DRAFT

SPECIFICATION P-141:80

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TRANSMISSION LINE EARTHWIRE FITTINGS

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PAKISTAN
WATER AND POWER DEVELOPMENT AUTHORITY
(DESIGN DEPARTMENT POWER)
 CONTENTS

0. FORWARD
1. SCOPE
2. TYPES OF EARTHWIRE FITTINGS AND MIDSPAN JOINT
3. RATINGS OF HARDWARE
4. GENERAL REQUIREMENTS
5. DIMENSIONS AND TOLERANCES
6. DESIGN AND MATERIAL

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7. TESTS

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8. VISUAL EXAMINATION

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9. VERIFICATION OF DIMENSIONS

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10. MECHANICAL TEST 01
11. RESISTANCE TO SLIPPAGE TEST
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12. GALVANIZING TEST
13. SAMPLING PLAN – ACCEPTANCE AND REJECTION
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14. MARKING AND PACKING

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15. INFORMATION TO BE SUPPLIED

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16. DRAWINGS
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PRINTING HISTORY
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First approved on 21st September, 1980

 SPECIFICATION P-141:80

TRANSMISSION LINE EARTHWIRE FITTINGS

0 FOREWORD

0.1 This standard has been introduced by WAPDA and has been prepared by the
Transmission Line Section of the office of the Chief Engineer (Design).

0.2 This standard is intended only for the purpose of technical specification to facilitate
procurement of materials and does not include provision of contract.

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0.3 This specification is subject to periodic revision as and when required.

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1. SCOPE

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1.1 This specification covers the hardware required for suspension & tension fittings and mid
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span joints of earthwire.
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2 TYPES OF EARTHWIRE FITTINGS AND MIDSPAN JOINT

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2.1 The fittings and joint described in this specification are of the following types:
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TABLE-I
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Sr. Description Designation

No.
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a) Suspension clamp for 9mm strand SF-9

b) Suspension clamp for 12mm strand SF-12
c) Tension fittings for 9mm strand TF-9
d) Tension Fittings for 12mm strand TF-12
e) Midspan Joints for 9mm strand MS-9
f) Midspan Joints for 12m strand MS-12

2.2 The hardware described above has been designated by the code numbers. These codes
have been assigned in the following manner:
i) The first 2 letter ‘S’ stands for type of fitting i.e. ‘SF’ for suspension fittings, ‘TF’
for tension fittings and ‘MS’ for midspan joints.

ii) The No. after the letters indicate the overall diameter of earthwire.
3. RATINGS OF HARDWARE

3.1 The hardware shall be of the ratings as specified in Table-II below:

TABLE-II

RATINGS OF HARDWARE

Sr. Description
No.
SF-9 SF-12 TF-9 TF-12 MS-9 MS-12

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1. Suspension clamp 5000 10300 - - - -

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vertically applied load.

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2. Shackle - - 5000 10300 - -
3. Tension clamp - - 5000 10300 - -

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4. Mid Span Joint - 01- - - 5000 1030
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4. GENERAL REQUIREMENTS
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4.1 Each tension fittings of earthwire shall consist of:

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2 Shackle
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2 Tension Clamp
1 Earthing Clamp
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4.3 All ferrous parts shall be hot dip galvanized in accordance with WAPDA Specification P-
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82 (latest revision).

4.5 The parts of hardware that mate with each other, shall not have a play clearance of more
than 2mm.

5. DIMENSIONS AND TOLERANCES

5.1 All hardware shall generally be in accordance with drawings forming a part of this
Specification.

5.2 The dimensions of these parts of hardware that mate with other hardware or that
determine the length of insulator string are binding and are shown enclosed on the
drawing.
5.3 For dimensions that are fixed and binding, the tolerance will be plus or minus 2 percent
with a maximum of 0.8mm. For dimensions that are shown as Max. or Min., there shall
be no plus and minus tolerance respectively. The tolerance is the opposite sense may
however be 4%.

6 DESIGN AND MATERIAL

6.1 Earthwire Suspension Clamp

These clamps are specifically used for the suspension of steel earthwire. The clamp
consists of the following items.

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6.1.1. Body and Keeper

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The bodies and keepers of ground wire suspension clamps shall be made of hot dip
galvanized steel, and the cotter pins of stainless steel or of copper alloy. Ends of the

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clamp body shall be curved to accommodate to take an angle of 50 degrees without
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causing any sharp bond in the wire. All surfaces shall be smoothand free from burrs or
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other manufacturing defects. Clamps shall be furnished with double hole
______________ pension and copper bond for earthing to tower body. The clamp shall
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be acc______ to Dwg. No.PDW/DF-320.

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6.1.2 Split Pin

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Split Pins are used as locking devices which prevent falling out of ball pin from the
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socket under any working conditions. They shall be made from half round brass wire
protected against corrosion by appropriate coating and shall be able to work under hot
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line conditions.

6.2 Earthwire Tension Clamp

These clamps are made from hot dip galvanized high grade forged steel and are suitable
for clamping earthwire without having to cut it. These clamps are composed of two plates
with slightly corrugated seat, connected with strong U-bolts. This clamp shall be in
accordance with Dwg. No.PDW/DF-321.

6.3 Earthing Clamp

 These clamps are made from hot dip galvanized, malleable iron. These clamps are also
composed of two plates with slightly corrugated seat connected with a U-Bolt. It shall be
in accordance with Dwg. No.PDW/DF-321.

6.4 Shackle

These shall be made from forged steel hot dip galvanized and shall be according to Dwg.
No.PDW/DF-321.

6.5 Midspan Joints

Midspan Joints shall be of the compression type. They shall be such that after
compression they shall assume a hexagonal cross-section.

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Earthing joints shall be made of hot dip galvanized steel. They shall be made according to

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Dwg. No.PDW/DF-330.

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7 TESTS
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7.1 Type Tests
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Type tests are intended to verify and establish design characteristics. They shall be made
once only on hardware identical in all essential details with those to be supplied.
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The following type tests shall be carried out in accordance with clause 8, 9 and 10.
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i) Mechanical Test On each individual item of hardware

ii) Resistance to conductor On tension clamps and mid span joints
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Slippage test only.

7.2 Sample Tests

Sample tests shall be made to verify the quality and workmanship.

i) Visual examination On each item

ii) Verification of dimensions Of hardware
iii) Mechanical test
iv) Resistance to conductor slippage On tension clamps and mid span joints only
test
v) Galvanizing test On all ferrous parts
8 VISUAL EXAMINATION

The test samples shall be examined visually for the following defects:

Visual Examination

Examination Defects
Material Construction Not as specified in relevant clauses. Not of the shape given in
relevant Drawing. Any part missing.
Finish Galvanizing not proper. Presence of burrs, black and bare spots,
dross and projections, which will interfere with proper use of the

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articles.

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9 VERIFICATION OF DIMENSIONS

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The binding dimensions of the hardware shall be measured and shall be as shown on the
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relevant approved drawings subject to the tolerance given in clause 5.
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10. MECHANICAL TEST
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The fitting shall be held in tensile testing machine in a manner approximating as nearly as
possible to the arrangement to be used in service. A Tensile load equal to one-half of the
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specified minimum failing load shall be applied and increased at a steady rate. Failure of
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the fitting shall not occur at a load less than the specified minimum failing load as per
Table-II.
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11 RESISTANCE TO SLIPPAGE TEST

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Test piece shall be assembled in accordance with manufacturer’s recommendations on

earthwire of the size and type with which it is to be used. The assembly shall be mounted
in a tensile testing machine and anchored in a manner approximating as nearly as possible
to the arrangement to be used in service. The length of earthwire joint in the test
assembly should preferably be not less than 100 times the overall diameter of the
earthwire.

A tensile load of about 50% of the minimum failing load of earthwire specified in Table-I
shall be applied and the earthwire shall be marked in such a way that movement relative to the
fitting can easily be detected without any subsequent adjustment of the fitting, the load shall be
steadily increased to 95% of the minimum failing load and then reduced to 90% of the minimum
failing load and maintained for 1 minute. There shall be no movement of the earthwire relative to
the fitting due to slip during this 1 minute period and no failure of the fitting.

12 GALVANISING TEST

This test shall be carried out on all ferrous parts complying with the following
requirements:

i) Weight of zinc coating

ii) Uniformity of zinc coating
iii) Adherence of zinc coating

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This test shall be performed in accordance with WAPDA Specification P-82 (latest
revision).

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13 SAMPLING PLAN – ACCEPTANCE AND REJECTION

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I. Sampling sizes are designated by code letters. Table-IV shall be used to find the
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applicable code letter for the particular lot or batch size for various tests specified
in this specification. While the number of units of product from each lot or batch
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which are to be inspected (sample size) and the criteria for determining the
acceptability of the lot or batch (acceptance and rejection numbers) for different
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code letters can be obtained from the Table-V given below.

II. The number of sample units inspected shall be equal to the first sample size given
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in Table-V. If the number of defective units found in the first sample is equal to or
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less than the first acceptance number, the lot shall be acceptable. If the number of
defectives found in the first sample is equal to or greater than the first rejection
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number, the lot shall be rejected, if the number of defectives found in the first
sample is between the first acceptance and rejection number, a second sample of
the size given by the plan shall be inspected. The number of defectives found in
the first and the second samples shall be accumulated. If the cumulative number
of defectives is equal to or less than the second acceptance number, the lot shall
be acceptable. If the cumulative number of defectives is equal to or greater than
the second rejection number, the lot shall be rejected.

TABLE-III Sample Size

Lot or Batch Size Sample Size for Test Sample size for dimensional
Specified in Clause and finish defects
8,9 & 13
 2 to 8 A A
9 to 15 A B
16 to 25 A C
26 to 50 A D
51 to 90 B E
91 to 150 B F
151 to 280 B G
281 to 500 B H
501 to 1200 C J

TABLE-IV Sample Acceptance Criteria

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Sample size Sample Sample Size Cumulative Acceptance Rejection

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Code Letters Sample Size Number Number
A First 1 1 0 1

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Second - - - -
B First 2 2 0 2

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Second 2 01 4 1 2
C First 3 3 0 2
Second 3 6 1 2
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D First 5 5 0 2
Second 5 10 1 2
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E First 8 8 0 2
Second 8 16 1 2
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F First 13 13 0 3
Second 13 26 3 4
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G First 20 20 1 4
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Second 20 40 4 5
H First 32 32 2 5
Second 32 64 6 7
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J First 50 50 3 7
Second 50 100 8 9

14 MARKING AND PACKING

The material shall be packed in wooden crates for export shipment to permit convenient
handling and to protect against loss or damage to final destination. Containers (wooden
crates) shall be designed for handling by forklifts, trucks and by slings around the
containers. This weight of each package should be between 100 and 150 kg.

Packages shall be designed for rough handling. All wooden crates shall be clearly marked
to indicate.
 1. Quantity
2. Name of hardware item
3. Manufacturer’s name

All packages shall be numbered consecutively so that total shipment can be readily
determined.

15 INFORMATION TO BE SUPPLIED

The following information shall be supplied with the bid and failure to supply the same
may subject the bid to disqualifications:

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i) Detailed fully dimensioned drawings of hardware for suspension strings for
bundle conductors.

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ii) Specification giving material grade & composition of all items of hardware.
iii) Catalogues/literature of standardized items.

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iv) Test Certificates
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v) One complete sample of hardware for all types of suspension strings for bundle
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conductor
vi) Detail of manufacturing & testing facilities available with manufacturers.
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16 DRAWINGS
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The following drawings form the part of this specification:

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a) Earthwire suspension and Tension Assemblies PDW/DF-319

b) Earthwire Suspension Clamp PDW/DF-320
c) Earthwire Tension Fittings PDW/DF-321
d) Earthwire mid span joint PDW/DF-330
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