIONS

3.1. ACCCis a registered trademark of CTC Global, and is defined as Aluminum ConductorComposite Core, stranded with Aluminum 1350-0 (where 0 stands for fully annealed) orAluminum 1350-0 Z-wire trapezoidal wire.

3.2. Initial Sag occurs when new conductor is pulled and clipped in.

3.3. Final Sag occurs when conductor has been energized.

3.4. Ruling Span is the assumed uniform, or average span that best represents the actual spansin any specified section of a line.

4. ASSOCIATED DOCUMENTS

4.1. IEEE Standard 524!Guide to the Installation of Overhead Transmission Line Conductors.

4.2. OSHA Electric Power Generation, Transmission, and Distribution Standards 1910.269 and1926.950 or ISO 29.240.20 or local country equivalents.

4.3. IEEE Standard 516!Guide for Maintenance Methods on Energized Power Lines

4.4. The remaining Chapters of the Installation Guidelines

5. SAGGING

5.1. There is nothing unique about sagging ACCCversus any other bare conductor. This

guideline assumes that the user is familiar with industry standard sagging techniques.

5.2. Any of the four common methods of sagging may be used: line of sight, transit, stopwatch,and dynometer (least preferred).

5.3. It is recommended that conductors not be allowed to hang in the stringing blocks more than24 hours before being pulled to the specified sag. If this time is exceeded, the cable

manufacturer should be consulted to determine if short-term creep correction factors arerequired. The total time that the conductors are allowed to remain in the stringing blocks

before being clipped should never be more than 72 hours. If this time is exceeded, damage


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may occur to the conductors and/or sheaves. Tension should be kept as low as possible

when snubbed-off; the tension should never approach that of the sagging tension value.Keeping the holding tension low and working within the 24-hour window avoids having to

rely on short-term creep correction curves for subsequent sagging. These curves becomeless accurate as time increases.

5.4. Sagging ACCCis most successful when time (overnight) is allowed for initial creep. Ifsagging must be done same day, an acceptable alternative is to subtract 5 C (9 F) from

ambient temperature in the sagging calculations.

6. INSTALL GRIPS

6.1. Never use wire mesh or sock grips for sagging.

6.2. The free end of the conductor MUST be supported during installation of grip and deadendhardware. This may be done with small ropes.

6.3. Grips are heavy and awkward, especially for larger size conductors. The free end of theconductor MUST be controlled to prevent over-bending and possible damage of the core.Good working platforms (hook ladders, bucket trucks, baker boards) should be provided

for personnel for these operations, if available.

6.4. The grip should be attached 4-5 meters from the end of the insulator to provide workingroom to install the deadend hardware. Install a split rubber hose over the conductor justwhere it leaves the grip to protect the aluminum from the grip attachment and use a small

rope to tighten the free end of the conductor to the grip attachment. This rope will help

prevent over-bend and possible damage to the conductor during subsequent operations.Protect the conductor where the grip and hoist are attached. Use ropes or other means to tieup the conductor to the hoist and sling to prevent the end of the conductor from falling

which could damage the conductor.


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6.5. Double Grips

6.5.1. In cases where gripping the conductor due to residual stranding oil or othercontamination or high tension due to long spans, or high sagging tension, it may benecessary to double grip the conductor.

6.5.2. In these cases, use a short sling (approximately 3 feet or 1 meter) to equalize thepull tension between the two grips. Protect the exposed portions of the conductor

between the grips with split rubber hose.

6.5.3. The grips MUST NOT touch when under full load, and they MUST NOT be toofar apart or a bird-cage will be created between them.

7. CUTTING THE CONDUCTOR

7.1. Rough cuts of the conductor may be made by any conventional tools or methods such asratchet cutters or cable cutters. Note that any method other than hacksaw WILL damage the

ACCC

core locally to the cut. When a rough cut of the conductor is made, ensure that thetension is relaxed so that a bird cage doesnt occur as the aluminum will flow towards the

grip under tension.

7.2. The final cut of ACCCcore must be done with a fine-tooth hacksaw only. Any othercutting method is unacceptable.

7.3. Cutting of the aluminum strands of ACCCmay be accomplished by either a fine toothhacksaw or approved conductor stripper with the correct bushing. However, the methodused must NEVER nick or scratch the core. To avoid core surface damage, the final

separation of the aluminum strands on the bottom layer must be by gentle, repetitivebending fatigue only.

7.4. To ensure proper sagging dimensions, measure all of the linkage attached to the structureincluding insulators and any linkage required to attach the dead end eye for the ACCC

conductor plus the dead end eye. Mark the conductor with this measurement. Aftermarking the conductor at the appropriate location, cut the conductor towards the structure

adding at least 12 inches (305 mm) of extra conductor in addition to the amount marked onthe conductor. The initial cut can be made with cable cutters or ratchet cutters. Make the

final cut according to the directions in the deadending kit.

Final Cut Rough Cut


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8. TERMINATIONS

8.1. Deadending

8.2. Installing ACCCdeadends is very similar to installing deadends for any common bareoverhead conductor with two exceptions:

8.2.1. Conductor, Grip, and Deadend Handling. The weight of the deadend and/orconductor is sufficient to damage the ACCC core at the point where it exits thegrip. The deadend must be supported in-line with the conductor during installation

and subsequent handling.

Similarly, it is possible to damage the ACCCcore at the point where it exits the

deadend if too much bending force or weight is allowed there.

8.2.2. Back Pressing. ACCCterminations are pressed from the conductor end towardthe eye end. The usual method of pressing from the eye toward the conductor candisplace the trapezoidal aluminum strands of ACCC

and cause a bird-cage.

8.2.3. Step by step instructions for correct installation of ACCCdeadends are found inACCCtraining programs, in the Appendices here, and are packaged with each

deadend hardware kit.

8.3. Splicing

8.4. Installing ACCCsplices is very similar to installing splices for any common bareoverhead conductor with two exceptions:

8.4.1. Conductor, Grip, and Splice Handling same issues as with deadends above.


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8.4.2. Pressing Direction. Splices must be pressed from the short side of the conductor

span toward the long side of the conductor span.8.5. Step by step instructions for correct installation of ACCCsplices are found in ACCC

training programs and are packaged with each splice hardware kit.

8.6. Terminal Pads

8.6.1. Installing ACCCterminal pads is identical to installing terminal pads for anycommon bare overhead conductor with one exception: ACCC

terminal pads are

back-pressed for the same reason as deadends.

8.7. T-Taps

8.7.1. Installing ACCCT-Taps is identical to installing T-Taps for any common bare

overhead conductor with one exception: ACCC

T-Taps must be pressed AWAYfrom the deadend, for the same reason that deadends are back-pressed.

8.7.2. Avoid placing T-Taps closer than 1meter from a deadend.

9. SUSPENSIONS and ANCILLARY HARDWARE

9.1. Armor rods or protector rods are always required for all suspension and ancillary hardwareand must be capable and rated for the higher operating temperatures for which ACCC israted.

9.2. ACCCis a high temperature, low sag (HTLS) conductor. It operates at much highertemperatures than conventional conductors, up to 180 C (350 F). Appropriate high

temperature suspension hardware and ancillary hardware is REQUIRED.

9.3. Tandem suspensions and yoke plates must be used where change of direction angles exceed30 degrees.


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10.BUNDLED CONDUCTORS

10.1.Considerations for bundled ACCCconductors are identical with any conventionalconductors. When ACCC

is used in bundled applications, all conductors in the bundle

should be pulled in together. Synchronized and multiple conductor tensioners and pullers

are typically used. Set-up areas must accommodate a set of equipment for each conductor.

10.2.All payout reel tensions should be consistent.

10.3.Multi-sheave blocks must be used (same diameter as would be used for single conductor

pulling). Running boards must be used for pulling, but not for alignment at anchors.Always keep running boards (gators) at a constant speed going through travelers. (Do notslow down when the gator gets to the blocks).

10.4.For sagging, horizontal spacing of sheaves should match the final horizontal spacing.

10.5.Never apply tension above the interim (final before energizing) sag tension. Over-tensionor over-sag will cause the conductors sag behavior to differ which will result in uneven

bundle sagging.


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11.TEN INSTALLATION DONTS

11.1.DONT OVER-BEND!

11.1.1. Dont allow the conductor to contact surfaces that present sharp angles or smalldiameters.

11.2.TWO Tensioner DON'TS

11.2.1. Dont use a conventional tensioner fairlead for ACCCconductor. A multiple-roller fairlead with large effective radius MUST be used.

11.2.2. Dont let ACCC run hard on the end roller of the fairlead. Use an interim sheaveto raise the conductor if needed.

11.3.TWO Payout Reel DON'TS

11.3.1. Dont allow the conductor to bounce or jump up and down between the payout reeland the tensioner. When the conductor is jumping or bouncing, the core can bedamaged.

11.3.2. Dont use a payout reel with insufficient brakes. Poorly maintained or undersizedbrakes will cause jumping and bouncing of the conductor between the payout reel

and the tensioner. The payout reel brakes should allow the tensioner to draw newconductor from the reel smoothly and evenly.

11.4.THREE Handling and Equipment DON'TS

11.4.1. Dont use grips that arent designed for installing ACCC. Use Klein Chicago

long jaw grips or equal, designed for the size conductor being installed. Never usepocketbook grips!

11.4.2. Don't allow the conductor tail or the deadend to fall or droop unsupported whilehandling the conductor. If the tail is not controlled, it will damage the core at the

back of the grip.

11.4.3. Dont hoist the conductor in any manner which causes a sharp bend in theconductor.

11.5.TWO Pulling / Stringing DONTS

11.5.1. Dont install any ACCCwith under-diameter sheaves on the first and last

structure or any angles that are over 30 degrees.11.5.2. Don't pull in conductor using old conductor if it is rusty. Dont use old conductor

with splices or broken strands for pulling. Instead, pull in a pilot line using the old

conductor and pull in ACCCusing the pilot line. Always use a pilot line for long

spans and river crossings.


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Appendix A ACCCDeadend Installation Instructions

1. With the tapered end of the inner sleeve facing the end of theACCC

conductor slide it down the conductor about 3.5 ft (1.1

mm).

2. Slide the outer sleeve over the ACCCconductor with the pad

3.5 ft (1.1 mm) from the cut end of the conductor (See Fig 1).

3. Tape aluminum strands measured at the length of the collet

housing plus 2 inches (50mm) from conductor end.

4. Expose the solid core by cutting aluminum strands at the markone layer at a time.

5. CAUTION: Do not cut or nick the core. Ensure that thecore end is cut with a fine tooth hacksaw. Failure to followthese instructions could result in a poor connection.

6. Wipe outer surface of the core clean and free from oil. Thenrub the core lightly with 220 mesh sanding paper (provided)until it becomes white and re-wipe the core with a clean cloth.

7. Slide the collet housing, wrench flats toward the aluminum

strands onto the core (See Fig. 2).

8. Install the collet (See Fig. 2), narrow end towards the housing,onto the core leaving 0.25 in (6mm) of the core exposed fromthe wide end of the collet (See Fig. 3).

9. Install the eye and hand tighten before fully tightening with awrench (85.0 ft-lbs or 115 N-m torque required). Ensure that

approximately 3.0 in (76 mm) of core is exposed between thealuminum and the collet after tightening (See Fig. 4). The 3inches occurs when you measure housing plus 2 inches (50mm). When starting to tighten the dead end eye into thehousing, ensure that the approximate ! still extends out ofthe collet.

10. Wire brush the aluminum strands that will be covered with

outer sleeve and liberally apply oxidation inhibitor (supplied)along the length of the brushed aluminum strands, then slidethe aluminum outer sleeve towards the eye up to thepainted/machined mark (See Fig. 4).

11. Liberally apply oxidation inhibitor to the outer diameter of thealuminum inner sleeve and slide the inner sleeve into theouter sleeve.

12. Crimp/compress starting at opposite end from the eye usingcorrect die size (Appendix C) and slightly overlapping thecrimps in the direction of the eye until thecrimps/compressions meet the mark on the aluminum outertube (See Fig. 5).

13. Crimp/compress in the area marked on the aluminum outertube to secure the eye. Ensure washer is flush with pad. Do

not over crimp to damage washer. This should require 1 to 3crimps to secure (See Fig. 5).

Note: Appropriate sized dies for each conductorsize must be utilized to complete

crimps/compressions see Appendix C


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Appendix B ACCCSplice Installation Instructions

1. With the tapered end of the inner sleeve facing the end of the ACCCconductor, slide the inner sleeves down the conductor about 3.5 feet (1.1 m).(See Fig 1)

2. Slide the outer sleeve over the side furthest from the structure (Side B) with theend of the tube 2.0 ft (0.61m) from the cut end of the conductor (See Fig 1).

3. Tape aluminum strands at the following distances from the conductor end:

a. Side A measure the length of the collet housing plus 2 inches(50mm)

b. Side B measure the length of the collet housing only

4. Expose the solid core by cutting aluminum strands at the mark one layer at atime (See Fig 1).

CAUTION: Do not cut or nick the core. Ensure that the core end isuncrushed; if necessary square off with a hacksaw. Failure to follow theseinstructions could result in a poor connection.

5. Wipe outer surface of the core clean and free from oil. Then rub the core lightlywith 220 mesh sanding paper (provided) until it becomes white and re-wipe thecore with a clean cloth.

6. Slide the collet housing, wrench flats toward the aluminum strands onto the core(See Fig. 2).

7. Install the collet (See Fig. 2), narrow end towards the housing, onto the coreleaving 0.25 in (6mm) of the core exposed from the wide end of the collet (SeeFig. 3). Repeat for opposite side.

8. Install the coupling on Side A (closet to structure) and the collet retainer on the

opposite Side B (furthest from structure) and tighten by hand; complete thetightening with wrenches (85 ft-lbs or 115 N-m torque required).

9. For Side A ensure that approximately 3.0 in (76 mm) core and the narrow end ofthe collet are visible after tightening (See Fig. 4).

10. For Side B ensure that approximately 1.0 in (25 mm) core and the narrow end ofthe collet are visible after tightening (See Fig. 4).

11. Bring the two sides together and hand-tighten the swivel end of coupling to thecollet retainer. Complete tightening with wrenches (85 ft-lbs or 115 N-m torquerequired) (See Fig. 5).

12. Mark the conductor, on Side A, 17.0 in (432 mm) from the end of the aluminumstrands using tape or a felt tip marker. This mark will be the location of the innersleeve nose end. NOTE: If using tape you must remove before crimping (SeeFig. 5).

13. Wire brush the aluminum strands that will be covered with outer sleeve andliberally apply oxidation inhibitor (supplied) along the length of the brushedaluminum strands.

14. Slide the outer sleeve over the coupling assembly.

15. Side A Liberally apply oxidation inhibitor to the outer diameter of the innersleeve, slide the inner sleeve, nose end, into the outer sleeve up to the 17 in

(432 mm) marked spot on the conductor. Make sure the outer tube bump is upagainst the inner sleeve. Move outer sleeve as necessary.

16. Once the outer sleeve is in place, crimp/compress (Appendix C) the outersleeve beginning form Side A, starting crimp point, in an inwards direction usingthe correct die size and overlapping the crimps approximately 1/8 1/4 in (3 6mm) ( to the end of the crimp zone on Side A (See Fig. 6).

17. Crimp the center of the outer tube to the coupling assembly with one crimp (SeeFig. 6).

18. Side B Liberally apply oxidation inhibitor to the outer diameter of the innersleeve; slide the inner sleeve into the outer sleeve. Make sure the outer tubebump is up against the inner sleeve. (See Fig. 6)

19. Crimp Side B beginning form the inside mark (compressing outwards) up untilthe ending crimp point. Ensure the inner sleeve is up against the bump of the

outer tube before making the first crimp. Overlap the crimps approximately 1/8 1/4 in (3 6 mm) to the end of the crimp zone on Side A (See Fig. 6).

Note: Appropriately sized dies for eachconductor size must be utilized to completecrimps/compressions see Appendix C


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Appendix C Compression Die Chart

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REVISION HISTORY

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chapter 8 — sagging, terminations, suspending

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