as 1154.3꞉2009 (en) ᴾᴼᴼᴮᴸᴵᶜᴽ

AS 1154.3—2009

Australian Standard®

Insulator and conductor fittings for overhead power lines

Part 3: Performance and general requirements for helical fittings

AS

11

54

.3—

20

09

This Australian Standard® was prepared by Committee EL-010, Overhead Lines. It was approved on behalf of the Council of Standards Australia on 4 November 2008. This Standard was published on 12 February 2009.

The following are represented on Committee EL-010:

• Australasian Railway Association • Australian Chamber of Commerce and Industry • Australian Electrical and Electronic Manufacturers Association • Australian Porcelain Insulators Association • Electricity Engineers Association, New Zealand • Energy Networks Association

This Standard was issued in draft form for comment as DR 07132. Standards Australia wishes to acknowledge the participation of the expert individuals that contributed to the development of this Standard through their representation on the Committee and through the public comment period.

Keeping Standards up-to-date Australian Standards® are living documents that reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments that may have been published since the Standard was published. Detailed information about Australian Standards, drafts, amendments and new projects can be found by visiting www.standards.org.au Standards Australia welcomes suggestions for improvements, and encourages readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at [email protected], or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.

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AS 1154.3—2009

Australian Standard®



Originated as AS 1154.3—1982. Previous edition 1985. Third edition 2009.

COPYRIGHT

© Standards Australia

All rights are reserved. No part of this work may be reproduced or copied in any form or by

any means, electronic or mechanical, including photocopying, without the written

permission of the publisher.

Published by Standards Australia GPO Box 476, Sydney, NSW 2001, Australia

ISBN 0 7337 9008 9

AS 1154.3—2009 2

PREFACE

This Standard was prepared by the Standards Australia Committee EL-010, Overhead

Lines, to supersede AS 1154.3—1985.

This Standard is one of a two-part series covering insulator and conductor fittings for

overhead lines as follows:

Part 1: Performance, material, general requirements and dimensions, which combines the

former Part 1 and Part 2.

Part 3: Performance and general requirements for helical fittings (this Standard).

The nature of helical fittings is such that they may be used for applications other than those

for which they were specifically designed. In this Standard, only the primary function is

considered and tests appropriate to that function are stipulated.

The use of fittings for purposes other than those for which they were designed is a matter

for negotiation between the purchaser and supplier.

For the purpose of this Standard, helical fittings are separated into two main groups, those

for bare conductors and those for insulated conductors. Helical fittings for bare conductors

are further subdivided into three classes as follows:

(a) Fittings that act as anchors to attach conductors under tension to structures and

fittings used for joining two conductors that will be used under tension.

(b) Fittings that grip a conductor and resist longitudinal slip and attach the conductor to

an insulator set or other support device.

(c) Fittings intended to protect a conductor from the electrical and/or mechanical stresses

to which it may be subjected in service. This class also includes fittings intended for

the repair of damaged conductors, to restore full electrical and mechanical integrity.


3 AS 1154.3—2009

CONTENTS

Page

SECTION 1 SCOPE AND GENERAL

1.1 SCOPE ........................................................................................................................ 4

1.2 REFERENCED AND RELATED DOCUMENTS ...................................................... 4

1.3 DEFINITIONS ............................................................................................................ 5

1.4 GENERAL REQUIREMENTS ................................................................................... 6

1.5 GENERAL REQUIREMENTS FOR TESTS............................................................... 6

1.6 VERIFICATION OF DIMENSIONS .......................................................................... 7

1.7 COLOUR CODES FOR HELICAL FITTINGS........................................................... 7

SECTION 2 ANCHOR AND TENSION FITTINGS

2.1 ITEMS TO BE SPECIFIED BY THE PURCHASER OR DECLARED BY THE

MANUFACTURER .................................................................................................... 9

2.2 TYPE TEST FOR GLUE........................................................................................... 10

2.3 MECHANICAL STRENGTH TYPE TESTS ............................................................ 10

2.4 ELECTRICAL TYPE TESTS ................................................................................... 12

2.5 BATCH TESTS......................................................................................................... 14

SECTION 3 SUSPENSION AND SUPPORT FITTINGS

3.1 SPECIFICATION DETAILS—ITEMS TO BE SPECIFIED BY THE PURCHASER

OR DECLARED BY THE MANUFACTURER........................................................ 15

3.2 MECHANICAL STRENGTH TYPE TESTS ........................................................... 16

3.3 MECHANICAL STRENGTH AND OPTICAL TYPE TESTS FOR FITTINGS FOR

OPGW CABLES ....................................................................................................... 20

3.4 ELECTRICAL TYPE TEST—SHORT-TIME CURRENT TEST ............................. 20

3.5 BATCH TESTS......................................................................................................... 21

SECTION 4 REPAIR AND PROTECTIVE FITTINGS


MANUFACTURER .................................................................................................. 22

4.2 REPAIR FITTINGS .................................................................................................. 23

4.3 PROTECTIVE FITTINGS......................................................................................... 23

4.4 BATCH TESTS......................................................................................................... 24

AS 1154.3—2009 4

© Standards Australia www.standards.org.au

STANDARDS AUSTRALIA

Australian Standard



S E C T I O N 1 S C O P E A N D G E N E R A L

1.1 SCOPE

This Standard specifies performance and general requirements for helical fittings for use on

overhead electric power lines.

Helical fittings for overhead lines, including OPGW and ADSS and stays, consist of sets of

rods, each of which has been formed into an open helix having normally the same direction

of lay as the outer strands of the conductor to which it is applied. In installation, the rods

are wrapped in accordance with the manufacturer’s recommendations around a conductor,

cable or stay having a diameter somewhat greater than the internal diameter of the fitting.

1.2 REFERENCED AND RELATED DOCUMENTS

1.2.1 Referenced documents

The following documents are referred to in this Standard:

AS

1154 Insulator and conductor fittings for overhead power lines

1154.1 Part 1: Performance, material, general requirements and dimensions

1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread

series)

1852 International electrotechnical vocabulary

AS/NZS

2947 Insulators—Porcelain and glass for overhead power lines—Voltages greater

than 1000 V a.c.

2947.1 Part 1: Test methods—Insulator units

4534 Zinc and zinc/aluminium-alloy coatings on steel wire

1.2.2 Related documents

This Standard may also require reference to the following documents:

AS

1111 ISO metric hexagon commercial bolts and screws—Product grade C (all parts)

1112 ISO metric hexagon nuts (all parts)

1222 Steel conductors and stays—Bare overhead

1222.1 Part 1: Galvanized (SC/GZ)

1531 Conductors—Bare overhead—Aluminium and aluminium alloy

1997 Plain limit gauges (metric series)

3607 Conductors—Bare overhead, aluminium and aluminium alloy—Steel reinforced


5 AS 1154.3—2009

www.standards.org.au © Standards Australia

1.3 DEFINITIONS

For the purpose of this Standard, the definitions given in AS/NZS 2947.1, AS 1852 and

those below apply.

1.3.1 All dielectric self-supporting (ADSS) cable

A non-metallic, all dielectric optical fibre cable that is physically and operationally separate

from the power conductors and that can generally support itself.

1.3.2 Anchor fittings

Fittings capable of anchoring or terminating conductors or cables.

1.3.3 Batch tests

Tests intended to verify the materials and workmanship of fittings that are performed on

fittings taken at random from batches offered for inspection.

1.3.4 Failing load

The load at which a fitting fails during the prescribed test conditions.

1.3.5 Nominated holding tension (NHT)

The test load that a support fitting is required to withstand without slip of the conductor.

(These values are stated by the manufacturer or specified by the purchaser).

1.3.6 Optical ground wire (OPGW)

A stranded metallic conductor incorporating optical fibres that has the dual performance

function of a conventional earth wire with telecommunication capabilities.

1.3.7 Repair and protective fittings

Fittings attached to a conductor to repair or protect it.

1.3.8 Slip

1.3.8.1 Suspension fittings

Any continuous movement of the conductor relative to the fitting in excess of 3 mm.

The elongation of the cable due to the test itself, or due to the movement of the fitting rods

as they tighten, or due to unequal bending of some of the rods, is not regarded as slippage.

1.3.8.2 Tension fittings

Any movement of the conductor relative to the fitting in excess of 3 mm with a

corresponding decrease of force.

The elongation of the cable due to the test itself, or due to the movement of the fitting rods

as they tighten, or due to unequal bending of some of the rods, is not regarded as slippage.

1.3.9 Specified minimum failing load (MFL)

The minimum failing load specified by the purchaser or declared by the supplier at which

mechanical failure will not take place.

1.3.10 Support fittings

Conductor fittings other than tension or non-tension fittings that grip a conductor and attach

to a string insulator unit, an insulator fitting or another support.

1.3.11 Tension fittings

Fittings capable of joining or splicing conductors.

AS 1154.3—2009 6


1.3.12 Type tests

Tests intended to validate design characteristics. They are normally performed once only

and repeated only when the design or the material of the fitting is changed.

1.4 GENERAL REQUIREMENTS

1.4.1 Defects

The fittings shall be free from defects that would be likely to cause them to be

unsatisfactory in service.

1.4.2 Design

Fittings shall be designed so that they comply with the test requirements of the relevant

Section of this Standard and so that the effects of vibration are minimized, both on the

conductor and the fitting.

1.4.3 Materials

Fittings may be made from any material or combination of materials acceptable to the

purchaser that enables the fitting to reach its design strength capability. Components shall

be compatible with other components and the conductor with which they will be in contact.

NOTE: The purchaser’s attention is drawn to any relevant statutory regulations governing the

nominated holding tension, failing load and nominated conductor tension.

Plastic materials shall be adequately protected from the effects of exposure to solar

radiation.

1.4.4 Surface finish

The fittings shall be designed, manufactured and finished to avoid sharp radii of curvature,

ridges and protrusions that might cause damage to the conductor in service.

1.4.5 Protection against corrosion

All parts of helical fittings shall either be inherently resistant to atmospheric corrosion or be

suitably protected against corrosion, both during storage and in service. All ferrous metal

parts that may be exposed to the atmosphere in service, except those made of stainless steel,

shall be protected by hot-dip galvanizing in accordance with AS 1214, or AS/NZS 4534

Class W10, or by other agreed means.

1.5 GENERAL REQUIREMENTS FOR TESTS

1.5.1 Type tests

Test certificates giving the results of the appropriate type tests, performed on no fewer than

three fittings identical in all essential details with those to be supplied, shall be regarded as

evidence of compliance with this Standard. These tests shall be repeated only if specified

by the purchaser. Type test certificates shall specify the overall dimensional details of the

fittings.

Full details of the conductor used in the test shall be given, including whether it was

ungreased, partly greased or wholly greased.

NOTE: Other evidence of compliance may be agreed upon by negotiation between the purchaser

and the supplier.

1.5.2 Batch tests

1.5.2.1 Sampling

Samples for batch tests shall be selected in accordance with Table 1.1.


7 AS 1154.3—2009


TABLE 1.1

SAMPLING FOR BATCH TESTS

Number in the lot (N)* Number of samples

>1 ≤100 To be specified by the purchaser

>100 ≤300 5

> 300 ≤1200 10

>1200 ≤3000 14

> 3000 ≤10 000 20

>10 000 0.002 × N

rounded up to the nearest whole number

* N is the number of fittings or devices offered for inspection.

1.5.2.2 Acceptance

If only one fitting fails to comply with any of the batch tests as prescribed, a new quantity

equal to twice the first quantity shall be tested. The testing shall comprise the test in which

failure occurred.

If two or more fittings fail to comply with the prescribed batch tests, the complete batch

shall be deemed not to comply with this Standard.

1.6 VERIFICATION OF DIMENSIONS

It shall be verified that the test samples are in accordance with the relevant drawings and

requirements agreed between the purchaser and the supplier.

1.7 COLOUR CODES FOR HELICAL FITTINGS

1.7.1 Colour codes for conductors

The centre/crossover marks should be made in the identifying colour listed in Table 1.2.

The colour is determined by the conductor wire diameter only, and should be applied to all

strandings and all conductor types. However, all fittings for SC/AC conductors shall have

an additional single green band placed midway along one leg of the fitting.

1.7.2 Colour codes for insulator neck diameters

Where a fitting is designed to fit on or around an insulator, a colour code denoting the

insulator neck diameter for which the fitting is suitable shall be placed approximately

50 mm from the end of one leg of the fitting.

The identification colour shall be as listed in Table 1.3.

AS 1154.3—2009 8


TABLE 1.2

COLOUR CODES FOR CONDUCTORS

Conductor wire diameter

mm

Colour

1.00 Black

1.25 Green

1.75 Purple

2.00 Yellow

2.25 Brown

2.50 Blue

2.75 White

3.00 Red

3.25 Orange

3.50 Purple

3.75 Black

4.25 Brown

4.50 Green

4.75 Blue

NOTES:

1 For ACSR, where the diameter of the steel wire is smaller than the

diameter of the aluminium wire, the colour code should refer to

the diameter of the aluminium wire.

2 Where a fitting is suitable for two conductor sizes, it bears both

colours.

3 Refer to the manufacturer for other details not covered above.

TABLE 1.3

COLOUR CODES FOR INSULATOR

NECK DIAMETERS

Insulator neck diameter

mm

Colour

54 Red

76 Yellow

112 Blue


9 AS 1154.3—2009


S E C T I O N 2 A N C H O R A N D T E N S I O N

F I T T I N G S


MANUFACTURER

2.1.1 Conductors

For each anchor and tension fitting, the following information shall be specified by the

purchaser or declared by the manufacturer:

(a) If complying with a relevant Australian Standard, the conductor size and type and

reference to the relevant Australian Standard. If not complying with a relevant

Australian Standard, all relevant details of the conductor.

(b) Whether the conductor is ungreased, partly greased or wholly greased.

(c) Nominated breaking load and details of the conductor if it is not an Australian

Standard size. The breaking load shall be calculated in accordance with the

appropriate Australian Standard covering similar types of conductors.

(d) Material or materials from which the fitting is made.

(e) Any other requirements, such as corona, radio-influence voltage, vibration

performance, corrosion resistance and optical attenuation for OPGW and ADSS.

(f) Whether the fitting is current carrying.

(g) If the temperature rise of the fitting is to be more than 200°C for aluminium and

ACSR and 400°C for SC/GZ and SC/AC, the purchaser should specify this.

Type test certificates for and performance data shall be made available to the purchaser if

requested.


For each anchor fitting, the following information shall be specified by the purchaser or

declared by the manufacturer:

(a) Description of the OPGW, including—

(i) diameter, stranding, lay, tube and strand sizes, areas and material properties;

(ii) number of optical fibres, signal wavelength, optical attenuation, etc.;

(iii) minimum bending radii;

(iv) CBL;

(v) short circuit rating for OPGW in kilo ampere squared seconds;

(vi) maximum cable temperature for OPGW (fault conditions); and

(vii) percentage of OPGW breaking load for unimpaired performance of fibre optical

properties. (If not stated, 70% of CBL shall be assumed.)

(b) The number of OPGW fittings to be tested.

Type test certificates and performance data shall be made available to the purchaser if

requested.

AS 1154.3—2009 10



For each anchor fitting, the following information shall be specified by the purchaser or


(a) Description of the ADSS cable, including—

(i) size, strength component (rods or fibre), sheath, tube and material properties;

(ii) number of optical fibres, signal wavelength, optical attenuation;

(iii) minimum bending radii; and

(iv) NHT.

(b) The number of ADSS fittings to be tested.

(c) Test arrangements if optical tests are required.


requested.

2.2 TYPE TEST FOR GLUE

2.2.1 General

Where glues are used to bind together individual wires in helical fittings, they shall be

shown to be of a type that will remain flexible and functional while the fitting is in storage

and in transit and whilst it is being installed.

To ensure that the glue used is of a suitable type, a ‘once only’ type test shall be carried out

on three representative sample fittings: one of each for small (<10 mm), medium (11 mm to

20 mm) and large (>21 mm) conductors. This test can be carried out on all three

concurrently or successively.

2.2.2 Test assembly and procedure

The fitting/s shall be soaked in water having a monitored temperature of between

65°C and 85°C for not less than 30 min. At the completion of this soak period, the fitting/s

shall be applied to a section of conductor they are designed for. Attention should be given

to the adherence of the glue and the ability to keep the wires together while ‘wrapping on’

of the fitting occurs. Any separation (to the point of splitting) of the wires, peeling or

flaking of the glue or other substantial signs of material degradation shall constitute failure.

2.3 MECHANICAL STRENGTH TYPE TESTS

2.3.1 Anchor fittings other than fittings for ADSS and OPGW cables

2.3.1.1 Test assembly and procedure

The fitting shall be assembled in accordance with the manufacturer’s recommendations for

the size and type of conductor with which it is to be used. The free length of the conductor

between the fitting under test and any other clamp or fitting in the test assembly should be

not less than 50 times the overall diameter of the conductor.

The process of assembling the same fitting on the same length of conductor shall be carried

out a total of three times.

A tensile force of approximately 50% of the nominated breaking load of the conductor shall

be applied and the conductor shall be marked in such a way that movement relative to the

fitting can be detected easily. Without any subsequent adjustments to the fitting, the force

shall be increased steadily to 90% of the nominated breaking load of the conductor and then

maintained for 1 min.

The force shall then be increased steadily until failure occurs. The load and the nature of

the failure shall be recorded.


11 AS 1154.3—2009


Where the heating cycle test specified in Clause 2.4.2 has been specified by the purchaser,

this test may be carried out prior to the strength test on the same conductor and fittings.

2.3.1.2 Requirement

During the 1 min period in which the tensile force is held at 90% of the nominated breaking

load of the conductor, there shall be no slip and no failure of the fitting.


corresponding decrease of force shall be classed as slip.

If doubt exists after the required 1 min holding period, the fittings shall re-marked at this

holding load and held for a further 1 min period. Any movement after this further 1 min

holding period shall be classed as slip.

The elongation of the cable because of the test itself, or because of the movement of the

fitting rods as they tighten, or because of unequal bending of some of the rods, is not

regarded as slippage.

2.3.2 Anchor fittings for ADSS cables


the size and type of ADSS cable it is designed for. If it is a range taking fitting, it shall be

the smallest practically available size. The free length between fittings is to be not less than

50 times the cable diameter.

The maximum short-term loading value for the ADSS cable shall be specified by the

purchaser and this value shall be taken as being the NHT considering that signal attenuation

can occur long before actual cable mechanical failure occurs.

A tensile force of approximately 50% of the NHT of the ADSS shall be applied and the

ADSS marked in such a way that movement relative to the fitting can be easily detected.

Without any subsequent adjustments to the fitting, the force shall be steadily increased to

the NHT and maintained for not less than 1 min. Any movement of the fitting relative to the

ADSS cable shall be noted and recorded.

If optical testing is required, the test procedure shall be subject to special arrangement

between the purchaser and the supplier. However, optical monitoring is usually not required

because the manufacturer’s stated maximum short-term loading value has not been

exceeded and therefore further loading of the fitting to failure is unnecessary.

2.3.3 Tension fittings



the size and type of conductor with which it is to be used. The free length of the conductor

between the fitting under test and any other clamp or fitting in the test assembly should be

not less than 50 times the overall diameter of the conductor.




shall be increased steadily to 90% of the nominated breaking load of the conductor and


The force shall then be increased steadily until failure occurs. The load and the nature of

the failure shall be recorded.

Where the heating cycle test specified in Clause 2.4.2 has been specified by the purchaser,

this test may be carried out before the strength test on the same conductor and fitting.

NOTE: OPGW and ADSS cables are not joined by tension fittings.

AS 1154.3—2009 12


2.3.3.2 Requirement


load of the conductor, there shall be no movement of the conductor relative to the fitting

due to slip nor any failure of the fitting.



If doubt exists after the required 1 min holding period, the fittings shall re-marked at this






2.3.4 Anchor fittings for OPGW cables


The procedure for the mechanical strength type test in Clause 2.3.1.1 shall be carried out. If

optical testing is required by the purchaser, the tests shall be carried out with the following

modifications:

(a) The number of times the fitting is assembled on the conductor shall be specified by

the purchaser.

(b) The optical properties of the fibres shall be monitored before and during the test.

(c) The tension in the OPGW shall be held when it reaches 70% CBL or the tension

specified for the unimpaired performance of optical properties. The optical fibre

signal attenuation shall be measured on all fibres.

The test shall then be continued.

2.3.4.2 Requirements

The optical signal at the nominated wavelength shall not be impaired by more than 0.3 dB

on all fibres for each tension fitting.

The requirements of Clause 2.3.1.1 shall be met.

NOTE: The failure to meet the requirements may be attributed to the design and construction of

the fitting or to the OPGW design and construction or a combination of the two.

2.4 ELECTRICAL TYPE TESTS

2.4.1 Resistance test (excluding OPGW)

2.4.1.1 General

The resistance test shall be made on all current-carrying type fittings.

The test shall be carried out before and after both the heating cycle and the short-time

current tests specified in Clauses 2.4.2 and 2.4.3.


The fitting shall be assembled in accordance with the manufacturer’s recommendations on a

conductor of the size and type with which it is to be used. A tensile force of approximately

10% of the nominated breaking load of the conductor shall be applied and the electrical

resistance shall be measured between points on the conductor on either side and just clear

of the fitting.


13 AS 1154.3—2009


The test may be performed with direct current or with alternating current at any convenient

power frequency. The current connections shall be at a distance of not less than 50 times

the diameter of the conductor, from the fitting and shall be made so that effective contact is

made with all those strands of the conductor that would be taken into account in calculating

its equivalent resistance.

2.4.1.3 Requirement

The resistance of the assembly shall not exceed 75% of the measured resistance of the

equivalent length of conductor.

2.4.2 Heating cycle test

2.4.2.1 General

The heating cycle test shall be carried out on all current-carrying type fittings.

The test shall be conducted in a draught-free space at ambient temperature. Air shall be able

to circulate freely around the assembly.

NOTE: A space is considered draught-free if the conductor temperature is 75°C to 85°C above the

ambient temperature at the end of each heating period.

2.4.2.2 Test current

The test current shall be adjusted during the first 25 heat cycles so that a steady-state

temperature rise of the conductor of 80°C above an ambient temperature of 5°C to 40°C is

achieved. This heating current shall then be used for the heating periods of the test,

regardless of subsequent changes in the steady-state conductor temperature rise.


The fitting shall be assembled in accordance with the manufacturer’s recommendations on a

conductor of the size and type with which it is to be used. The assembly shall be erected

indoors with the conductor approximately horizontal, and a tensile force not exceeding 20%

of the nominated breaking load of the conductor shall be applied.

The current connections shall be at a distance from the fitting of not less than 50 times the

diameter of the conductor.

The test current shall be passed continuously through the assembly for a period of 30 min.

The current shall then be interrupted and the assembly allowed to cool to within 5°C above

the ambient temperature. This sequence of operations shall be repeated for 250 cycles of

heating and cooling. The fitting shall not be adjusted during the test.

2.4.2.4 Requirement

During the last five cycles, the maximum temperature, measured when the test current is

flowing, at any point on the surface of the fittings, shall not exceed that of the conductor.

The fitting shall afterwards be removed and there shall be no sign of local heating, burning

or fusing of any part of the fitting or of the conductor.

2.4.3 Short-time current test

2.4.3.1 General

The short-time current test shall be made on all current-carrying type fittings. This test is

also applicable to earth leads used in conjunction with helical fittings.

2.4.3.2 Test current

The test current shall be the short-time current rating of the highest rated conductor

associated with the fitting.

AS 1154.3—2009 14


Unless otherwise specified by the purchaser, the test current shall be applied for a sufficient

period to raise the temperature of the conductor for which the fitting is intended to 200°C

for aluminium and ACSR and 400°C for SC/GZ and SC/AC. By agreement between the

purchaser and the manufacturer, the I2t equivalent of the above current may be used up to a

maximum period of 5 s.


The fittings shall be assembled in accordance with the manufacturer’s recommendations.

The test assembly shall be erected indoors with the conductor approximately horizontal. Air

shall be able to circulate freely around the assembly.

The current connections shall be at a distance from the fitting of not less than 50 times the

diameter of the conductor.

The ambient temperature during the test shall not be less than 5°C and the conductor shall

be marked so that any conductor movement relative to the fitting may be detected easily.

The assembly shall be tensioned to 2.5% of the nominated breaking load of the conductor

and the test current shall be applied. Without subsequent adjustments to the fitting, the

same assembly shall then be tensioned to 50% of the nominated breaking load of the

conductor and the test current shall be applied. The time interval between the two tests is

determined by the person conducting the tests.

2.4.3.4 Requirement

There shall be no movement of the conductor relative to the fitting due to slip nor any

mechanical failure of the fitting. The fitting shall afterwards be removed and there shall be

no sign of local heating, burning or fusing of any part of the fitting or the conductor.

2.5 BATCH TESTS

2.5.1 Verification of dimensions

The dimensions of the fittings shall be verified as specified in Clause 1.6.

2.5.2 Mechanical and electrical tests

Mechanical and electrical batch tests shall not be performed on anchor or tension fittings

except by special arrangement between the purchaser and the supplier. Where required,

such tests shall be the same as the type tests except when performing the strength test

specified in Clause 2.3.1, in which case—

(a) the fitting need only be assembled on the conductor once; and

(b) the test shall not be continued until failure occurs.

2.5.3 Galvanizing tests

The galvanized samples shall be tested in accordance with AS 1214 or AS/NZS 4534, Class

W10, or by other agreed means.


15 AS 1154.3—2009


S E C T I O N 3 S U S P E N S I O N A N D S U P P O R T

F I T T I N G S

3.1 SPECIFICATION DETAILS—ITEMS TO BE SPECIFIED BY THE

PURCHASER OR DECLARED BY THE MANUFACTURER

3.1.1 Conductors

For each suspension or support fitting, the following information shall be specified by the


(a) Conductor size and type and relevant Australian Standard.


(c) Diameter over armour rods for support fittings.

(d) NHT.

(e) Failing load of suspension or support fitting.

(f) Maximum angle of conductor deviation.

(g) Type and failing load of attachment and coupling parts, e.g. clevis, tongue, socket,

eye, thimble or sheave wheel. (See AS 1154.1.)

(h) Material or materials from which the fitting is made.

(i) As appropriate, insulator type, failing load and head dimensions.

(j) Any other requirements, such as corona, radio influence voltage, vibration

performance, fault current and corrosion resistance.

Type test certificates and performance data shall be made available to the purchaser, if

requested.




(a) An OPGW description including—




(iv) CBL;


(vi) maximum cable temperature for OPGW (fault conditions);

(vii) percentage of OPGW breaking load for unimpaired performance of fibre optical

properties (if not stated, 70% of CBL shall be assumed);

(viii) failing load for suspension fittings if required;

(ix) maximum deviation angle of OPGW at a suspension or support fitting (if not

stated, the angle of 30 degrees shall be assumed); and

(x) NHT if required.


AS 1154.3—2009 16



requested.




(a) Description of the ADSS cable including—

(i) size, strength component (rods or fibre), sheath, tube and material properties;



(iv) NHT.




requested.

3.2 MECHANICAL STRENGTH TYPE TESTS

3.2.1 Holding tension (withstand slip) test

3.2.1.1 General

The holding tension test shall be performed on all suspension or support fittings.


The fitting shall be assembled in accordance with the manufacturer’s recommendations on

the conductor and armour rods if required with which it is to be used. The test shall be

carried out in a manner approximating as nearly as possible the arrangement to be used in

service. The free length of conductor shall be not less than 50 times the diameter of the

conductor, as shown in Figure 3.1.

Unless otherwise specified by the purchaser, a tensile force of approximately 50% of the

nominated holding tension shall be applied. The conductor shall then be marked in such a

way that movement relative to the fitting can be detected easily. Without any subsequent

adjustment to the fitting, the force shall be increased steadily until the nominated holding

tension is reached and shall be maintained for 1 min.

The load shall be increased steadily until a movement of the conductor relative to the fitting

of approximately 3 mm occurs or the fitting fails, at which point the load shall be recorded.

NOTE: This test is not relevant to ADSS fittings.

3.2.1.3 Requirement

During the 1 min period in which the tensile force is held at the nominated holding tension,

there shall be no movement of the conductor relative to the fitting due to slip and no failure

of the fitting.



If doubt exists after the required 1 min holding period, the fittings shall be re-marked at this







17 AS 1154.3—2009


Load

50d min.

Load

Test machine

end jaws

d

LoadLoad

50d min.

d

50d min.Test machine

end jaws

d

Mandrel s imulat ing

Insulator neck

Load

50d min.

d Load

FIGURE 3.1 TYPICAL TEST ARRANGEMENTS FOR HOLDING STRENGTH

(WITHSTAND SLIP) TEST

3.2.2 Failing load test

3.2.2.1 Suspension fittings

The failing load test shall be made on suspension fittings.

(a) Test assembly and procedure The fittings shall be assembled in accordance with the

manufacturer’s recommendations using either the conductors for which they were

designed or mandrels. A tensile force shall be applied and increased steadily until the

fitting separates from the test mandrel or the fitting breaks.

NOTE: A typical test arrangement is illustrated in Figure 3.2.

(b) Requirement The failing load shall be not less than the specified minimum failing

load and failure shall be of a ductile nature.

AS 1154.3—2009 18


3.2.2.2 Support fittings

The failing load test shall be performed on support fittings.

(a) Test assembly and procedure The fittings shall be assembled in accordance with the

manufacturer’s recommendations using either the conductors for which they were

designed or mandrels. A tensile force shall be applied and increased steadily until the

fitting breaks or separates from the mandrel. The direction of the force shall be as

shown in Figure 3.3 and the failing load for each direction recorded.

(b) Requirement The failing load shall be not less than the specified minimum failing

load.

Load

direct ion

FIGURE 3.2 FAILING LOAD TEST: SUSPENSION FITTING


ww

w.s

tan

da

rds.o

rg.a

u

©

Sta

nd

ard

s A

ustra

lia

19

A

S 1

15

4.3

—2

00

9

(a) Top groove f i t t ing (b) S ide groove f i t t ing (c) Other f i t t ings

Transverse

load

(Meta l sheave/shack le insu lator )

Ver t ica l

load

(He l ica l suppor t f i t t ing)

Load

Direct ion

Mandre l s imulat ing

insu lator neck

Ver t ica l

load

Ver t ica l

load

Transverse

loadTransverse

load

FIGURE 3.3 FAILING LOAD TEST: SUPPORT FITTINGS

AS 1154.3—2009 20


3.3 MECHANICAL STRENGTH AND OPTICAL TYPE TESTS FOR FITTINGS

FOR OPGW CABLES

3.3.1 General

If specified by the purchaser, mechanical strength and optical type tests shall be performed

in accordance with Clauses 3.3.2.1 and 3.3.2.2.

3.3.2 Suspension fittings

3.3.2.1 Optical performance at maximum deviation

A modified failing load test (see Clause 3.2.2) shall be carried out to verify the optical

performance when the OPGW is at the maximum deviation angle for a suspension clamp

and is subject to OPGW at the nominated percentage of conductor breaking load for

unimpaired optical performance.

The optical properties of the fibres shall be monitored during the test. (This test can be

carried out concurrently with the tension fitting mechanical and optical test.)

NOTE: A typical test arrangement is illustrated in Figure 3.4.

3.3.2.2 Optical performance and withstand slip

A modified holding tension test (withstand slip) (see Clause 3.2.1) shall be carried out,

during which the optical properties of the fibres shall be monitored up to and after clamp

slip.

3.3.2.3 Requirement

The optical signal at the nominated wavelength shall not be impaired by more than 0.3 dB

on all fibres for each suspension fitting.

Load

70% OPGW CBL70% OPGW CBL

15° 15°

FIGURE 3.4 FAILING LOAD TEST: MODIFIED ARRANGMENT FOR OPGW FITTINGS

3.4 ELECTRICAL TYPE TEST—SHORT-TIME CURRENT TEST

3.4.1 General

This test is applicable to OPGW and other suspension assemblies that are connected to

ground through an earth lead.

3.4.2 Test current

Unless otherwise specified by the purchaser, the test current shall be the short-time current

calculated from the nominated short-circuit rating.


21 AS 1154.3—2009


3.4.3 Test assembly and procedure

The test assembly and procedure shall be in accordance with Clause 2.4.3, with the

exception that the current shall pass from the OPGW or ground wire through the suspension

fittings and earth connection. The test need not be carried out with OPGW or ground wire

under tension.

3.4.4 Requirement

There shall be no burning or fusing of any part of the fitting, earth lead or OPGW or ground

wire at the fitting. OPGW optical performance shall remain unaffected.

3.5 BATCH TESTS



3.5.2 Mechanical tests

Mechanical tests for suspension fittings other than fittings for OPGW cables shall be the

same as the type tests specified in Clause 3.2. The mechanical tests for suspension fittings

for ADSS cables and support fittings are not required.


The galvanized samples shall be tested in accordance with AS 1214 or AS/NZS 4534,

Class W10, as appropriate.

AS 1154.3—2009 22


S E C T I O N 4 R E P A I R A N D P R O T E C T I V E

F I T T I N G S


MANUFACTURER

4.1.1 Conductors

For each repair and protective fitting, the following information shall be specified by the


(a) Conductor size and type and relevant Australian Standard.


(c) Nominated breaking load and details of the conductor, if it is not an Australian

Standard size. The breaking load shall be calculated in accordance with the

appropriate Australian Standard covering similar types of conductors.

(d) Material or materials from which the fitting is made.

(e) Any other requirements, such as corona, radio-influence voltage, vibration

performance and corrosion resistance.


requested.


For each repair and protective fitting, the following information shall be specified by the


(a) An OPGW description including—




(iv) CBL;


(vi) maximum cable temperature for OPGW (fault conditions);

(vii) OPGW stringing criteria (nominal everyday tension and temperature); and

(viii) material or materials from which the fitting is made.



requested.


For each protective fitting, the following information shall be specified by the purchaser or


(a) Description of the ADSS cable, including—

(i) Size, strength component (rods or fibre), sheath, tube and material properties;




23 AS 1154.3—2009


(iv) ADSS stringing criteria (nominal everyday tension and temperature).




requested.

4.2 REPAIR FITTINGS

4.2.1 General requirements

Repair fittings shall be designed to make good conductors, cables, stays and OPGW of

which not more than 25% of the wires in the outermost layer have been severed or have

other equivalent damage to that outermost layer. Repair fittings shall not be used to make

good damaged steel wires. Repair fittings shall comply with the type tests specified in

Clause 4.2.3.

NOTE: If the amount of damage to a conductor cannot be determined to be less than 25% of the

wires, a ‘tension fitting’ should be used to repair the conductor.

4.2.2 Preparation of conductor for the type test

A length of conductor of the size and type with which the fitting is to be used shall be taken

and the appropriate number of adjacent strands in the outermost layer shall be severed.

The cuts shall be dispersed over a conductor length of approximately three conductor

diameters. The repair fitting shall then be assembled in accordance with the manufacturer’s

recommendations to make good the damaged conductor.

4.2.3 Mechanical strength type test


The fitting shall be assembled in accordance with the manufacturer’s recommendations on

the size and type of conductor with which it is to be used. The assembly shall be mounted in

a tensile testing machine, with the length of the conductor between the fitting under test and

any other clamp or fitting in the test assembly not less than 50 times the overall diameter of

the conductor.




shall be increased steadily to 90% of the nominated breaking load of the conductor and


4.2.3.2 Requirement


load of the conductor, there shall be no failure of the fitting.

4.3 PROTECTIVE FITTINGS

4.3.1 Armour rods and line guards

Armour rods and line guards shall be designed to reduce bending stress in the conductor

and/or protect the conductor from damage that could be caused by electrical arcing at

support points.

4.3.2 Spiral vibration dampers

Vibration dampers shall be designed to reduce the amplitude of Aeolian vibrations and shall

be constructed from a suitable polymer designed to minimize the effects of solar radiation

degradation.

AS 1154.3—2009 24


4.4 BATCH TESTS




The galvanized samples shall be tested in accordance with AS 1214 or AS/NZS 4534,

Class W10, or by other agreed means.


Standards Australia Standards Australia develops Australian Standards® and other documents of public benefit and national interest. These Standards are developed through an open process of consultation and consensus, in which all interested parties are invited to participate. Through a Memorandum of Understanding with the Commonwealth Government, Standards Australia is recognized as Australia’s peak non-government national standards body. Standards Australia also supports excellence in design and innovation through the Australian Design Awards. For further information visit www.standards.org.au Australian Standards® Committees of experts from industry, governments, consumers and other relevant sectors prepare Australian Standards. The requirements or recommendations contained in published Standards are a consensus of the views of representative interests and also take account of comments received from other sources. They reflect the latest scientific and industry experience. Australian Standards are kept under continuous review after publication and are updated regularly to take account of changing technology. International Involvement Standards Australia is responsible for ensuring the Australian viewpoint is considered in the formulation of International Standards and that the latest international experience is incorporated in national Standards. This role is vital in assisting local industry to compete in international markets. Standards Australia represents Australia at both the International Organization for Standardization (ISO) and the International Electrotechnical Commission (IEC). Sales and Distribution Australian Standards®, Handbooks and other documents developed by Standards Australia are printed and distributed under license by SAI Global Limited.

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