IS 2121 ( Part 4 ) : 1991

( Reaffirmed 2002 )

CONDUCTORSANDEARTHWIRE
ACCESSORIESFOROVERHEADLINES
PART 4 NON-TENSION JOINTS - SPECIFICATION

UDC 621’315’171 : 621’315’65

0 BIS 1991

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002~

May 1991 Price Group 2

Conductors and Accessories for Overhead Lines Sectional Committee, ETD 37

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by
the Conductors and Accessories for Overhead Lines Sectional Committee had been approved by
the Electrotechnical Division Council.

The use cf ACSR and all aluminium conductors for power transmission is now well established.
As a natural consequence, special type of fittings are required to be used for such power lines.
This standard has been prepared with a view to ensure uniform requirements of the various types
of fittings and to provide necessary guidance to the manufacturers and the buyers.

The fittings that are used in overhead power lines are anchor clamps and suspension clamps
which could be considered either as conductor fittings or insulator fittings. Indian Standard
specification on insulator fittings has been published separately. To avoid duplication, these two
types of fittings have been included in the Indian Standard on insulator fittings.

For the revision of IS 2121 : 1962, it was decided to prepare four parts covering the individual
accessories used in overhead power lines as follows:

Specification for conductors and earthwire accessories for overhead power lines:

Part 1 Armour rods, bending wires and tapes for conductors;

Port 2 Mid-span joints and repair sleeves for conductors;
Part 3 Accessories for earth wire ( under preparation ); and
Part 4 Non-tension joints ( for example tee joints, parallel groove clamps, etc )

Opportunity has also been taken to upgrade many of the essential performance requirements of
these accessories in the light of present day International practices.

Parallel groove connectors

for use in the substations and generating stations are covered in
IS 5561 : 1470 ‘Electric power connectors’. This standard has been prepared to cover the require-
ments of parallel groove lamps intended to be used on overhead transmission lines.
NOTE-At present, dimensions and materials of accessories are not covered in the standard. Details are,
therefore, solicited on these two aspects with a view to cover them in the standard

If agreed between the purchaser and the supplier, the conductor and earthwire accessories may
also be made suitable for application of hot line techniques.

In the preparation of this standard, assistance has been derived from the following standards :

AS 1154. 1 : 1965 Insulator and conductor fittings for overhead power lines : Part 1 Performance
and general requirements. Standards Association of Australia ; and

BS 3288 Part 1 : 1973 Insulator and conductors fittings for overhead power lines : Part 1 Perfor-
mance and general requirements. British Standards Institution.

For the purpose of deciding whether a particular requirement of this standard is complied with
the final value, observed or calculated, expressing the result of a test, shall be rounded off in
accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘. The number of
significant places retained in the rounded off value should be the same as that of the specified
value in this standard.
 JS 2121( Part 4 ) : 1991

Indian Standard
CONDUCTORSANDEARTKWIRE
ACCESSORIESFOROVERHEADLINES
PART 4 NON-TENSION JOINTS - SPECIFICATION

1 SCOPE 3.5 Acceptance Tests

1.1 This standard ( Part 4 ) covers performance Tests carried out on samples taken from a lot
and general requirements for non-tension joints for the purpose of acceptance of the lot.
for joining ACSR, all aluminium and aluminium
alloy conductors. 3.6 Routine Tests
Tests carried out’on each fitting to check the
2 REFERENCES requirements which are likely to vary during
2.1 The following Indian Standards are necessary production.
adjuncts to this standard:
4 CONSTRUCTIONAL AND GENERAL
IS No. Title REQUIREMENTS

2121 Conductors and earthwires 4.1 Non-tension joints ( including tee joints )
( Part 1 ) : 1988 accessories for overhead shall be designed so that they meet the appro-
power lines: Part 1 Armour priate requirements specified in this standard.
rods, binding wires and The manufacturer may assign a rated curre@ tc
tapes for conductors ( first a joint, which shall then be the basis for the
revision ) electrical type test [see 6.6.2.3(a) 1. Other-
wise, the joint shall be tested as specified
2633 : 1986 Method of testing uniformity in 6.6.2.3(b).
of coating on zinc coated
articles ( second revision ) 4.1.1 Fitting intended to connect conductors of
two dissimilar metals shall be designed to avoid
6745 : 1972 Methods for determination
of mass of zinc coating on harmful bimetallic corrosion when erected in
zinc coated iron and steel accordance with the manufacturer’s recom-
articles mendations.
4.2 The following information shall be specified
3 TERMINOLOGY by the purchaser or, if not, declared by the
manufacturer:
3.0 For the purpose of this standard, the
definitions given in IS 2121 ( Part 1 ) : 1981, and a) Conductor size, type, breaking load and
the following shall apply. appropriate standard;
b) Whether conductor is ungreased, partly
3.1 Non-Tension Joint greased or wholly greased;
A joint for electrical connection not subjected c) Material or materials from which the non-
to line tension. tension fitting is made;
d) The dimension of dies to be used if a
3.2 Parallel Groove Clamp compression type non-tension fitting is
specified; and
A connector designed for the purpose of
connecting two or more conductors whose axes e) The recommended bolt tightening torque
ar’e parallel to each other. if bolted type fitting is specified.

NOTE - Any other requirements such as corona,

3.3 Tee Connector radio influence voltage, vibration performance and
corrosion resistance, are to be specified by the
A connector designed for the purpose of purchaser.
connecting two conductors whose faxes are per-
pendicular to each other. 4.3 Materials

3.4 Type Tests Fittings may be made from any material or

combination of materials acceptable to the pur-
Tests intended to prove that the quality and chaser which enables the fittings to reach its
design of a given type of article are in accord- specified capability. Components shall be com-
ance with the specification. patible with other components and the conductor

1
Is 2121‘(
Part4): 1991

with which they will be in contact. The pur- 6.4.1.1 General

chaser shall give due regard to any relevant
statutory regulations governing the nominated When specified by the purchaser, non-tension
holding tensions, failing load and nominated joints other than the joints shall comply with the
conductor tension. requirements of the following test.
Plastic materials shall be adequately protected 6.4.1.2 Test assembly
from the effects of exposure to solar radiation.
The joint shall be assembled in accordance with
5 MARKING the manufacturer’s recommendations on con-
ducters of the sizes and types with which it is
5.1 The fittings may also be marked with the to be used. The assembly shall be mounted in
Standard Mark. a tensile testing machine and anchored in such
a way that the test force is applied along the
6 TESTS axis of the conductor.
6.1 Classification of Tests
6.4.1.3 Procedure
6.1.1 Type Tests The procedure shall be as follows:
The following shall constitute the type tests: a) Conductors less than 12 kN breaking load
a) Visual examination ( see 6.2), When breaking load is less than 12 kN,
b) Verification of dimensions ( see 6.3 ), a tensile force of about 5 percent of the
breaking load shall be applied and the
c) Mechanical tests on joints other than tee conductor shall be marked in such a way
joints ( see 6.4 ), that movement relative to the fitting can
d) Mechanical tests on tee joints where dy. w
applicable ( see 6.5 ), sequent adjustment of the fitting, the force
shall be steadily increased to 10 percent
e) Electrical test ( see 6.6 ), and of the breaking load. This force shall be
f) Galvanizing test where applicable mainlained for 1 minute; and
( see 6.7 ).
b) Conductors 12 kN or more breaking load
6.1.2 Acceptance Tests Where the breaking load is 12 kN or
The following shall constitute the acceptance more, a tensile force of 0’6 kN shall be
tests: applied and the conductor shall be marked
in such a way that movement relative to
a) Visual examination ( see 6.2 ), the fitting can be detected easily. Without
b) Verification of dimensions ( see 6.3 ), any subsequent adjustment of the fitting,
the force shall be steadily increased to
c) Mechanical tests ( see 6.4 and 6.5 ), 1’2 kN. This force shall be maintained
d) Electrical tests ( see 6.6 ), for 1 minute.
NO’FE - For the purpose of acceptance test, the 6.4.1.4 Requirement
mechanical and electrical tests shall not be made
on non-tension joint except by special agreement There shall be no movement of the conductor
between the purchaser and the supplier. When relative to the fitting due to slip during the
required such tests shall be same as the type tests l-minute period and no failure of the fitting.
specified in 6.4 to 6.6; and

e) Galvanizing test ( see 6.7 ). 6.5 Mechanical Tests on Tee points

6.1.3 Routine Test 6.5.1 Tensile and Slip Test
Visual examination ( see 6.2 ). 6.5.1.1 General

6.2 Visual Examination When specified by the purchaser, non-tension

tee joints shall comply with the requirements of
All fittings shall be checked visually for good this test.
workmanship and smooth finish.
6.5.1.2 Test assembly
6.3 Verification of Dimensions The tee joint shall be assembled on a tee
conductor of the size and type with which it is
The dimensions shall be checked as per the to be used in accordance with the manufacturer’s
approved drawings. recommendation.
6.4 Mechanical Tests The assembly shall be mounted in a tensile
testing machine and anchored in such a way
6.4.1 Mechanical Tests on Joints Other Than Tee that the test force is applied axially to the tee
Joints conductor.

2
 IS 2121 ( Pari. 4 ) : 1991

6S.i.3 Procedure ductors of the size and type with which it is to

be used. When measured from the outlet of
a) Tee conductors less than 12 kN breaking the fitting, the length of each conductor shall
load be not less than 50 times the diameter of the
Where the breaking load of the tee con- conductor.
ductor is less than 12 kN, a tensile force The assembly shall be erected indoor so that air
of about 5 percent of the breaking load may circulate freely around it. It shall not be
shall be applied to the conductor and the exposed to draughts. The conductor(s) shall be
conductor marked in such a way that any approximately horizontal and tensioned by a
movement relative to the fitting may be force of approximately 2’5 percent of the
detected. Without further adjustment of breaking load.
the fitting, the force shall be gradually
increased to 10 percent of the breaking NOTE - A space is considered draught-free if the
load and maintained for 1 minute; and conductor temperature is WC! to 80°C above
ambieot temperature at the end of the each heatmg
b) ca5 conductors 12 kN or TmFe breaking period.

Where the breaking load of the conductor Current connections made to the conductors
is 12 kN or more, a tensile force of shall make effective contact with all those strands
0’6 kN shall be applied by the conductor of the conductors which would be taken
and the conductor marked in such a way into account in calculating their equivalent
that any movement relative to the fitting resistances.
may be detected. 6.6.2.3 Test current
outfurther The test current shall be determined as follows:
force shall be gradually increased to 1’2 kN and
maintained for 1 minute. a>Test current of fittings to which a rated
current has been assigned
6.5.1.4 Requirement The test current for fittings to which a
There shall be no movement of the tee con- rated current has been assigned shall be
ductor relative to the fitting during the l-minute rated current multiplied by fl. For
period. tee fittings the test current shall be the
rated currect multiplied by 1*12/y
6.6 Electrical Type Test ( 1.55).
6.6.1 General b) Test current for fitting to which no rated
current has been assigned
Electrical type tests shall be carried out on all
types of non-tensioned fittings, including tee The test current for fittings to which no
joints and shall comprise the heating-cycle test rated current has been assigned, shall be
specified in 6.6.2 and the short-time current test that current which raised the surface
specified in 6.6.3, using the test assembly of temperature of the reference conductor/
fitting and conductors specified in 6.6.2.2. The connector 40°C above the ambient tem-
tests shall be made with alternating current at perature and maintains that temperature
power frequency. at a steady level.
6.6.2 Heating Cycle Test The reference conductor connector shall
be that one of the conductors associated
6.6.2.1 General with the fitting in the test which reaches
the highest temperature when carrying
The heating-cycle test shall be carried out on an the same test current. The minimum
assembly of conductor(s) and fitting(s), assembled length of conductor used for determining
in accordance with the manufacturer’s recom- this current shall be 50 times the diameter
mendations and heated by passing a current of the conductor and the temperature
through the assembly. Assessment of the fitting
shall be measured near the centre of this
is made by reference to measurements of resis-
test length.
tance taken both before and after the heating-
cycle test and by visual examination of the 6.6.2.4 Procedure
opened fitting(s) after the test.
The procedure shall be as follows:
NOTE - Some fittings are intended to be used in
groups of two or more. In such cases, the heating a) Electrical resistance
cycle test should be made on a complete assembly,
as used in service. The test certificate should show i) Method - The resistance of the assem-
clearly the arrangement used in the test. bly shall be measured between points
6.6.2.2 Test assembly on the conductor either side and just
clear of the fitting and this measure-
The fitting shall be assembled in accordance with ment recorded. The measurement may
the manufacturer’s recommendations on con- be made with direct current or with

3
IS 2121( Part 4 ) : 1991

alternating current at any convenient tance shall not exceed 130 percent of the initial
frequency or by any other suitable value.
means; and
The fitting shall then be opened and there shall
ii) Requirement - The resistance measured be no sign of local heating, burning or fusing of
shall not exceed 75 percent of the any part of the fitting or of the conductor.
measured resistance of the equivalent
length of conductor. For a tee fitting, 6.6.3 Short-Time Current Test
this shall be the resistance of the equi- 6.6.3.1 Test assembly
valent length of the tee conductor.
Fitting(s) and conductors shall be assembled as
b) Heating cycle specified in 6.6.2.2 and erected indoors with the
The test current(s) shall be passed through conductors approximately horizontal.
the assembly continuously for a period 6.6.3.2 Procedure
of 30 min.
The test current shall then be interrupted The short-time current shall be passed through
and the assembly allowed to cool to 5°C the assembly using the conductors that are not
above the ambient temperature. continuous, for example for a tee fitting the
current shall flow through the main conductor
This sequence of operation shall be repeat- and the tee conductor.
ed for 250 cycles of heating and cooling.
The short-time current shall be maintained for
The fitting shall not be tightened or a period of 2 seconds.
adjusted during the test; and
NOTE -See Annex A for calculation of short-
4 Fitting temperature time current rating.
During the last five temperature cycles,
the temperature of the fitting shall be
measured while the test current is flowing. Following the test, the fitting shall be opened
and there shall be no sign of local heating,
6.6.2.5 Requirement burning or fusing of any part of the fitting or
During the last five temperature cycles, the the conductor. .
maximum temperature at any point on the
surface of the fitting, shall not exceed that of the 6.7 Galvanizing Test
conductor, or for a tee fitting the conductor with Galvanized parts shaJ1 be tested in accordance
the higher temperature. with IS 2633 : 1986 for uniformity, and IS 6745 :
At the end of the test, the resistance shall be 1972 for weight of zinc coating, and shall meet
measured again as in 6.6.2.4 (a), and this resis- the requirements of these standards.

ANNEX A
( Clause 6.6.3.3 )
METHOD OF CALCULATING TEST CURRENT FOR SHORT-TIME
CURRENT TEST ( INITIAL CONDUCTOR TEMPERATURE 50°C )

A-l To obtain the test current in amperes, genous conductors, the whole cross-sectional
multiply the appropriate cross-sectional area area should be used. For ACSR conductors,
expressed in square millimetres of the conductor the cross-sectional area of the aluminium strands
by the constant given in Table 1. For homo- only should be used.

Table 1 Conductor Type and Multiplier Constant

Conductor Type Multiplier Constant

for Test Current
(1) (2)
Hard-drawn copper 104
SC/AC 70
Ali aluminium AA 62
All aluminium alloy AAA 61
6/l ACSR
617 ACSR
3017 ACSR
5417 ACSR
;;;1;;gzRSR

;L%&Z
NOTE - The conductor cross-sectional area is calculated from the number of strands multiplied by the
area of each wire. that is. it is not the equivalent aluminium area.
Standard Mark

The use of the Standard Mark is governed by the provisions of the Bureau of Indian
Standards Act, 2986 and the Rules and Regulations made thereunder. The Standard Mark on
products covered by an Indian Standard conveys the assurance that they have been produced
to comply with the requirements of that standard under a well defined system of inspection,
testing and quality control which is devised and supervised by BIS and operated by the pro-
ducer. Standard marked products are also continuously checked by BIS for conformity to
that standard as a further safeguard. Details of conditions under which a licence for the use
of the Standard Mark may be granted to manufacturers or producers may be obtained from
the Bureau of Indian Standards.
Bnreas of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of
goods and attending to connected matters in the country.

Copyright

BIS has the copyright of all its publications. No part of these publications may be reproduced in
any form without the prior permission in writing of BIS. This does not preclude the free use, in
the course of implementing the standard, of necessary details, such as symbols and sizes, type or
grade designations. Enquiries relating to copyright be addressed to the Director ( Publication ), BPS.

Revision of Indian Standards

Indian Standards are reviewed periodically and revised, when necessary and amendments, if any,
are issued from time to time. Users of Indian Standards should ascertain that they are in
possession of the latest amendments or edition. Comments on this Indian Standard may be sent
to BIS giving the following reference :

Dot : No. ETD 37 ( 3044 )

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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