Overhead Wiring Fittings and Materials

© State of NSW through Transport for NSW 2021

Overhead Wiring Fittings and Materials

T HR EL 08004 ST

Standard

Version 2.0

Issue date: 26 May 2021

T HR EL 08004 ST Overhead Wiring Fittings and Materials

Version 2.0 Issue date: 26 May 2021

© State of NSW through Transport for NSW 2021

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© State of NSW through Transport for NSW 2021 Page 3 of 30

Standard governance

Owner: Director Energy Networks and Systems, Asset Management Branch Authoriser: Director Engineering, Asset Management Branch Approver: Executive Director, Asset Management Branch on behalf of the AMB Configuration Control

Board

Document history

Version Summary of changes

1.0 Initial release, 9 May 2014

2.0 Second issue. The changes to previous content include updating references, allowance of existing fittings to be sourced from suppliers that are not accredited to AS/NZS ISO 9001, incorporation of the relevant content of ETN 07/02, and minor amendments and clarification to content.




Preface

The Asset Management Branch (AMB), formerly known as Asset Standards Authority (ASA) is a key strategic branch of Transport for NSW (TfNSW). As the network design and standards authority for NSW Transport Assets, as specified in the ASA Charter, the ASA identifies,

selects, develops, publishes, maintains and controls a suite of requirements documents on

behalf of TfNSW, the asset owner.

The ASA deploys TfNSW requirements for asset and safety assurance by creating and

managing TfNSW's governance models, documents and processes. To achieve this, the ASA focuses on four primary tasks:

• publishing and managing TfNSW's process and requirements documents including TfNSW

plans, standards, manuals and guides

• deploying TfNSW's Authorised Engineering Organisation (AEO) framework

• continuously improving TfNSW’s Asset Management Framework

• collaborating with the Transport cluster and industry through open engagement

The AEO framework authorises engineering organisations to supply and provide asset related products and services to TfNSW. It works to assure the safety, quality and fitness for purpose of

those products and services over the asset's whole-of-life. AEOs are expected to demonstrate how they have applied the requirements of ASA documents, including TfNSW plans, standards

and guides, when delivering assets and related services for TfNSW.

Compliance with ASA requirements by itself is not sufficient to ensure satisfactory outcomes for

NSW Transport Assets. The ASA expects that professional judgement be used by competent personnel when using ASA requirements to produce those outcomes.

About this document

This standard sets out the technical requirements for fittings and materials used in the

1500 V dc overhead wiring in the TfNSW Metropolitan Heavy Rail Network.

This is the second issue of this standard. The changes to previous content include the following:

• update of references

• allowance of existing fittings to be sourced from suppliers that are not accredited to

AS/NZS ISO 9001

• incorporation of the relevant content of ETN 07/02

• minor amendments and clarification to content




Table of contents 1. Introduction ................................................................................................................................... 7

2. Purpose ......................................................................................................................................... 7 2.1. Scope ......................................................................................................................................... 7 2.2. Application .................................................................................................................................. 7

3. Reference documents ................................................................................................................... 7

4. Terms and definitions.................................................................................................................. 10

5. General requirements .................................................................................................................. 10 5.1. Work health and safety............................................................................................................... 10 5.2. Vibration and cyclic loading ........................................................................................................ 10 5.3. Tools for tensioning bolts and nuts .............................................................................................. 10 5.4. Maintainability............................................................................................................................ 11 5.5. Safety factors ............................................................................................................................ 11 5.6. Metallurgical compatibility ........................................................................................................... 11 5.7. Tolerances ................................................................................................................................ 11 5.8. Inventory minimisation................................................................................................................ 11 5.9. Packaging and delivery .............................................................................................................. 11

6. Type approval.............................................................................................................................. 12

7. OHW fittings suppliers ................................................................................................................ 12

8. Inspection and tests .................................................................................................................... 12 8.1. Type tests ................................................................................................................................. 12 8.2. Batch conformance .................................................................................................................... 13 8.3. Acceptance inspection and tests ................................................................................................. 13

9. OHW materials............................................................................................................................. 14 9.1. Copper and high copper alloys.................................................................................................... 14 9.2. Brass and gunmetal castings ...................................................................................................... 15 9.3. Mild steel ................................................................................................................................... 16 9.4. Cast iron ................................................................................................................................... 17 9.5. Stainless steel fabrications and bolts ........................................................................................... 17 9.6. Stainless steel castings .............................................................................................................. 18 9.7. Aluminium ................................................................................................................................. 20 9.8. Polymeric materials .................................................................................................................... 20 9.9. Laminated timber ....................................................................................................................... 21

10. OHW components and fittings .................................................................................................... 21 10.1. Stranded conductors .............................................................................................................. 21 10.2. Contact wire........................................................................................................................... 22 10.3. Splices and termination for overhead wiring conductors ............................................................ 22 10.4. 1500 V dc insulators ............................................................................................................... 23 10.5. Stainless steel threaded fasteners ........................................................................................... 23 10.6. Galvanized mild steel threaded fasteners ................................................................................. 24




10.7. Stainless steel connecting pins................................................................................................ 25 10.8. Galvanized mild steel connecting pins ..................................................................................... 26 10.9. Laminated timber beams ........................................................................................................ 26

11. Fitting identification .................................................................................................................... 26 11.1. Format of fitting numbers ........................................................................................................ 26 11.2. Similar fittings ........................................................................................................................ 27

12. Line tension components ............................................................................................................ 27 12.1. Connection arrangements with pins ......................................................................................... 27 12.2. Threaded components in tension............................................................................................. 27 12.3. Cast fittings subject to full line tension ..................................................................................... 28

13. Fitting drawings........................................................................................................................... 28 13.1. Component drawings.............................................................................................................. 28 13.2. Assembly drawings ................................................................................................................ 29

Appendix A Electrical goods inspection codes of Sydney Trains ................................................ 30




1. Introduction Overhead wiring (OHW) is used to transmit power from traction substations to electric trains. OHW generally consists of catenary and contact wires. The traction current to the trains is

carried by the catenary and contact wires, and auxiliary feeders when installed. The contact wire provides a mechanically continuous path for train pantographs, and the catenary wire is

used to support the contact wire.

Refer to T HR EL 08012 ST Overhead Wiring Standards for Design and Construction for design

and construction requirements of OHW.

2. Purpose This document aims to set out the technical requirements for overhead wiring fittings and materials.

2.1. Scope This document covers the technical requirements for overhead fittings and materials in the TfNSW Metropolitan Heavy Rail Network.

Refer to TS TOC 1 Train Operating Conditions (TOC) Manual – General Instructions, which

defines the areas associated with the network.

2.2. Application The requirements in this document apply to overhead wiring fittings and materials for new OHW

installations, and for modifications and re-construction of existing OHW in the TfNSW Metropolitan Heavy Rail Network.

Existing non-complying fittings may remain in service, and only be used for the replacement of damaged fittings of the same type, unless specifically prohibited in this standard.

In addition to the requirements of this standard, asset decisions take into account the life cycle cost considerations specified in T MU AM 01001 ST Life Cycle Costing.

If the intent of stated requirements in this standard is not clear, a clarification should be sought from the Director Energy Networks and Systems, AMB.

3. Reference documents The following documents are cited in the text. For dated references, only the cited edition

applies. For undated references, the latest edition of the referenced document applies.

International standards

ASTM A276/A276M Standard Specification for Stainless Steel Bars and Shapes




Australian standards

AS 1100.101 Technical drawing – Part 101: General principles

AS 1111.1 ISO metric hexagon bolts and screws – Product grade C – Bolts

AS 1111.2 ISO metric hexagon bolts and screws – Product grade C – Screws

AS 1112.3 ISO metric hexagon nuts – Product Grade C

AS 1154.1 Insulator and conductor fittings for overhead power lines – Part 1: Performance, material, general requirements and dimensions

AS 1154.3 Insulator and conductor fittings for overhead power lines – Part 3: Performance and general requirements for helical fittings

AS 1237.1 Plain washers for metric bolts, screws and nuts for general purposes – General plan

AS 1237.2 Tolerances for fasteners – Washers for bolts, screws and nuts – Product grades A,

C and F

AS 1442 Carbon steels and carbon-manganese steels – Hot rolled bars and semi-finished

products

AS 1565 Copper and copper alloys – Ingots and castings

AS 1566 Copper and copper alloys – Rolled flat products

AS 1721 General purpose metric screw threads

AS 1746 Conductors – Bare overhead – Hard-drawn copper

AS 1830 Grey cast iron

AS 1831 Ductile cast iron

AS 2074:2003 Cast steels

Note: AS 2074 has been withdrawn. However, the grades of stainless steels defined in

AS 2074 are still widely used in the industry.

AS 2400 (all parts) Packaging

AS 2738 Copper and copper alloys – Compositions and designations of refinery products,

wrought products, ingots and castings

AS 4100 Steel structures

AS ISO 1302 Geometrical product specifications (GPS) – Indication of surface texture in technical product documentation

AS/NZS 1214 Hot dip galvanized coatings on threaded fasteners (ISO metric coarse thread series) (ISO 10684:2004, MOD)




AS/NZS 1554.6 Structural steel welding – Part 6: Welding stainless steels for structural

purposes

AS/NZS 1734 Aluminium and aluminium alloys – Flat sheet, coiled sheet and plate

AS/NZS 3678 Structural steel – Hot-rolled plates, floorplates and slabs

AS/NZS 3679.1 Structural steel – Part 1: Hot-rolled bars and sections

AS/NZS 3679.2 Structural steel – Part 2: Welded I sections

AS/NZS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles

AS/NZS 4792 Hot-dip galvanized (zinc) coatings on ferrous hollow sections, applied by a continuous or a specialized process

AS/NZS ISO 9001 Quality management systems – Requirements

Transport for NSW standards

T HR EL 08008 SP Contact Wire

T HR EL 08009 ST Designations of Overhead Wiring Conductor Systems

T HR EL 08012 ST Overhead Wiring Standards for Design and Construction

T HR EL 08013 ST Overhead Wiring Insulators

T MU AM 01001 ST Life Cycle Costing

T MU MD 00005 GU Type Approval of Products

T MU MD 00006 ST Engineering Drawings and CAD Requirements

TS TOC 1 Train Operating Conditions (TOC) Manual - General Instructions

TfNSW drawings

CV0518426 Argyle – Waverton – North Shore Line – Section 2 – North Sydney – Hotel

Airspace – NSA Drop Vertical – Steelwork Details

EL0004229 Railway Overhead Wiring – Penrith Bowenfels – Compound Fixed O.H.W. – Steady

Wire Dropper Arrangement

EL0017030 General – Railways Overhead Wiring – Twin Contact Dropper – Link Bar – Fitting

Details

EL0017724 Railways Overhead Wiring – Cantilever Jib Bottom End Thrust Bearing – Fitting

Details

EL0474297 General – Railways Overhead Wiring – Insulated Dropper Sleeve – Fitting Details

EL0474317 General – Railways Overhead Wiring – Insulated Sleeve for Short Dropper – Fitting Details




EL0474359 General – Railways Overhead Wiring – Secondary Insulation – Plate and Ferrule –

Fitting Details

EL0474372 General – Railways Overhead Wiring – Insulating Block for Short Dropper – Fitting

Details

4. Terms and definitions The following terms and definitions apply in this document:

AEO Authorised Engineering Organisation

ASA Asset Standards Authority

OHW overhead wiring

TfNSW Transport for New South Wales

5. General requirements OHW fittings and materials shall comply with the requirements in Section 5.1 to Section 5.9.

5.1. Work health and safety Fittings shall be designed, and materials shall be selected so that risks of injury to persons

involved in manufacture, fabrication, storage, handling, installation, maintenance and disposal are reduced to so far as is reasonably practicable (SFAIRP). Potential hazards may include the

following:

• excessive weight

• sharp edges and burrs

• toxic emissions during manufacture

• hazardous substances that may be present in fittings application, such as lubricants and dusts

5.2. Vibration and cyclic loading Fittings shall be designed to maintain their integrity when subjected to conditions of vibration and cyclic loading that might reasonably be expected in service.

5.3. Tools for tensioning bolts and nuts Fittings shall be designed so that bolts and nuts can be tensioned using long wall sockets (approximately 85 mm deep) and ratchet wrenches where possible. Allowance shall be made

for clearance for the head of the ratchet.




If use of the long wall socket and ratchet wrenches is not possible, the design shall allow

standard ring or flat spanners to be used.

5.4. Maintainability Fittings shall be designed to facilitate efficient and safe replacement of components in service.

Factors that affect maintainability include the following:

• provision of adequate rigging points

• ease of attachment and removal of components such as split pins

5.5. Safety factors Unless otherwise specified in this document, the safety factor shall not be less than:

• four for cast fittings and materials

• three for all other fittings and materials

5.6. Metallurgical compatibility Dissimilar metals shall not be connected together unless test results indicate that the electrolytic action between them will not result in corrosion of the metals.

5.7. Tolerances Unless otherwise specified in this document, the OHW fittings shall comply with the tolerance requirements of both of the following:

• the fitting drawings

• the Australian standards that the fittings shall comply with in accordance with this

document

5.8. Inventory minimisation Where practicable, the design of overhead wiring fittings should facilitate the minimisation of inventory for the overhead wiring system.

Prior to designing a new overhead wiring fitting, the designer should check for the existence of similar fittings. The feasibility of modifying existing fittings to suit both existing and new

requirements should be considered.

5.9. Packaging and delivery Goods delivered shall be suitably packaged in accordance with relevant Transport standards and specifications, and comply with the relevant parts of AS 2400 Packaging.




Packets that may require manual handling shall be appropriately packaged to minimise the risk

of personal injury or damage to material.

Where special arrangements, such as the provision of cranes, are required to take delivery of

goods, the supplier shall advise the receiving organisation of the requirements and with sufficient time to allow for such arrangements to be made.

6. Type approval The requirement for type approval for an OHW fitting is determined by the Director Energy

Networks and Systems, AMB.

Refer to T MU MD 00005 GU Type Approval of Products for the type approval process.

7. OHW fittings suppliers Overhead wiring fittings shall be sourced from suppliers that are certified to the latest edition of AS/NZS ISO 9001 Quality management systems – Requirements. The compliance of this

requirement is preferable but not mandatory for fittings that are in existing installations in the

overhead wiring of the TfNSW Metropolitan Heavy Rail Network at the time of publication of this standard, and for fittings that are similar to and using the same design as the existing fittings.

The compliance of the OHW fitting with relevant Transport, Australian and international standards and specifications shall be assured by provisions in the quality system of the supplier,

or that of the Authorised Engineering Organisation (AEO) procuring the material, or a combination of both.

AEOs procuring OHW fittings and materials shall have a system in which the performance of suppliers with respect to the quality of materials are monitored and recorded.

8. Inspection and tests The requirements for type tests, batch conformance and acceptance inspection and tests are

given in Section 8.1, Section 8.2, and Section 8.3.

8.1. Type tests Type tests for new OHW fittings, where required, shall comply with the type approval process in accordance with T MU MD 00005 GU.

Tests shall be performed by a National Association of Testing Authorities Australia (or ASA approved equivalent) registered test facility.




8.2. Batch conformance The manufacturer or supplier shall have provisions in their quality system that assure batch

conformance for the product. Where batch tests are required, test certificates issued by a National Association of Testing Authorities Australia (or ASA approved equivalent) registered

test facility shall be supplied with the delivery of the batch.

For fittings that are in existing installations in the overhead wiring of the TfNSW Metropolitan

Heavy Rail Network at the time of publication of this standard, and for fittings that are similar to and using the same design as the existing fittings, the arrangements agreed between Sydney

Trains and the current suppliers to demonstrate batch conformance may continue to be used.

8.3. Acceptance inspection and tests The AEO receiving the material shall check that appropriate compliance and test certificates are

provided by the supplier. The AEO shall also have an acceptance inspection and testing system to ensure that the material is fit for installation and service. This acceptance inspection and

testing system shall have the following elements as a minimum:

• one or more experienced OHW engineers that have detailed knowledge of the design

intent, and the failure modes and criticality of the overhead wiring fittings

• inspection and testing requirements for each overhead wiring fitting, including sampling

requirements for different batch sizes, which are determined from the following:

o compliance with specified Transport, Australian and international standards

o risk and criticality of fitting failure and other issues during construction and

maintenance, balanced against the cost of inspection and testing

o historical information on the performance of the fitting type

o quality profile and performance history of the supplier

o feedback from constructors and maintainers

An example of such an acceptance inspection and testing system is the one that has been implemented in Sydney Trains. With the system at Sydney Trains, overhead wiring materials

are assigned inspection codes by the Senior Materials Engineer. See Appendix A on the inspection and testing requirements for each inspection category.

For AEOs that have not developed a compliant acceptance inspection and testing system, this requirement may be satisfied by having materials supplied from an AEO that has such a

system. The supply of materials from Sydney Trains should be arranged with the Logistics section of Sydney Trains.




9. OHW materials The technical requirements for the main material types used in the overhead wiring are given in Section 9.1 to Section 9.9.

9.1. Copper and high copper alloys Refer to AS 2738 Copper and copper alloys – Compositions and designations of refinery

products, wrought products, ingots and castings for the definition of copper and high copper

alloys.

9.1.1. Approved alloys and applications The approved alloy for fabrication is C11000 (electrolytic tough pitch copper) in accordance with

AS 2738.

Blades and jaws of switches shall comply with AS 1566 Copper and copper alloys – Rolled flat

products.

Cable terminating plates shall comply with AS 1566.

Feeder clamp pads shall comply with AS 1565 Copper and copper alloys – Ingots and castings,

with alloy designation C80100.

See Section 10.1 for approved materials for stranded copper conductors.

See Section 10.2 for approved materials for contact wires.

9.1.2. Prohibited applications Castings of copper or high copper alloys shall not be used in fittings that are subject to line

tension.

9.1.3. Surface finish Fabrications and castings shall be clean, smooth and free from sharp edges.

Electrical contact surfaces shall have a minimum surface finish of Ra 3, 2 in accordance with AS ISO 1302 Geometrical product specifications (GPS) – Indication of surface texture in

technical product documentation.

Machining is required to achieve this surface finish for sandcast components.

Machining is not required for investment cast components.

9.1.4. Design requirements The design for sandcast items shall specify minimum radii on all corners and adequate draw

(taper) for cored holes to facilitate the casting process.




9.1.5. Identification and marking

Fittings made from copper and copper alloy casting shall be identified and marked in accordance with the relevant fitting drawings. The marking requirements of AS 1565 need not

be complied with.

9.2. Brass and gunmetal castings Refer to AS 2738 for the definition of brass.

For the purpose of this document, gunmetal is copper alloy C92610A in accordance with

AS 1565.

See Section 12.3 for requirements for cast fittings that are subject to full line tension.

9.2.1. Approved alloys and applications The approved alloys are designations C85710 and C92610A in accordance with AS 1565.

These alloys are approved for components that are in contact with copper conductors.

9.2.2. Surface finish Electrical contact surfaces shall have a minimum surface finish of Ra 3, 2 in accordance with

AS ISO 1302.

Machining is required to achieve this surface finish for sandcast components.

Machining is not required for investment cast components.

9.2.3. Design requirements

The design for sandcast items shall specify minimum radii on all corners and adequate draw (taper) for cored holes to facilitate the casting process.

9.2.4. Acceptance criteria Micro and gas porosity shall be minimal and consistent with best casting practices.

All castings shall be free of visible shrinkage porosity.

Remedial treatment to conceal shrinkage porosity shall not be applied to line tension cast fittings.

Line tension fittings shall satisfy all relevant testing requirements of AS 1154.1 Insulator and

conductor fittings for overhead power lines – Part 1: Performance, material, general

requirements and dimensions.




9.3. Mild steel For the purpose of this document, mild steel refers to the range of steel for which AS/NZS 3678 Structural steel – Hot-rolled plates, floorplates and slabs, AS/NZS 3679.1 Structural steel –

Part 1: Hot-rolled bars and sections and AS/NZS 3679.2 Structural steel – Part 2: Welded I

sections are applicable.

9.3.1. Approved grades and applications Mild steel shall be of minimum grade 250 to AS/NZS 3678 and of minimum grade 300 to

AS/NZS 3679.1 as applicable. Approved applications include the following:

• brackets

• chains

• turnbuckles

• pull off arms

• connecting pins

• U bolts

See Section 10.6 for requirements for materials for mild steel fasteners.

9.3.2. Prohibitions Punched holes are not permitted in mild steel sections due to high stresses created around the

punched holes.

9.3.3. Welding Seal welding shall be used if two sections are to be welded together.

To prevent points where corrosion may start, holes shall not be drilled through two sections that are lapped as the interface within the hole would not be sealed so that a continuous coating of

galvanizing could not be achieved.

9.3.4. Surface finish and coating

All sharp edges and burrs shall be removed.

Mild steel fittings shall be galvanized in accordance with AS/NZS 4680 Hot-dip galvanized (zinc)

coatings on fabricated ferrous articles or AS/NZS 4792 Hot-dip galvanized (zinc) coatings on

ferrous hollow sections, applied by a continuous or a specialized process as appropriate. All

slags and scales from welds shall be removed by chipping, wire brushing or grit blasting prior to galvanizing.




9.3.5. Edge distance for fasteners

Refer to AS 1154.1 for applicable requirements. The minimum edge distances specified in AS 4100 Steel structures are not applicable to overhead wiring fittings.

9.4. Cast iron For the purpose of this document, cast iron refers to castings from the range of iron alloys for which AS 1830 Grey cast iron and AS 1831 Ductile cast iron are applicable.

9.4.1. Approved alloys and applications

Tension regulator weights shall be made from cast iron designation ISO 185/JL/150 in accordance with AS 1830.

Tension regulator pulleys shall be made from cast iron designation ISO1083/JS/700-2/S in accordance with AS 1831.

9.4.2. Prohibited applications Cast iron shall not be used for current carrying components.

9.4.3. Surface finish and coating

Cast iron fittings shall be galvanized in accordance with AS/NZS 4680. Surfaces shall be free from burrs and sharp edges before galvanizing.

9.5. Stainless steel fabrications and bolts Stainless steel refers to corrosion resistant alloy steels containing 10.5% or more chromium.

9.5.1. Approved alloys and applications See Section 10.5 for approved alloy for stainless steel bolts and U-bolts.

See Section 10.7 for approved alloy for stainless steel connecting pins.

The approved alloy for stainless steel shafts, such as tension regulator pulley shafts, is ASTM A276/A276M Standard Specification for Stainless Steel Bars and Shapes Type 431.

The approved alloy for stainless steel welded components, such as bridge attachment bolts, is

ASTM A276/A276M Type 321.

9.5.2. Prohibited applications Stainless steel shall not be used to conduct current in the OHW system. The use of stainless

steel for live equipment is only permitted in cases where there is a low resistance parallel path,




such as in U-bolt type feeder clamps, or where insulation is provided so that there can be no

current flow.

9.5.3. Heat treatment

Hot formed components shall be heat treated in accordance with the Australian and international standards specified for the components.

9.5.4. Surface finish All burrs and sharp edges shall be removed for fabricated components.

Smooth ground or polish finish shall be applied where specified in the fitting drawing.

9.5.5. Tolerances Where smooth ground or polish finish is specified, the tolerance shall be:

• + 0, - 0.08 mm for smooth ground finish

• + 0, - 0.062 mm for polish finish

9.6. Stainless steel castings See Section 9.5 for the definition of stainless steel.

9.6.1. Approved alloys and applications Grade H5A alloy to AS 2074:2003 Cast steels or equivalent shall be used for all cast austenitic

(300 series) stainless steel fittings.

The material for stainless steel wedges for contact wire splice and anchor fittings shall have properties equivalent to Type 431.


9.6.2. Prohibited applications Grade H5B alloy to AS 2074:2003 shall not be used due to problems with grain boundary

carbides.

Stainless steel shall not be used to conduct current in the OHW system. The use of stainless

steel for live equipment is only permitted in cases where there is a low resistance parallel path, or where the component is insulated so that no current can flow.

9.6.3. Heat treatment Heat treatment shall be applied in accordance with the requirements set out in the drawings of

the relevant fittings.




9.6.4. Surface treatment

Grade H5A items shall have all surfaces passivated with a suitable acid treatment.

Surface treatment is not required for Items with properties equivalent to Type 431.

9.6.5. Tolerances Unless otherwise specified on the fitting drawings, the tolerances shall be:

• +/- 1 degree for angles

• +/- 0.2 mm for linear dimensions

9.6.6. Acceptance criteria Cast stainless steel fittings shall be subject to type tests and batch acceptance tests.

Type tests

Test samples for type testing shall be provided in accordance with AS 2074:2003.

Sample fittings shall be subjected to tensile or compressive loads to prove suitability for in service duty.

Samples shall be tested to destruction to verify that the safety factor requirements are met.

Accelerated weathering and ageing tests shall be carried out to prove that the fitting is suitable

for the in service environment.

Sample fittings shall be subjected to a chemical composition analysis.

Batch acceptance tests

Samples for batch acceptance tests shall be provided in accordance with the requirements

shown on the fitting drawings.

A batch of material grade H5A fittings from the same melt is deemed acceptable when:

• the sample fittings comply with the physical dimensions specified on the drawing

• a chemical composition analysis, in accordance with AS 2074:2003, for samples from each melt meets specification

Hardness test is not required for H5A material.

A batch of material Type 431 fittings from the same melt is deemed acceptable when:

• every fitting from the batch complies with the physical dimensions specified on the drawing

• the Brinell hardness test result conducted on one fitting randomly selected from each heat

treatment batch is in the range 300 – 350 Brinell




• a chemical composition analysis, in accordance with AS 2074:2003, for samples from each

melt meets specification

Having the same fitting used for both the hardness test and the chemical composition analysis is acceptable.

9.6.7. Batch identification All stainless steel castings shall be marked to identify the manufacturer and manufacturer's job

or batch number. Markings of components shall be positioned to be visible when the components are in an assembly.

9.7. Aluminium Aluminium is not used in OHW except for signs and labels.

9.7.1. Approved alloys and applications Marine grade aluminium alloys in accordance with AS/NZS 1734 Aluminium and aluminium

alloys – Flat sheet, coiled sheet and plate shall be used for warning signs and labels.

9.7.2. Surface finish Surfaces shall be clean, smooth and free from sharp edges.

9.8. Polymeric materials The approved applications for polymeric materials are listed in Table 1. Details of the approved polymeric materials are given in the relevant fitting drawings.

Polymeric materials should be protected against degradation by ultra-violet radiation.

Table 1 - Approved polymeric materials and applications

Application Fitting No. Reference drawing number

Insulators See Section 10.4 See Section 10.4

Cantilever jib thrust washers 248/49 EL0017724

Twin contact dropper link bar 95/21 EL0017030

Insulating block for short dropper

95/29 EL0474372

Insulated sleeve for dropper lower loop

95/31 EL0474297

Insulated sleeve for short dropper

95/32 EL0474317

Insulation for connections between conductors in compound system

Nil EL0004229




Application Fitting No. Reference drawing number

Supplementary insulation for OHW fitting attachment to structures

Nil CV0518426

Secondary insulation plate and ferrule

454/3 454/4

EL0474359

9.9. Laminated timber See Section 10.9 for approved laminated timber products.

10. OHW components and fittings The technical requirements for the major OHW components and fittings are given in Section

10.1 to Section 10.9.

10.1. Stranded conductors Unless otherwise specified in this document, stranded conductors shall comply with AS 1746 Conductors – Bare overhead – Hard-drawn copper with a right-hand lay. Existing left-hand lay

conductors may remain in service.

Rope (Hauser) laid conductors shall not be used.

10.1.1. Safety factor A safety factor of at least three, when referenced to the calculated breaking load, shall apply.

10.1.2. Acceptance criteria Each drum of wire shall be covered by a certificate of compliance in accordance with AS 1746.

10.1.3. Aproved conductors for catenary wires

Catenary wires shall be made from alloy Designation C11000 – Electrolytic tough pitch (ETP) copper in accordance with AS 2738 and AS 1746.

The approved catenary wires are listed in Table 2.

Table 2 - Approved catenary wires

Nominal area (mm2)

Stranding and wire diameter (mm)

Conductor diameter (mm)

Mass (kg/m) Calculated Breaking Load (kN)

510 37/4.19 29.34 4.62 181.9

327 37/3.35 23.47 2.95 121.2

270 37/3.05 21.34 2.45 101.9




Nominal area (mm2)

Stranding and wire diameter (mm)

Conductor diameter (mm)

Mass (kg/m) Calculated Breaking Load (kN)

267 (Note 1) 61/0.093 in 21.26 2.42 103.9

179 (Note 2) 19/3.48 17.40 1.63 66.8

165 19/3.35 16.75 1.51 62.2

Note 1: 61/0.093 in (0.4 square inch) wire may remain in service but shall not be used

in new installation or replacement of existing wire.

Note 2: Auxiliary catenary in overhead wiring conductor system 27. Refer to

T HR EL 08009 ST Designations of Overhead Wiring Conductor Systems.

10.1.4. Approved conductor for in-span feeder wires

In-span feeder wires shall be made from alloy Designation C11000 – Electrolytic tough pitch (ETP) copper in accordance with AS 2738 and AS 1746.

In-span feeder wire shall have stranding of 91/1.12 mm and a maximum lay ratio of 10:1.

10.1.5. Approved conductor for span wires The span wire shall have stranding of 37/1.75 mm.

The material of the wires shall be tin bearing copper alloy consisting of ETP copper in accordance with AS 2738 with an addition of 0.30% by weight of commercially pure tin.

10.2. Contact wire Refer to T HR EL 08008 SP Contact Wire for requirements for contact wires.

10.3. Splices and termination for overhead wiring conductors Splices and terminations for stranded conductors shall comply with AS 1154.1.

Helical wrap-on fittings for stranded conductors shall also comply with AS 1154.3 Insulator and

conductor fittings for overhead power lines – Part 3: Performance and general requirements for

helical fittings.

For span wires, copper twisted jointing sleeves or U-bolt wire clips may be used where space is limited.

Type approved forked collar sockets may be used for termination of catenary and contact wires in accordance with the type approval conditions.





10.4. 1500 V dc insulators Refer to T HR EL 08013 ST Overhead Wiring Insulators for requirements for insulators.

10.5. Stainless steel threaded fasteners Stainless steel threaded fasteners include bolts, U-bolts, nuts, and bolts with welded heads or plates for attachment of OHW fittings to bridges.

10.5.1. Bolts Stainless steel bolts shall be made from ASTM A276/A276M Type 316 or Type 321 by hot forging, or from ASTM A276/A276M 300 series by cold forming.

The method of forging bolts shall be to preheat the component slowly to 800 oC to 870 oC. The temperature is then raised to 1100 oC to 1150 oC. The forging temperature should not fall below

900 °C.

Bolts made by hot forging shall be heat treated by heating to 1100 oC, followed by quenching in

water. The components may be re-heated to 600 °C prior to thread cutting.

10.5.2. U-bolts Stainless steel U-bolts shall be cold formed from ASTM A276/A276M 300 series.

The minimum bending radius shall be 7.5 mm for U-bolts of 10 mm diameter, and 13 mm for U-bolts of 12mm diameter.

10.5.3. Nuts Stainless steel nuts shall be cold formed or machined from austenitic ASTM A276/A276M 300

series.

Nuts shall be double chamfered.

10.5.4. Bridge attachment bolts Bolts with welded heads or plates that are to be cast into bridges for overhead wiring support shall be made of ASTM A276/A276M Type 321 stainless steel.

Welding shall be in accordance with AS/NZS 1554.6 Structural steel welding – Part 6: Welding

stainless steels for structural purposes.

10.5.5. Threads Thread profiles and tolerances shall be in accordance with AS 1721 General purpose metric

screw threads. M10 and M12 stainless steel threads shall have a 1.25 mm pitch and shall have

tolerance class:




• 6H for internal threads

• 6g for external threads

Threads for U-bolts shall be cut.

Threads for bolts may be cut or rolled.

10.5.6. Tightening torque Stainless steel fasteners in fittings shall be tightened in accordance with the fitting drawings or

the fitting manufacturer’s instructions. In the absence of such information, the tightening torques for M10 and M12 stainless steel fasteners shall be in the ranges specified in Table 3.

Table 3 - Tightening torques for stainless steel threaded fasteners

Bolt size (diameter) Min torque (Nm) Max torque (Nm)

M10 30 40

M12 55 60

10.5.7. Acceptance criteria

U-bolts shall be inspected for correct material and dimensions.

Bridge attachment bolts with welded heads or plates shall have a certificate confirming that the

material and the welding process are correct.

All other fasteners shall be accepted if they are certified for conformance with the relevant

Australian standards.

10.6. Galvanized mild steel threaded fasteners Grade 1010 to grade 1015 in accordance with AS 1442 Carbon steels and carbon-manganese

steels – Hot rolled bars and semi-finished products shall be used for mild steel U-bolts.

Unless otherwise specified on the fitting or arrangement drawings, mild steel bolts, screws, nuts and washers shall comply with the following Australian standards, as applicable:

• AS 1111.1 ISO metric hexagon bolts and screws –Product grade C – Bolts

• AS 1111.2 ISO metric hexagon bolts and screws –Product grade C – Screws

• AS 1112.3 ISO metric hexagon nuts – Product Grade C

• AS 1237.1 Plain washers for metric bolts, screws and nuts for general purposes – General

plan

• AS 1237.2 Tolerances for fasteners – Washers for bolts, screws and nuts – Product grades

A, C and F




10.6.1. Threads

Threads for bolts may be cut or rolled.

Threads for U-bolts shall be cut.

Thread profiles shall be in accordance with AS 1721.

10.6.2. Surface finish and coating Mild steel fasteners shall be galvanized in accordance with AS/NZS 1214 Hot dip galvanized

coatings on threaded fasteners (ISO metric coarse thread series) (ISO 10684:2004, MOD).

10.6.3. Tightening torque

Galvanized mild steel fasteners in fittings shall be tightened in accordance with the fitting drawings or the fitting manufacturer’s instructions. In the absence of such information, the

fastener shall be tightened using a standard wrench until the spring washer is fully compressed, followed by an additional one-third of a turn.

10.6.4. Design requirements Galvanized steel spring washers shall be used with all galvanized mild steel bolts and set screws.

10.6.5. Acceptance criteria U-bolts shall be checked for clean thread to ensure free nut running.

Other mild steel fasteners shall be checked for compliance with the relevant Australian

standards.

10.6.6. Prohibitions

Aluminium or copper nuts and bolts shall not be used with mild steel fasteners in a fastener assembly.

Mild steel shall not be used for bolts of a diameter less than 12 mm.

10.7. Stainless steel connecting pins Stainless steel connecting pins shall be made from ASTM A276/A276M Type 431.

10.7.1. Surface finish

Stainless steel connecting pins shall be smooth, clean and free from sharp edges and burrs.




10.7.2. Acceptance criteria

Pins shall be free from burrs and sharp edges.

Drill holes shall accept the specified split pin.

10.8. Galvanized mild steel connecting pins Galvanized mild steel connecting pins shall be made from grade 300 mild steel in accordance

with AS/NZS 3679.1.

10.8.1. Surface finish

Surfaces shall be galvanized in accordance with AS/NZS 1214.

10.8.2. Acceptance criteria Pins shall be free from burrs and sharp edges.

Drilled holes shall accept the specified split pin.

Pins shall be free of deep corrosion and forging fins.

10.9. Laminated timber beams Lignostone grade HI/2/30 E3 laminated densified wood beams may be used for:

• insulator beam in catenary stop assemblies at overbridges

• maintenance replacement of insulator beams in insulated knuckle arrangements in existing

fixed anchored overhead wiring

Laminated timber beams shall not be used in insulated knuckle arrangements for new overhead

wiring construction.

11. Fitting identification Except for conductors and commercial off the shelf items, all OHW components and assemblies are identified by fitting numbers.

Fitting numbers are obtained from the Principal Engineer Mains, Sydney Trains.

11.1. Format of fitting numbers The format of fitting numbers shall be a one, two, or three digit number optionally followed by a

'/' (forward slash) and a one or two digit sub-number.

Sub-numbers shall be used for series of similar or related components or fittings.




11.2. Similar fittings When a range of very similar fittings is created, field staff may have difficulty in correctly

distinguishing between them. These fittings shall be marked with the fitting number, sub-number or any other distinguishing feature. An example is the range of clamps that fit the various

catenary conductors, which all look very similar. Correct selection is important as they may look the same but have different radii to fit the corresponding conductors. For these clamps, each

fitting is identified by the size of conductor that the fitting is designed to fit.

12. Line tension components All tension fittings, such as fittings that are assembled in series with catenary or contact wires, shall comply with the requirements of AS 1154.1.

12.1. Connection arrangements with pins Where line tension components are connected with tongue, clevis and pin arrangements, the

hole and pin sizes shall be in accordance with AS 1154.1. The connection arrangements shall comply with the requirements given in Table 4.

Tolerances shall be in accordance with AS 1154.1.

Table 4 - Line tension components - Connection arrangements with pins

Requirement 16 mm systems 19 mm systems

Nominal diameter of pin or bolt (mm) 16 19

Nominal maximum working tension (kN) 23.3 53.3

Hole size for mild steel fabrications (mm) (Note – holes shall be drilled in line for clevises)

17.5 22

Hole size for castings and forgings (mm) 17.5 21.5

Nominal tongue thickness (mm) 16 20

Tongue thickness for mild steel fabrications (mm)

16 20

Tongue thickness for castings and forgings (mm)

15 19

Clevis opening for mild steel fabrications (mm) 17.5 min 22 min

Clevis opening for castings and forgings (mm) 18 22.5

12.2. Threaded components in tension Where threaded components are used at line tension for length adjustment, such as in

turnbuckles and eyebolts, split pins or lock nuts shall be provided to prevent the components from disconnection.




12.3. Cast fittings subject to full line tension Cast fittings that are subject to full line tension shall not be re-used after removal from the OHW.

Examples of cast fittings that are subject to full line tension include:

• catenary termination clamps

• strain insulator clevis thimble for catenary termination

• contact wire splice

• contact wire anchor fitting

Where cast fittings in existing installations are subjected to an increase in line tension during construction or maintenance activities, the fittings shall be replaced by new fittings in

accordance with currently approved arrangements.

13. Fitting drawings Fitting drawings shall comply with T MU MD 00006 ST Engineering Drawings and CAD

Requirements.

13.1. Component drawings Component drawings show one or more related components. Several components may be

shown on the same drawing where the components are similar.

Component drawings shall show the following:

• all necessary information for manufacture of the component, including the following where

applicable:

o relevant dimensions with tolerances to be applied

o welding

o machining

o heat treatment

o surface treatment and coating

• safe working loads

• fitting number for each individual fitting




13.2. Assembly drawings Assembly drawings show one or more related assemblies. Assemblies shall consist only of

components shown on component drawings and commercial off the shelf items such as washers.

Assembly drawings shall show the following:

• functional dimensions only

• all necessary instructions for assembly, including the following where applicable:

o tightening torque for fasteners

o cleaning

o application of grease and lubricants

• only the hidden outlines that are essential for the assembly of the components

• outlines of the components associated with but not part of the assembly, with type K lines in accordance with AS 1100.101 Technical drawing – Part 101: General principles




Appendix A Electrical goods inspection codes of Sydney Trains

Sydney Trains has a logistics procedure that assigns inspection codes for receiving goods in

accordance with the criticality and risk profiles of the goods. The inspection codes applicable to overhead wiring fittings and materials are listed in Table 5.

Table 5 - Sydney Trains logistics electrical inspection codes and requirements

Inspection code Inspected by Other requirements

Nil Receiving Officer Completion of relevant parts of the Material Certificate of Conformance by supplier

2R Receiving Officer Completion of relevant parts of the Material Certificate of Conformance by supplier

3X Materials Inspector authorised by Electrical Engineering

Completion of relevant parts of the Material Certificate of Conformance by supplier

4E Electrical Engineer Completion of relevant parts of the Material Certificate of Conformance by supplier

4T Receiving Officer Certificate of Timber Inspection

5E Electrical Engineer Completion of relevant parts of the Material Certificate of Conformance by supplier; Test certificates

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