DESIGN PRACTICE NOTE

USE OF HELICAL TERMINATIONS AND SPLICES IN

THE OVERHEAD WIRING SYSTEM
L1-NAM-INS-006 Version: 1 Effective from: 19th April 2013

Approval

Amendment Record

Approval Date Version Description

19/04/2013 1 Initial Issue under MTM

Approving Manager: Network Asset Manager Approval Date: 19/04/2013 Next Review Date: 19/04/2015
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 DESIGN PRACTICE NOTE
USE OF HELICAL TERMINATIONS AND SPLICES IN
THE OVERHEAD WIRING SYSTEM
L1-NAM-INS-006 Version: 1 Effective from: 19th April 2013

Table of Contents

1. Purpose .............................................................................................................................. 3

2. Scope ................................................................................................................................. 3

3. Abbreviations and Acronyms ........................................................................................... 4

4. Responsibilities ................................................................................................................. 4

5. Background........................................................................................................................ 4

6. The Issue............................................................................................................................ 4

7. The Requirement ............................................................................................................... 5

8. Type Approval.................................................................................................................... 5

9. MTM Requirements............................................................................................................ 5

10. Related Documents ........................................................................................................... 5

11. References and Legislation .............................................................................................. 5

12. Appendices ........................................................................................................................ 5

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 DESIGN PRACTICE NOTE
USE OF HELICAL TERMINATIONS AND SPLICES IN
THE OVERHEAD WIRING SYSTEM
L1-NAM-INS-006 Version: 1 Effective from: 19th April 2013

1. Purpose
To advise all project, maintenance and renewal staff involved in the 1500V DC overhead
wiring system that the use of helical wrap on terminations and splices is prevented from use
until further notice.
The existing assembly drawings listed in table one below allowing for:
 Termination assemblies of contact wire and catenary wire
 Splices required on catenary wire
 Installation of in span equipment such as insulation and Section Insulators
 Any other applications of helical wrap on termination are utilised on the 1500V DC
overhead system.
are withheld from use unless helical wrap on terminations are substituted with forked collar
sockets.
Table One

Drawing No. Drawing Title

D3214 / 21 161 / 181 mm² catenary terminations
D3636 Contact termination
D3637 Catenary termination
D5372 In span insulation
D7264 Contact fixed termination
D7785 BWA termination (Non Compliant Vault Version)
H6636 Twin BWA for UC Masts
Q6372 Mid Point Anchor
L9563 Section Insulator Arthur Flury High & Low speed
D8245 Mid Point Anchor inclined cantilever
D8246 Contact Wire Termination
D8254 181 mm² Copper Conductor Termination

The use of Arthur Flury Forked Collar Sockets and Splices are an acceptable substitute and
shall be used in accordance with Drawings STD-E0021, STD-E0022, D7785 and technical
installation instructions provided by the manufacturer. Refer to Appendix A for copy of the
Arthur Flury installation instructions.

2. Scope
The use of Arthur Flury Forked Collar is required for all 161 / 181 mm² catenary wire
terminations including all Mid Point Anchor and Feeder Assemblies.
Helical wraps are not to be used on any 161 / 181 catenary wire terminations.

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 DESIGN PRACTICE NOTE
USE OF HELICAL TERMINATIONS AND SPLICES IN
THE OVERHEAD WIRING SYSTEM
L1-NAM-INS-006 Version: 1 Effective from: 19th April 2013

3. Abbreviations and Acronyms

VDC Volts Direct Current
BWA Balance Weight Anchor
UC Universal Column
kN Kilo Newton
MTM Metro Trains Melbourne

4. Responsibilities
PROJECT MANAGERS – ensure that design consultants and contractors are made aware
of this practice note.
DESIGNERS – designs prepared avoid the use and reference to the use of helical
terminations and splices.
CONTRACTORS – Construction techniques to avoid the use of helical terminations and
splices
ELECTRICAL NETWORK MANAGER – maintenance staff are made aware of the failures
occurring with these terminations and splices and continue to report and assess existing
assets in service.

5. Background
The Metropolitan Rail Network consists of a 1500VDC overhead distribution system to
supply power to trains. The electric traction system comprises lengths of copper catenary
and contact wires anchored at regular intervals. At each anchor point a short length of
catenary wire is inserted between the electrical insulators and the anchor point.
The use of helical terminations and splices has been permitted in the Melbourne
Metropolitan overhead system for many years. During the change over from imperial to
metric cable in the 1980’s some potential problems were identified with the co-existence
and use of multiple wire sizes requiring some special fittings to be developed. No reported
failures of these helical wraps have occurred until the failure of 5 terminations on recent
projects.

6. The Issue
A number of failures in the 5m tails at South Morang of the helical wrap on termination has
led to two catenary and one contact tensioned wires releasing from the terminations. More
recently a failure occurred at Keon Park with a live side wrap failing leading to the disruption
of train running.
The sudden release of wires under tension is potentially life threatening to lineworkers and
is considered to be an unacceptable risk requiring an investigation of the cause of the
failure.
An additional failure has been reported at Craigieburn.
The investigation will require examination of the materials, equipment and processes used
to install the helical wraps and until the investigation is concluded the installation of further
helical wraps is prevented. All unused 161 / 181 mm² catenary helical wrap terminations and
splices are to be quarantined.
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 DESIGN PRACTICE NOTE
USE OF HELICAL TERMINATIONS AND SPLICES IN
THE OVERHEAD WIRING SYSTEM
L1-NAM-INS-006 Version: 1 Effective from: 19th April 2013

7. The Requirement
The overall requirement is to so far as is reasonably practical remove the possibility of
failure of any further helical wrap connections until the full and detailed investigation is
concluded.
For project, maintenance and renewal works, an alterative connection, the Arthur Flury
forked Collar Sockets and conical splices are an approved alternative that is permitted
within the Metropolitan Overhead System.
The use of Arthur Flury Forked Collar Sockets and Splices shall be in accordance with
Drawings STD-E0021, STD-E0022, D7785 and technical installation instructions provided
by the manufacturer.

8. Type Approval
The Arthur Flury forked collar terminations and splices have been used in the MTM
environment and will not be subjected to the MTM “type approval” process.
Any alternative products may only be used after successful application of the MTM type
approval process and approval of the Electrical Network Asset Manager.

9. MTM Requirements
This MTM Requirement replaces the termination assemblies referred to in the Overhead
Wiring Design Standards until further notice.

10. Related Documents

Not Applicable

11. References and Legislation

Arthur Flury Installation Instructions
MTM High Voltage Rules
Electricity Safety Installation regulations 2009
Infrastructure Safety Alert No. 034

12. Appendices
Appendix 1 - Arthur Flury Installation Instructions – Forked Collar Socket
Appendix 2 - Arthur Flury Installation Instructions – Conical Coupling

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 DESIGN PRACTICE NOTE
USE OF HELICAL TERMINATIONS AND SPLICES IN
THE OVERHEAD WIRING SYSTEM
L1-NAM-INS-006 Version: 1 Effective from: 19th April 2013

Appendix 1 - Arthur Flury Installation Instructions – Forked Collar Socket

Approving Manager: Network Asset Manager Approval Date: 19/04/2013 Next Review Date: 19/04/2015
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 DESIGN PRACTICE NOTE
USE OF HELICAL TERMINATIONS AND SPLICES IN
THE OVERHEAD WIRING SYSTEM
L1-NAM-INS-006 Version: 1 Effective from: 19th April 2013

Appendix 2 - Arthur Flury Installation Instructions – Conical Coupling

Approving Manager: Network Asset Manager Approval Date: 19/04/2013 Next Review Date: 19/04/2015
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