We were just talking the other night about wire pulls and some of the tough ones. What is the longest, biggest pull you guys have pulled in? The biggest one we could come up with was 200' 4-500 MCM. I got to looking at the pull tables and 500 MCM can pull up to 12K LB's So you could actually pull a long ways. Anyhow, just curious. I can remember one pull that was done, they had just pulled it in, really long and was for a RV Park. It was a pain the neck. They got the head into the can and everybody went into the electrical room to clean up. All of a sudden the head made a jerk and it went flying back down the pipe. They all ran outside and amazingly a backhoe had pulled up and started digging totally were they told it not too. It had the conduit and burial ribbon in its teeth. Ouch.
Longest, biggest pull you guys have done?
- Thread starter copper123
- Start date
- Status
- Location
- New Jersey
- Occupation
- Journeyman Electrician
Re: Longest, biggest pull you guys have done?
On a horizontal run we've pulled in excess of 350' with 4-500kcmil. On a vertical run we've pulled 3-750kcmil up about 22 stories in a commercial building. That's over 225'. The key to long pulls is how it's set up, how many bends are in the conduit and is the conduit sized for just about maximum fill or is it sized one size larger with some wiggle room. The advantage of pulling a riser straight up is it that you can engineer the pull knowing the conductor weight, rope strength and capacity of your puller. On long or difficult pulls our setup usually involves attaching the puller directly to the conduit so you're not going to pull the pipe through the box, panel swichgear, etc. I've seen that done a few times where the machine was bolted to the floor and pulled the connector right through the panel.
On a horizontal run we've pulled in excess of 350' with 4-500kcmil. On a vertical run we've pulled 3-750kcmil up about 22 stories in a commercial building. That's over 225'. The key to long pulls is how it's set up, how many bends are in the conduit and is the conduit sized for just about maximum fill or is it sized one size larger with some wiggle room. The advantage of pulling a riser straight up is it that you can engineer the pull knowing the conductor weight, rope strength and capacity of your puller. On long or difficult pulls our setup usually involves attaching the puller directly to the conduit so you're not going to pull the pipe through the box, panel swichgear, etc. I've seen that done a few times where the machine was bolted to the floor and pulled the connector right through the panel.
- Location
- Massachusetts
Re: Longest, biggest pull you guys have done?
I have been the one to repair the damage done from improper puller set up.
It's a real bummer when your 4" EMT connector pulls right through the top of a panel tub.
All to familiar.
I have been the one to repair the damage done from improper puller set up.
It's a real bummer when your 4" EMT connector pulls right through the top of a panel tub.
hardworkingstiff
Senior Member
- Location
- Wilmington, NC
Re: Longest, biggest pull you guys have done?
My longest is (traditional) 650' of 3-3/0 Cu. and 1-#2 cu. in a 2.5" PVC conduit with 4-60 degree bends.
Here are some type W cables I've pulled in docks.
4/0-4C 700'
3/0-4c 750'
type G
350-3C (plus it has 2-1/0 gr.) 225'
My longest is (traditional) 650' of 3-3/0 Cu. and 1-#2 cu. in a 2.5" PVC conduit with 4-60 degree bends.
Here are some type W cables I've pulled in docks.
4/0-4C 700'
3/0-4c 750'
type G
350-3C (plus it has 2-1/0 gr.) 225'
M
mkoloj
Guest
Re: Longest, biggest pull you guys have done?
I am no electrician but I was expecting some bigger #'s on this thread, for me as the Comm. guy I twice did a 2300' run of 144 strand armored fiber. Not once but twice for redundancy in the facilities network back-bone. I know someone is going to say why didn't we do it in one pull??
The spec's called for it to be ran on opposite sides of the building. This was in one of NYC's museums, which was a lot of brick and terra-cotta block interior walls. That has got to be the longest, most tedious pull I have ever done. No tuggers as the buiilding had no way that conduits could be installed and the risk for damage was too great and not something we could risk.
It was like pulling a half mile of 1" flex conduit stuffed with glass.
[ July 14, 2005, 09:16 AM: Message edited by: mkoloj ]
I am no electrician but I was expecting some bigger #'s on this thread, for me as the Comm. guy I twice did a 2300' run of 144 strand armored fiber. Not once but twice for redundancy in the facilities network back-bone. I know someone is going to say why didn't we do it in one pull??
The spec's called for it to be ran on opposite sides of the building. This was in one of NYC's museums, which was a lot of brick and terra-cotta block interior walls. That has got to be the longest, most tedious pull I have ever done. No tuggers as the buiilding had no way that conduits could be installed and the risk for damage was too great and not something we could risk.
It was like pulling a half mile of 1" flex conduit stuffed with glass.
[ July 14, 2005, 09:16 AM: Message edited by: mkoloj ]
growler
Senior Member
- Location
- Atlanta,GA
Re: Longest, biggest pull you guys have done?
In 1992, I was involved in a very long, very stupid pull. I'd just got my final on one building when I was told to supervise a wire pull that these guys were to have a little trouble with. When I got there, they were setting up to pull 890 ft of 750 mcm X 4 in 4" pcv with at least 4 factory 90's. They had a tugger and 1K ft. of 1/2" nylon rope and a bucket of soap that was supposed to make this work. The temp. was about 105 F. I assessed the situation as a fools errand. So I argued with the project manager for a few minutes, trying to get a decent pull rope. He was of the mind, that ropes are an unnecessary expense and so the comedy began. We got about 400 ft. into the pipe each time before the rope broke. Pull it out, reel it up, with most of the crew looking as if they would die from heat stroke. The pull was not made and they pulled some 500 in a couple days later. I still think there was a good chance of success with the proper rope. The company thought I had a bad attitude and fired me. To this day I don't like project managers that think you can make chicken salad out of the brown stuff.
In 1992, I was involved in a very long, very stupid pull. I'd just got my final on one building when I was told to supervise a wire pull that these guys were to have a little trouble with. When I got there, they were setting up to pull 890 ft of 750 mcm X 4 in 4" pcv with at least 4 factory 90's. They had a tugger and 1K ft. of 1/2" nylon rope and a bucket of soap that was supposed to make this work. The temp. was about 105 F. I assessed the situation as a fools errand. So I argued with the project manager for a few minutes, trying to get a decent pull rope. He was of the mind, that ropes are an unnecessary expense and so the comedy began. We got about 400 ft. into the pipe each time before the rope broke. Pull it out, reel it up, with most of the crew looking as if they would die from heat stroke. The pull was not made and they pulled some 500 in a couple days later. I still think there was a good chance of success with the proper rope. The company thought I had a bad attitude and fired me. To this day I don't like project managers that think you can make chicken salad out of the brown stuff.
kentirwin
Senior Member
- Location
- Norfolk, VA
Re: Longest, biggest pull you guys have done?
As an apprentice in 1972 I took part in a short pull, less than 100', of 1000kcmil cu. What I really remember is having to shape and terminate it! It was like trying to shape a baseball bat.
As an apprentice in 1972 I took part in a short pull, less than 100', of 1000kcmil cu. What I really remember is having to shape and terminate it! It was like trying to shape a baseball bat.
macmikeman
Senior Member
- Location
- Planet macmikeman
Re: Longest, biggest pull you guys have done?
We once pulled 6 multi strand fiber optic cables thru a series of manholes at Honolulu International Airport that reached from one end of the airport to the cargo terminals at far side of the property- It was roughly 3,800 ft total. The spec was firm on no splices.
We once pulled 6 multi strand fiber optic cables thru a series of manholes at Honolulu International Airport that reached from one end of the airport to the cargo terminals at far side of the property- It was roughly 3,800 ft total. The spec was firm on no splices.
M
mkoloj
Guest
Re: Longest, biggest pull you guys have done?
Did you guys run innerduct then pull thru that or did you use the armored stuff ??? How many strands was this pull ??
- Location
- Illinois
- Occupation
- retired electrician
Re: Longest, biggest pull you guys have done?
A long time ago as an apprentice I worked on a pull involving some 3 conductor, 15 Kv, 750 kcmil, oil filled cable. I don't remember how long it was, but it weighed about 15 pounds a foot.
I have done a number of 1200' to 2300' pulls with 3 350kcmil 5kV and a 4/0 bare ground. These were in underground duct banks and there were manholes every 300' to 600'.
don
A long time ago as an apprentice I worked on a pull involving some 3 conductor, 15 Kv, 750 kcmil, oil filled cable. I don't remember how long it was, but it weighed about 15 pounds a foot.
I have done a number of 1200' to 2300' pulls with 3 350kcmil 5kV and a 4/0 bare ground. These were in underground duct banks and there were manholes every 300' to 600'.
don
petersonra
Senior Member
- Location
- Northern illinois
- Occupation
- engineer
Re: Longest, biggest pull you guys have done?
an acquaintance of mine once was involved in a fiasco involving a run of (3) #14 wires in pvc conduit for several miles along the ground in the deserts of saudi arabia.
this was supposed to provide 120VDC power to some kind of rtu.
not surprisingly, the thing never did work. something about the capacitance in the wiring causing the 120VDC power supply output to swing wildly due to some kind of wierd feedback loop.
seems there was also a problem with the heat making the conduit soft.
an interesting tale, told much better and with more flair by him than by I.
an acquaintance of mine once was involved in a fiasco involving a run of (3) #14 wires in pvc conduit for several miles along the ground in the deserts of saudi arabia.
this was supposed to provide 120VDC power to some kind of rtu.
not surprisingly, the thing never did work. something about the capacitance in the wiring causing the 120VDC power supply output to swing wildly due to some kind of wierd feedback loop.
seems there was also a problem with the heat making the conduit soft.
an interesting tale, told much better and with more flair by him than by I.
tx2step
Senior Member
- Location
- North Texas, DFW area
Re: Longest, biggest pull you guys have done?
I've been involved with some riser pulls like that. If we could get the wire reels to the top of the pull, we always tried to pull from the top down to the bottom. It was much easier. The pull got easier as you got more wire into the pipe. Toward the end, the guys at the top were having to hold the wire back to keep it from being sucked into the pipe by its own weight.
- Location
- Massachusetts
Re: Longest, biggest pull you guys have done?
On such a heavy vertical pull I would leave the spools at the bottom.
I once lost a set of 350s from the 11th floor to the basement, I would not wish that on anyone.
It is easer if you are sure the top guys can control it.
On such a heavy vertical pull I would leave the spools at the bottom.
I once lost a set of 350s from the 11th floor to the basement, I would not wish that on anyone.
tx2step
Senior Member
- Location
- North Texas, DFW area
Re: Longest, biggest pull you guys have done?
luckyshadow
Senior Member
- Location
- Maryland
Re: Longest, biggest pull you guys have done?
I did a job about 6 years ago that had 2 parallel
4" rigid conduit runs that where 800' each.
We pulled 4 - 500 mcm in them.
I fed them from the middle of the run through a well placed pull box. We had no splices in either run. It took 5 men 10 hours to pull the first conduit, then 5 men 8 1/2 hours to pull the second run.
I did a job about 6 years ago that had 2 parallel
4" rigid conduit runs that where 800' each.
We pulled 4 - 500 mcm in them.
I fed them from the middle of the run through a well placed pull box. We had no splices in either run. It took 5 men 10 hours to pull the first conduit, then 5 men 8 1/2 hours to pull the second run.
- Location
- Massachusetts
Re: Longest, biggest pull you guys have done?
One green helper and myself installed four - 500 Kcmil CU in three 350' 3" EMTs.
He ran the puller I lubed the conductors and made sure they where going in correctly.
We got all three sets installed in one 8 hour day.
Proper equipment and set up makes it possible.
[ July 14, 2005, 06:27 PM: Message edited by: iwire ]
One green helper and myself installed four - 500 Kcmil CU in three 350' 3" EMTs.
He ran the puller I lubed the conductors and made sure they where going in correctly.
We got all three sets installed in one 8 hour day.
Proper equipment and set up makes it possible.
[ July 14, 2005, 06:27 PM: Message edited by: iwire ]
macmikeman
Senior Member
- Location
- Planet macmikeman
Re: Longest, biggest pull you guys have done?
Posted by mklojo: Did you guys run innerduct then pull thru that or did you use the armored stuff ??? How many strands was this pull ??
It was a mix of 10 strand loose tube and 20 strand loose tube. There was no innerduct, we pulled strait thru 4" pvc communications duct as per directed by blueprints. Out of all that we only had one bad fiber. By the way, I remember about half of those manholes had water all the way to the top, we had to pump out for hours to get em dry. Also there were lots of direction changes. We used big sheeves anchored to the manhole sides with come alongs and a tension meter at the head end.
Posted by mklojo: Did you guys run innerduct then pull thru that or did you use the armored stuff ??? How many strands was this pull ??
It was a mix of 10 strand loose tube and 20 strand loose tube. There was no innerduct, we pulled strait thru 4" pvc communications duct as per directed by blueprints. Out of all that we only had one bad fiber. By the way, I remember about half of those manholes had water all the way to the top, we had to pump out for hours to get em dry. Also there were lots of direction changes. We used big sheeves anchored to the manhole sides with come alongs and a tension meter at the head end.
highkvoltage
Senior Member
Re: Longest, biggest pull you guys have done?
When I worked on the Transmission towers 3 miles. Working as a wireman 2000 ft of armored 500 kcmil 3 conductor on the side of a steel mill about 40 feet in the air.Used 2 super tuggers with one tugger with a mare's tail in the middle.The toughest pull 1000' of 1000 kcmil 80 feet in the air for a blast furnace. Of course installing the 6" rigid conduit wasn't much fun either. used a special hydrualic puller with a steel winch line. Make a supper tugger look like a toy.
[ July 15, 2005, 12:21 AM: Message edited by: highkvoltage ]
When I worked on the Transmission towers 3 miles. Working as a wireman 2000 ft of armored 500 kcmil 3 conductor on the side of a steel mill about 40 feet in the air.Used 2 super tuggers with one tugger with a mare's tail in the middle.The toughest pull 1000' of 1000 kcmil 80 feet in the air for a blast furnace. Of course installing the 6" rigid conduit wasn't much fun either. used a special hydrualic puller with a steel winch line. Make a supper tugger look like a toy.
[ July 15, 2005, 12:21 AM: Message edited by: highkvoltage ]
luke warmwater
Senior Member
Re: Longest, biggest pull you guys have done?
I once had to pull 3 #14's through a 10' piece of 1/2" emt.
I hope I never have to do that again!!
Seriously, I don't really remember the 'longest' or 'longer' pulls, but I remember some of the 'hardest' pulls.
And, some of the hardest pulls were with smaller wire and smaller conduit, and usually a 'freakin moron' (technical term) on the feed end of the pull.
I once had to pull 3 #14's through a 10' piece of 1/2" emt.
I hope I never have to do that again!!
Seriously, I don't really remember the 'longest' or 'longer' pulls, but I remember some of the 'hardest' pulls.
And, some of the hardest pulls were with smaller wire and smaller conduit, and usually a 'freakin moron' (technical term) on the feed end of the pull.
rcarroll
Senior Member
- Location
- Fort Collins, Colorado
Re: Longest, biggest pull you guys have done?
I was pulling a 230' run of #1 cu 3-phase & while running the tugger, I noticed the 3/8" rope was looking a little stretched. BOOM! it broke. I didn't have much room but to turn & duck as the rope snapped out of the pipe.
I was pulling a 230' run of #1 cu 3-phase & while running the tugger, I noticed the 3/8" rope was looking a little stretched. BOOM! it broke. I didn't have much room but to turn & duck as the rope snapped out of the pipe.
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