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Wire pulling is done using several kinds of pull wire inside pipelines. Some common types include:
Pulling Cables
Pulling cables are usually metal or fiber composite sheathed cables with a wire that runs through the center. Such cables are usually pulled into conduits or cableways for electricity or data wiring. Many pulling wires feature strength elements to ease pulling and ensure the wire remains straight inside the conduit.
Signal Wires
These are low-voltage wires that are pulled into pipelines to carry signals such as control or monitoring system data. Signal wires generally have a thin insulation size compared to power cables. Thus, they are easier to pull and occupy less space inside conduits.
Optical Fiber Wires
Optical fiber wires come with insulated glass or plastic strands pulled through conduits for telecommunications and data transmission. It should be noted that optical wires need to be pulled very gently as they are fragile and may break during vigorous pulling.
Heat tracers
Heat tracers are wires run inside pipelines for keeping fluids warm or preventing wax formation in case of cold weather. These wires can be electrical or self-regulating. A pulling wire may be used to install heat tracers to make the process easier.
Grounding Wires
Grounding wires are run inside conduits or electrically conductive metallic pipelines to ground electrical installation. These wires help prevent electric shock and fire by carrying excess current away safely.
There are many commercial uses of pull wire inside pipelines. Some of them are listed below:
Power Transmission
Pull wires are extensively used in electrical wiring systems and aim to simplify installation and maintenance. They are used to pull electric cables through conduits of just about any size, and they provide a smooth and friction-free surface for carrying electric current over long distances.
Telecommunications
Pull wires have a crucial application in pulling fiber optic cables, coaxial cables, and other telecommunication wires inside conduits used in communication networks. Communication networks are the lifelines of all commercial and business activities, and pulling wires have to be readily available to install and maintain these networks.
HVAC Systems
Pull wires are also used in the installation of heating, ventilation, and air conditioning (HVAC) systems, pulling electric cables for thermoregulation, heating and air conditioning ducts, and electric wires for proper ventilation systems. This is essential in commercial buildings so that HVAC systems function properly for comfort and air quality.
Industrial Pipelines
Pull wire is also used in industrial wiring practices and in the installation of various pipes used in industries. Whether the pipes are for transporting fluids, gases, or chemicals, pull wires are used to install the cabling necessary for monitoring, controlling, and powering the machines that do the pulling.
Construction and Real Estate Development
Real estate and construction development application uses pull wires during the wiring stage in building commercial real estate. Pull wires in construction help ensure that buildings have appropriate electrical, communication, and HVAC wiring installed to provide comfort, safety, and functionality in the real estate space.
There are so many advantages to using a Pull wire inside a pipeline. Here are some of the most notable ones:
Cable Installation
The primary function of a pull wire is that it eases the pulling of heavy electrical or communication cables through conduits, thus requiring less manpower and helping in a faster installation of cables.
Durability
Pull wire is made from high-strength materials like steel or stainless steel because they are not only strong and long-lasting but also able to withstand great tensile pull force without snapping.
Lightweight and Flexible Design
Pull wires are light and flexible, which makes them portable and easy to work with in tight places or hard-to-reach spaces.
Cost-Effective Solution
Wire pulling saves lots of money by avoiding extra labor and special equipment to install cables while ensuring easy availability of the product.
Versatile Applications
Pull wires can be used in many applications, such as electrical wiring, telecommunications, and HVAC installations, making pull wires a versatile product in the mechanical and electrical works of buildings.
As mentioned above, pull wires are usually made with high-strength materials that can bear great tensile loads. Below are some common materials and compositions of pull wires:
High-Strength Steel Alloys
Steel alloys provide higher strength than regular steel. Moreover, they are specially designed to provide extra pull force. Many have extra smooth surfaces to reduce friction and the chances of wire snapping during heavy pulling.
Stainless Steel
Stainless steel is strong, rustproof, and corrosion-resistant; it is used on wires installed in places like pipelines with high humidity or inside the marine environment, where dc electric corrosion might be a lot more severe. An example is the use of stainless steel in mining pull wire because of moisture and electrical currents in underground mines.
Coated Steel
Coated steel pulling wires add a polymer coating such as PVC or nylon on the steel wire to reduce friction and increase resistance to electromagnetic corrosion. Coated pull wires can be used on wires for pulling inside conduits, cables, or pipelines exposed to moisture and chemicals.
Kevlar or Aramid Fibers
Kevlar pulling wires are lightweight, easy to work with, and strong enough to pull electrical wiring or fibers through pipelines. Normally, Kevlar pull wires are used where metal wires can potentially create sparks because they are self-extinguishing when they pull on them hard enough.
brass
Brass pullwires are electrically conductive, corrosion-resistant, and very smooth; hence, they are mostly used in pipelines where electromagnetic corrosion is extremely high, such as pipelines to and under the sea. The wire pulls easily, and generally, there is no tarnishing on the surface.
Not all pulling wires are ideal for all piping conditions. Pull wires are usually selected based on the specific wire installation environment and the cable being pulled to ensure maximum efficiency. This might include elements like the conduit size, wiring type, atmospheric conditions, and the distance to pull. Cable pullers take these variables into consideration when picking pull wires to reduce pulling force, protect the cable from damage, and ensure corrosion resistance.
There are multiple ways to install pullwires in pipelines. The commonest method of installation is 'laying in,' where the pull wire is laid inside the pipeline as the wires are pulled in. Another method is the 'pull-through' method, where an initial short wire is pulled through the conduit; then, the wire is connected to a machine that wires a smooth surface around the outer wire.
The easiest way to maintain pull wires is to prevent and eliminate the conditions that cause wear. Regular monitoring for mechanical damage, corrosion, or deposits and conducting routine cleaning or protective coating whenever necessary help with maintaining pull wires. The use of wire guards or conduit seals to minimize exposure to harmful elements can increase the lifespan of pull wires.
Some common factors that affect the lifespan of pull wires include environmental factors such as corrosive elements, temperature extremes, and moisture levels. Mechanical factors such as friction during pulling, physical damage, or improper installation may also affect the lifespan of pulling wires. Other factors that contribute to the wear and tear on pull wires include electrical interference as well as internal mechanical obstructions within the pipeline.
Pull wires, especially those made of steel or stainless steel, have a very long life and are therefore recyclable. Coated pull wires with corrosion-resistant coatings are also eco-friendly because once they have lived their useful life, they can be taken to a recycling depot. Some companies now offer pull wires made from bio-based polymers to reduce ecological impact. These eco-friendly pull wires have a smooth surface for easy pulling and can be used in various applications.
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