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AS 1154.1-2004

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Insulator and conductor fittings for overhead power lines - Performance, material, general requirements and dimensions

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Superseded date

30-06-2017

Language(s)

English

Published date

01-01-2004

Publisher

Standards Australia

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1 - AS 1154.1-2004 INSULATOR AND CONDUCTOR FITTINGS FOR OVERHEAD POWER LINES - PERFORMANCE, MATERIAL, GENERAL REQUIREMENTS...
4 - PREFACE
6 - CONTENTS
8 - SECTION 1 SCOPE AND GENERAL
8 - 1.1 SCOPE
8 - 1.2 REFERENCED DOCUMENTS
10 - 1.3 DEFINITIONS
10 - 1.3.1 Batch tests
10 - 1.3.2 Calculated breaking load (CBL)
10 - 1.3.3 Class A joints
10 - 1.3.4 Class B joints
10 - 1.3.5 Conductor fittings
11 - 1.3.6 Coupling position
11 - 1.3.7 Electrical control fittings
11 - 1.3.8 Failing load
11 - 1.3.9 Full tension fittings
11 - 1.3.10 Insulator fittings
11 - 1.3.11 Insulator pins
11 - 1.3.12 Locking position
11 - 1.3.13 Nominated conductor tension (NCT)
11 - 1.3.14 Nominated holding tension (NHT)
11 - 1.3.15 Non°tension fittings
11 - 1.3.16 Protective fittings
11 - 1.3.17 Routine tests
11 - 1.3.18 Specified minimum failing load (MFL)
11 - 1.3.19 Support fittings
12 - 1.3.20 Type tests
12 - 1.4 GENERAL REQUIREMENTS
12 - 1.4.1 Defects
12 - 1.4.2 Design
12 - 1.4.3 Materials
12 - 1.4.4 Surface finish
12 - 1.4.5 Protection against corrosion
13 - 1.4.6 Forming of carbon steel components (other than stainless steel or coated sheet steel and strip)
14 - 1.4.7 Fasteners
14 - 1.5 GENERAL REQUIREMENTS FOR TESTS
14 - 1.5.1 General
14 - 1.5.2 Type tests
14 - 1.6 VERIFICATION OF DIMENSIONS
15 - SECTION 2 INSULATOR PINS
15 - 2.1 DIMENSIONS
15 - 2.2 DESIGN
15 - 2.3 IDENTIFICATION REFERENCE AND MARKING
17 - 2.4 PIN DETAILS
17 - 2.4.1 General
17 - 2.4.2 Shank thread
17 - 2.4.3 Material
17 - 2.4.4 Failing load
17 - 2.5 PIN HEAD DETAILS
17 - 2.5.1 General
17 - 2.5.2 Threads
17 - 2.5.3 Material
17 - 2.6 MECHANICAL TYPE TEST
17 - 2.6.1 General
17 - 2.6.2 Test assembly and procedure
18 - 2.6.3 Requirement
19 - SECTION 3 INSULATOR FITTINGS
19 - 3.1 GENERAL
19 - 3.2 MECHANICAL STRENGTH TYPE TEST
19 - 3.2.1 Test assembly
19 - 3.2.2 Procedure
19 - 3.2.3 Requirement
19 - 3.2.4 Extended strength test
20 - SECTION 4 TENSION FITTINGS
20 - 4.1 GENERAL
20 - 4.2 MECHANICAL STRENGTH TYPE TEST-HOLDING STRENGTH TEST FOR FULL TENSION FITTINGS
20 - 4.2.1 General
20 - 4.2.2 Test assembly
21 - 4.2.3 Procedure
21 - 4.2.4 Requirement
21 - 4.3 ELECTRICAL TYPE TEST
22 - SECTION 5 NON-TENSION FITTINGS
22 - 5.1 GENERAL
23 - 5.2 MECHANICAL TYPE TESTS FOR FITTINGS OTHER THAN TEE FITTINGS
23 - 5.2.1 General
23 - 5.2.2 Test assembly
23 - 5.2.3 Procedure
24 - 5.2.4 Requirement
24 - 5.3 MECHANICAL TYPE TESTS FOR TEE FITTINGS WHERE THE MAIN CONDUCTOR IS CONTINUOUS
24 - 5.3.1 Main conductor integrity test
24 - 5.3.2 Tensile and slip test
25 - 5.4 ELECTRICAL TYPE TESTS OPTIONAL
26 - SECTION 6 SUPPORT FITTINGS
26 - 6.1 GENERAL REQUIREMENTS FOR TESTS ON SUPPORT FITTINGS
26 - 6.2 MECHANICAL STRENGTH TYPE TESTS
26 - 6.2.1 Holding tension (withstand slip) test
26 - 6.2.2 Failing load test
26 - 6.3 CLAMP BOLT TIGHTENING TEST
28 - SECTION 7 ELECTRICAL CONTROL FITTINGS
28 - 7.1 GENERAL REQUIREMENTS
28 - 7.2 TYPE TESTS
28 - 7.2.1 Mechanical strength test
28 - 7.2.2 Electrical tests
29 - SECTION 8 PROTECTIVE FITTINGS
29 - 8.1 VIBRATION DAMPERS (STOCKBRIDGE TYPE)
29 - 8.1.1 General requirements
29 - 8.1.2 Damper efficiency type test
31 - 8.1.3 Mechanical impedance type test
31 - 8.1.4 Fatigue type test
32 - 8.1.5 Weight pull°off type test
32 - 8.2 SUBCONDUCTOR SPACERS
32 - 8.2.1 General requirements
32 - 8.2.2 Mechanical type tests
33 - 8.3 GENERAL MECHANICAL TYPE TESTS
33 - 8.3.1 Clamp slip test
33 - 8.4 GENERAL ELECTRICAL TYPE TESTS
33 - 8.4.1 General
33 - 8.4.2 Corona and radio interference voltage (RIV) test
34 - SECTION 9 DIMENSIONS AND MARKING
34 - 9.1 DIMENSIONS
34 - 9.1.1 General
34 - 9.1.2 Ball and socket couplings
34 - 9.1.3 Socket depth
34 - 9.1.4 Locking devices for socket-ended fittings
34 - 9.1.5 Bolts for shackle and clevis end fittings
34 - 9.1.6 Split pins
34 - 9.1.7 Tolerances
34 - 9.1.8 Point of measurement
34 - 9.1.9 Conductor fittings
35 - 9.1.10 Tube sizes for compression fittings
35 - 9.1.11 Palm terminals
36 - 9.2 MARKING
36 - 9.2.1 General
37 - 9.2.2 Insulator fittings
37 - 9.2.3 Conductor fittings of the compression type
48 - APPENDIX A - FORGED STEEL FOR LOW TEMPERATURE APPLICATIONS
48 - A1 GENERAL
48 - A2 CHARPY TEST REQUIREMENTS
49 - APPENDIX B - DIMENSIONS OF HEADS OF INSULATOR PINS
49 - B1 BASIS OF DIMENSIONS
49 - B2 DIMENSIONS OF THE HEADS OF INSULATOR PINS
49 - B3 GAUGING PROCEDURE FOR HEADS OF INSULATOR PINS.
54 - APPENDIX C - METHODS OF CALCULATING VIBRATION DAMPER EFFICIENCY
54 - C1 VIBRATION DAMPER EFFICIENCY
54 - C2 POWER METHOD
54 - C3 STANDING WAVE METHOD
57 - APPENDIX D - MECHANICAL IMPEDANCE TESTING
57 - D1 GENERAL
57 - D2 TEST METHOD
57 - D3 RESULTS
58 - APPENDIX E - TUBE SIZES FOR COMPRESSION FITTINGS
58 - E1 GENERAL
58 - E2 MATERIALS
58 - E2.1 Steels
58 - E2.2 Aluminium
61 - APPENDIX F - ITEMS TO BE SPECIFIED BY THE PURCHASER OR SUBJECT TO AGREEMENT BETWEEN THE PURCHASER AND MANUFACTURER
61 - F1 GENERAL
61 - F2 ITEMS TO BE SPECIFIED BY THE PURCHASER
61 - F2.1 General
61 - F2.2 Insulator pins
61 - F2.3 Insulator fittings
61 - F2.4 Tension fittings
62 - F2.5 Non°tension fittings
62 - F2.6 Support fittings
62 - F2.7 Electrical control fittings
63 - F2.8 Protective fittings
64 - APPENDIX G - MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD
64 - G1 SCOPE
64 - G2 BATCH AND ROUTINE TESTS
64 - G2.1 Statistical sampling
64 - G2.2 Typical batch and routine tests
67 - G3 PRODUCT CERTIFICATION
67 - G4 SUPPLIER'S QUALITY SYSTEM
67 - G5 OTHER MEANS OF ASSESSMENT
68 - APPENDIX H - ELECTRICAL HEAT CYCLE TEST
68 - H1 PURPOSE
68 - H2 JOINTS
68 - H2.1 General
68 - H2.2 Service temperatures
68 - H2.3 Classification for test purposes
69 - H3 TEST SPECIMENS
69 - H3.1 General
69 - H3.2 Multi-range connectors
69 - H3.3 Preparation
69 - H3.4 Data on test specimens
69 - H4 TEST ARRANGEMENTS
69 - H4.1 Test conditions
70 - H4.2 Reference conductor
70 - H4.3 Potential points
70 - H4.4 Installation of test loop
70 - H4.5 Measurements
71 - H5 HEAT CYCLE TEST PROCEDURE
71 - H5.1 General
72 - H5.2 Joints of class A
73 - H5.3 Joints of class B
75 - APPENDIX I - CORONA AND RADIO INTERFERENCE VOLTAGE TESTS
75 - I1 PURPOSE
75 - I2 DESCRIPTION OF TEST METHODS
76 - I3 GENERAL
76 - I4 TEST CIRCUIT AND INSTRUMENTS
77 - I5 CORONA AND RIV TEST PROCEDURES
77 - I6 ACCEPTANCE CRITERIA
77 - I7 TEST REPORT
78 - APPENDIX J - TYPICAL JOINT TYPES
79 - APPENDIX K - TYPICAL TEST CIRCUIT-CLASS A JOINTS
80 - APPENDIX L - TYPICAL TEST CIRCUIT-CLASS B JOINTS
81 - APPENDIX M - DIAGRAMMATIC REPRESENTATION OF HEAT CYCLE TEST SEQUENCE
82 - APPENDIX N - MATHEMATICAL ACCEPTANCE CRITERION
82 - N1 GENERAL
82 - N2 DESIGNATION OF RESISTANCE MEASUREMENTS
83 - N3 CALCULATION OF MEAN RESISTANCE
83 - N4 CALCULATION OF SLOPE OF LINE OF BEST FIT OF RESISTANCE MEASUREMENTS
83 - N5 CALCULATION OF CHANGE OF RESISTANCE AS A FRACTION OF MEAN RESISTANCE BASED ON LINE OF BEST FIT
83 - N6 COMPARISON OF M WITH ACCEPTANCE CRITERION
83 - N7 EXTEND CHANGE OF RESISTANCE CALCULATION TO TAKE ACCOUNT OF THE SCATTER OF RESISTANCE READINGS AROUND THE LINE OF...
83 - N8 COMPARE M + S WITH ACCEPTANCE CRITERION
84 - APPENDIX O - POTENTIAL POINTS

Provide users and manufacturers of fittings with definitions of terms, performance requirements, dimensions, test methods and acceptance criteria.

This Standard sets out performance and general requirements for insulator and conductor fittings (other than helical fittings, which are covered in AS 1154.3) together with the critical dimensions for a limited range of insulator pins and cast, forged or fabricated insulator fittings for use on overhead electric power lines using insulators with minimum failing loads of 70 kN, 120 kN and 160 kN. Pulling eyes provided to assist installation and fittings for insulated service lines, aerial bundled cables and high-voltage covered conductors are not covered by this Standard. NOTES: 1 Appendix G provides guidance on means of demonstrating compliance with this Standard. 2 Appendix F provides guidance on items to be specified by purchasers of insulator and conductor fittings.

Committee	EL-010
DocumentType	Standard
ISBN	0 7337 6271 9
Pages	77
PublisherName	Standards Australia
Status	Superseded
SupersededBy	AS 1154.1-2009
Supersedes	AS 1154.2-1985 AS 1154.1-1985 DR 99491
UnderRevision	DR 07133

First published as AS C345.1-1962 and AS C345.2-1967.AS C345.1-1962 revised and redesignated as AS 1154.1-1972.AS C345.2-1967 revised and redesignated as AS 1154.2-1972.Second edition AS 1154.1-1980.Second edition AS 1154.2-1980.Third edition AS 1154.1-1985.Third edition AS 1154.2-1985.AS 1154.1-1985 and AS 1154.2-1985 revised, amalgamated and designated as AS 1154.1-2004. First published as AS C345.1-1962 and AS C345.2-1967. AS C345.1-1962 revised and redesignated as AS 1154.1-1972. AS C345.2-1967 revised and redesignated as AS 1154.2-1972. Second edition AS 1154.1-1980. Second edition AS 1154.2-1980. Third edition AS 1154.1-1985. Third edition AS 1154.2-1985. AS 1154.1-1985 and AS 1154.2-1985 revised, amalgamated and designated as AS 1154.1-2004.

AS 1112.1-2000	ISO metric hexagon nuts Style 1 - Product grades A and B
AS/NZS 4680:2006	Hot-dip galvanized (zinc) coatings on fabricated ferrous articles (Reconfirmed 2017)
AS 1214-1983	Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread series)
AS 1110.1-2000	ISO metric hexagon bolts and screws - Product grades A and B - Bolts
AS/NZS CISPR 16.1.1:2004	Specification for radio disturbance and immunity measuring apparatus and methods Radio disturbance and immunity measuring apparatus - Measuring apparatus
AS 1275-1985	Metric screw threads for fasteners (Reconfirmed 2017)
AS 1931.1-1996	High-voltage test techniques - General definitions and test requirements
AS 1832-2002	Malleable cast iron
AS/NZS 2947.1:1999	Insulators - Porcelain and glass for overhead power lines - Voltages greater than 1000 V a.c. Test methods - Insulator units
AS 1442-1992	Carbon steels and carbon-manganese steels - Hot-rolled bars and semifinished products
AS/NZS 4680:1999	Hot-dip galvanized (zinc) coatings on fabricated ferrous articles
AS 2947.3-1995	Insulators - Porcelain and glass for overhead power lines - Voltages greater than 1000 V a.c. Couplings
AS/NZS ISO 9000:2000	Quality management systems - Fundamentals and vocabulary
AS/NZS CISPR 16.1.5:2004	Specification for radio disturbance and immunity measuring apparatus and methods Radio disturbance and immunity measuring apparatus - Antenna calibration test sites for 30 MHz to 1000 MHz
AS 1544.2-2003	Method for impact tests on metals Charpy V-notch (Reconfirmed 2017)
AS 1816.3-2002	Metallic materials - Brinell hardness test Calibration of reference blocks
AS 1112.4-2000	ISO metric hexagon nuts Chamfered thin nuts - Product grades A and B
AS 1448-1981	Carbon steels and carbon-manganese steels - Forgings (ruling section 300 mm maximum)
AS 1832-2007	Malleable cast iron (Reconfirmed 2017)
AS/NZS ISO 9000:2006	Quality management systems - Fundamentals and vocabulary
AS/NZS 4435.2:1999	Insulators - Composite for overhead power lines - Voltages greater than 1000 V a.c. Standard strength classes and end fittings for string insulator units (Reconfirmed 2016)
AS/NZS 1867:1997	Aluminium and aluminium alloys - Drawn tubes (Reconfirmed 2020)
AS 1733-1976	Methods for the determination of grain size in metals (Reconfirmed 2018)
AS 1444-1996	Wrought alloy steels - Standard, hardenability (H) series and hardened and tempered to designated mechanical properties
AS 1816.2-2002	Metallic materials - Brinell hardness test Verification and calibration of testing machines
AS/NZS CISPR 16.1.4:2004	Specification for radio disturbance and immunity measuring apparatus and methods Radio disturbance and immunity measuring apparatus - Ancillary equipment - Radiated disturbances
AS 1112.2-2000	ISO metric hexagon nuts Style 2 - Product grades A and B
AS 1816.2-2007	Metallic materials - Brinell hardness test Verification and calibration of testing machines
AS/NZS 2947.4:1999	Insulators - Porcelain and glass for overhead power lines - Voltages greater than 1000 V a.c. Test methods - Insulator strings and insulator sets
AS 1237.2-2002	Plain washers for metric bolts, screws and nuts for general purposes - Tolerances
AS 1154.3-1985	Insulator and conductor fittings for overhead power lines - Performance and general requirements for helical fittings
AS 1816.1-2002	Metallic materials - Brinell hardness test Test method (ISO 6506-1:1999, MOD)
AS 1112.3-2000	ISO metric hexagon nuts - Product grade C
AS 2837-1986	Wrought alloy steels - Stainless steel bars and semi-finished products
AS 1199.0-2003	Sampling procedures for inspection by attributes Introduction to the ISO 2859 attribute sampling system (Reconfirmed 2016)
AS/NZS CISPR 16.1.2:2004	Specification for radio disturbance and immunity measuring apparatus and methods Radio disturbance and immunity measuring apparatus - Ancillary equipment - Conducted disturbances
AS 1448-2007	Carbon steel and carbon-manganese steels - Forgings (ruling section 300 mm maximum)
AS/NZS 1390:1997	Cup head bolts with ISO metric coarse pitch threads (Reconfirmed 2016)
AS/NZS CISPR 16.1:2002	Specification for radio disturbance and immunity measuring apparatus and methods Radio disturbance and immunity measuring apparatus
AS/NZS 3678:1996	Structural steel - Hot-rolled plates, floorplates and slabs
AS/NZS 3679.1:1996	Structural steel Hot-rolled bars and sections
AS 1199.1-2003	Sampling procedures for inspection by attributes Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection (Reconfirmed 2016)
AS 2395-1980	Terminals for switchgear assemblies for alternating voltages above 1 kV
AS 1831-2002	Ductile cast iron
AS 1816.1-2007	Metallic materials - Brinell hardness test Test method (ISO 6506-1:2005, MOD) (Reconfirmed 2017)
AS/NZS ISO 9004:2000	Quality management systems - Guidelines for performance improvements
AS 1816.3-2007	Metallic materials - Brinell hardness test Calibration of reference blocks
AS 1444-2007	Wrought alloy steels - Standard, hardenability (H) series and hardened and tempered to designated mechanical properties (Reconfirmed 2017)
AS/NZS CISPR 16.1.3:2004	Specification for radio disturbance and immunity measuring apparatus and methods Radio disturbance and immunity measuring apparatus - Disturbance power (Reconfirmed 2016)
AS 1111.1-2000	ISO metric hexagon bolts and screws - Product grade C - Bolts
HB 18.44-1991	Guidelines for third-party certification and accreditation - Guide 44: General rules for ISO or IEC international third-party certification schemes for products
AS/NZS 1559:1997	Hot-dip galvanized steel bolts and associated nuts and washers for tower construction
AS/NZS 1866:1997	Aluminium and aluminium alloys - Extruded rod, bar, solid and hollow shapes (Reconfirmed 2020)
AS 2074-2003	Cast steels
AS 1442-2007	Carbon steels and carbon-manganese steels - Hot rolled bars and semifinished products (Reconfirmed 2017)
AS 1831-2007	Ductile cast iron (Reconfirmed 2017)
AS/NZS CISPR 16.1.3:2004 (2ND EDITION)	Specification for radio disturbance and immunity measuring apparatus and methods Radio disturbance and immunity measuring apparatus - Ancillary equipment - Disturbance power (Reconfirmed 2016)

AS 2947.3-1995	Insulators - Porcelain and glass for overhead power lines - Voltages greater than 1000 V a.c. Couplings
AS 3768-1990	Guide to the effects of temperature on electrical equipment
AS 1154.3-2009	Insulator and conductor fittings for overhead power lines Performance and general requirements for helical fittings (Reconfirmed 2019)
AS 1154.1-2009	Insulator and conductor fittings for overhead power lines Performance, material, general requirements and dimensions (Reconfirmed 2019)
AS 2067-1984	Switchgear assemblies and ancillary equipment for alternating voltages above 1 kV
AS 4899-2007	Pin insulators - Porcelain and glass for overhead power lines - Voltages greater than 1000 V a.c. (Reconfirmed 2018)
AS 3766-1990	Mechanical fittings for low voltage aerial bundled cables
AS 3608-2005	Insulators - Porcelain and glass, pin and shackle type - Voltages not exceeding 1000 V a.c.

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AS 1154.1-2004

Superseded

Table of Contents

Abstract

Scope

General Product Information

History

Standards Referenced By This Book

Standards Referencing This Book

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