T HR EL 08004 ST
Standard
Overhead Wiring Fittings and
Materials
Version 2.0
Issue date: 26 May 2021
© State of NSW through Transport for NSW 2021
T HR EL 08004 ST
Overhead Wiring Fittings and Materials
Version 2.0
Issue date: 26 May 2021
Important message
This document is one of a set of standards developed solely and specifically for use on
Transport Assets (as defined in the Asset Standards Authority Charter). It is not suitable for any
other purpose.
The copyright and any other intellectual property in this document will at all times remain the
property of the State of New South Wales (Transport for NSW).
You must not use or adapt this document or rely upon it in any way unless you are providing
products or services to a NSW Government agency and that agency has expressly authorised
you in writing to do so. If this document forms part of a contract with, or is a condition of
approval by a NSW Government agency, use of the document is subject to the terms of the
contract or approval. To be clear, the content of this document is not licensed under any
Creative Commons Licence.
This document may contain third party material. The inclusion of third party material is for
illustrative purposes only and does not represent an endorsement by NSW Government of any
third party product or service.
If you use this document or rely upon it without authorisation under these terms, the State of
New South Wales (including Transport for NSW) and its personnel does not accept any liability
to you or any other person for any loss, damage, costs and expenses that you or anyone else
may suffer or incur from your use and reliance on the content contained in this document. Users
should exercise their own skill and care in the use of the document.
This document may not be current and is uncontrolled when printed or downloaded. Standards
may be accessed from the Transport for NSW website at www.transport.nsw.gov.au
For queries regarding this document, please email the ASA at
standards@transport.nsw.gov.au or visit www.transport.nsw.gov.au
© State of NSW through Transport for NSW 2021
T HR EL 08004 ST
Overhead Wiring Fittings and Materials
Version 2.0
Issue date: 26 May 2021
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.
© State of NSW through Transport for NSW 2021
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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
© State of NSW through Transport for NSW 2021
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Overhead Wiring Fittings and Materials
Version 2.0
Issue date: 26 May 2021
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
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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
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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
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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)
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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
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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.
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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:
5.5.
•
provision of adequate rigging points
•
ease of attachment and removal of components such as split pins
Safety factors
Unless otherwise specified in this document, the safety factor shall not be less than:
5.6.
•
four for cast fittings and materials
•
three for all other fittings and materials
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.
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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.
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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.
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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.
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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.
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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.
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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,
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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:
9.6.
•
+ 0, - 0.08 mm for smooth ground finish
•
+ 0, - 0.062 mm for polish finish
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.
See Section 12.3 for requirements for cast fittings that are subject to full line tension.
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.
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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:
9.6.6.
•
+/- 1 degree for angles
•
+/- 0.2 mm for linear dimensions
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
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•
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
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9.9.
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
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
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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.
See Section 12.3 for requirements for cast fittings that are subject to full line tension.
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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 Ubolts 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:
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•
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
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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.
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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.
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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
12.2.
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
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.
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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
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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
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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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