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VRIOGS 010.3
Railway Traction Substation Design
Standard
Revision:
Issue Date:
08/09/2009
ii
STATUS
DATE
QUALIFICATIONS
Document Developer
VRIOG
Infrastructure Sub
Committee
Approved
All Sections
Not Applicable
Interstate Train
(ARTC)
Not Applicable
Tram
Not Applicable
(Yarra Trams)
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iii
DISCLAIMER
The Standard is published by the Director of Public Transport for information
purposes only and does not amount to any kind of advice.
Each person is responsible for making his or her own assessment of all such
information and for verifying such information. The content of this publication is not a
substitute for professional advice.
The Director of Public Transport and VRIOG accept no liability for any loss or
damage to any person, howsoever caused, for information contained in this
publication, or any purported reliance thereon.
COPYRIGHT STATEMENT
Director of Public Transport 2005.
This publication is copyright. No part may be reproduced by any process
except in accordance with the provisions of the Copyright Act.
Where information or material is so used, it should be used accurately and the
Standard should be acknowledged as the source of the information.
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iv
TABLE OF CONTENTS
SECTION 1.0
CONVENTIONS ...............................................................................1
SECTION 2.0
DEFINITIONS ...................................................................................2
SECTION 3.0
SCOPE AND GENERAL ..................................................................3
3.1
Scope .......................................................................................................... 3
3.2
Application................................................................................................... 4
3.3
Background ................................................................................................. 4
SECTION 4.0
TRACTION POWER SUPPLY SYSTEM DESIGN ...........................5
SECTION 5.0
SAFETY IN DESIGN ........................................................................6
SECTION 6.0
RISK MANAGEMENT.......................................................................7
SECTION 7.0
BUILDING DESIGN ..........................................................................8
7.1
Building Location Considerations ................................................................ 8
7.2
Building Design ........................................................................................... 8
7.3
Amenities and Ancillary Equipment Area .................................................. 10
7.4
Ventilation.................................................................................................. 11
7.5
Security and access requirements ............................................................ 11
SECTION 8.0
TRACTION POWER SUPPLY DETAIL DESIGN ...........................14
8.1
Equipment Layout ..................................................................................... 14
8.2
Equipment Requirements .......................................................................... 15
8.3
Interconnecting Cables.............................................................................. 17
8.4
Fault Protection Equipment and Settings ............................................... 20
8.5
Electrolysis Mitigation ................................................................................ 20
8.6
Metering Requirement ............................................................................... 21
8.7
Substation Lighting and Power Requirements .......................................... 22
8.8
HV and 1500V DC Switchboards .............................................................. 24
8.9
Switchboards 415V/240V and 110V DC................................................. 25
8.10 Ergonomics ............................................................................................... 26
8.11 Safety Clearances ..................................................................................... 27
8.12 Maintainability............................................................................................ 27
8.13 Earthing Requirements.............................................................................. 28
8.14 Negative Requirements ............................................................................. 30
SECTION 9.0
ENVIRONMENTAL IMPACT ..........................................................31
9.1
General Requirements .............................................................................. 31
9.2
Energy Conservation ................................................................................. 31
9.3
Noise Abatement ....................................................................................... 31
SECTION 10.0 ALTERATIONS AND ADDITIONS TO EXISITING PLANT ............32
SECTION 11.0 DOCUMENTATION AND RECORDS ............................................33
11.1 Documentation .......................................................................................... 33
11.2 Detailed Drawings ..................................................................................... 34
11.3 Final Design and Documentation .............................................................. 36
SECTION 12.0 REVIEW AND APPROVAL PROCESS IN DESIGN.......................38
SECTION 13.0 REGULATIONS AND PUBLISHED STANDARDS.........................39
13.1 Acts, Codes, Regulations and Published Standards ................................. 39
13.2 Application & Interpretation ....................................................................... 43
APPENDIX A: Electrical Maintenance Instruction - PRO-FORMA............................44
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Department of Transport
Department
High Voltage (HV)
MAINCO
Traction
Power
System (TPS)
SCADA
(Supervisory
Control and Data
Acquisition System)
VRIOG
Substations
Tiestation
Switching Station
NOTE:
VicTrack
V/Line Passenger
Metro Trains Melbourne
Yarra Trams
Australian Rail Track Corporation
Public Transport Division of the Department of
Transport
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SCOPE
The purpose of this standard is to provide the framework for the design for Greenfield
and Brownfield railway traction substations. This standard provides the general
substation building and plant design requirements and considerations that a designer
shall adhere to.
Detailed design specifications are not provided in the standard. The designer shall
refer to, where provided, the electrical specifications for more detailed requirements
of plant to be incorporated in the substation. A list of available specifications is
provided in section SECTION 13.0.
This standard is not intended to be applied in retrospect to equipment in existing
traction substations. It is however intended to apply to alterations and modifications
to existing substations.
The requirements for the design of a traction supply substation at any location shall
include:
Complete design, including specifications, architectural, structural and detail
drawings to enable erection of the required building. The designer shall also
refer to the Substation Construction Standard.
Hardware requirements of all electrical equipment to convert incoming supply
to traction supply (at a nominal 1500V DC).
Ancilliary equipment as required.
Full consideration for personnel safety, equipment efficiency, availability,
reliability of supply, security of electrical equipment, cost effectiveness,
maintenance and maintainability aspects.
Complete detailed design, including drawings, specifications and other
documentation needed to enable total electrical construction and fit-out-works
to be completed.
The electrical design shall be based on the latest proven equipment in-service, rather
than untried principles or equipment.
Any alternative innovative designs shall be considered if the benefits and outcomes
are satisfactorily proven to the Department and its representatives.
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3.2
APPLICATION
The design of the substation building and associated infrastructure shall comply with
the latest revisions of the following acts and any regulations, by-laws or planning
schemes made under these Acts.
All noise and other environmental matters pertaining to the traction substation
installation and operation of all substation electrical equipment shall comply with all
requirements of the Environmental Protection Authority.
A detailed list of regulations, codes, standards and specifications are provided in
section SECTION 13.0 of this standard.
3.3
BACKGROUND
Prior to the development of this standard, substation design was specified on the
basis of the standards produced by the Public Transport Corporation who are no
longer in operation. Therefore the design criteria are being updated in this new
standard by bringing it up to the current technical and statutory requirements.
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The designer shall use the above mentioned information in determining the
requirements for the substation detailed design.
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The following considerations shall be made when determining the location to site the
traction substation:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
7.2
a)
The construction of the substation building shall comply with all relevant
clauses of the Australian Standards and/or the Building Code.
b)
c)
d)
Termite Control - The whole of the area of the building, and a strip 300mm
beyond the perimeter wall shall be treated against termites. The treatment
is to be carried out by a specialist firm. The Contractor shall provide
certification that the treatment has been carried out in accordance with AS
3660.
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e)
f)
g)
h)
The substation building shall be designed so that the areas hereunder form
separate rooms:
- High Voltage and 1500V DC equipment room
- Signals Switchgear room. (Only if required)
- Communications. (Only if required)
- External LV supplied switchgear room. (Only if required)
- Amenities room
- Toilet.
i)
The substation external walls and doors shall provide adequate security
commensurate with safety of personnel and security of HV equipment
contained therein and has a minimum Fire Resistance Level of
120/120/120.
External wails and roof to be of colour that is to suit the amenity of the
area.
j)
NOTE:
Internal walls shall have a Fire Resistance Level of 120/60/60 and be fitted
with doors, where required, of a matching Fire Resistance Level.
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k)
l)
The substation roof shall be bird proof, vermin proof and vandal proof. If
the roof is of metal deck construction, it shall be colorbond finish, together
with all flashings, trims and rainwater pods. Internal gutters are not
permitted. The roof shall not have any penetrations such as skylights.
m)
n)
All conduit, ducts (used or empty) and cable entries shall be temporarily
sealed during construction and permanently sealed after construction to
prevent water and vermin ingress.
o)
p)
q)
r)
s)
The floor is to be 200mm (min.) above the adjacent ground level with
required steps and landings. Tenders shall be based on a concrete slab
floor, but may offer some other floor system as an alternative tender. In
the case of the latter, full details of the alternative system and any
consequences arising from the use of such a system, shall accompany the
tender. Acceptance of a system other than concrete will be at the sole
discretion of the Department.
t)
u)
Building floor and sub floor may contain conduits and ducts to facilitate
power and control wiring to equipment.
v)
7.3
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Where the hand wash facilities are considered to be remote from the substation
battery bank and the battery back is a non-sealed type battery bank, a separate
eyewash unit shall be provided in the vicinity of the battery bank.
Substation Low Voltage and ancillary equipment, e.g. The SCADA Remote Terminal
Unit, battery, battery charger, telephone, etc. shall also be located in this area.
The area of 3 x 4 m used as the amenities area is in addition to the floor area used
by the above mentioned ancillary equipment.
It is recommended that this area, equipped with an exterior door, is the normal
means of entry to the substation.
7.4
VENTILATION
The substation shall provide security for the prevention of unauthorised entrance into
all area(s) for the purposes of safety, reliability and security reasons.
7.5.1
BUILDING ACCESS
Access doors, internal doors and gates shall provide security and of sufficient size to
enable ease of equipment installation/replacement. The dimensions and locations of
the doors and gates together with the plant layout shall be such that efficient removal
of any item of plant can be performed without the need to relocate any in service
plant.
The lock system installed after the commissioning 1 of the substation shall be such
that only authorised personnel can access each of the different rooms within the
1
Note that during construction the contractor shall have its own method of securing the substation. At
handover of the substation after commissioning the Departments representative shall install its own
locks to the doors of the substation using this standard.
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7.5.2
SUBSTATION ACCESS
All internal roadways and external access roads shall be designed for all-weather
access. Road design and construction shall comply with VicRoads or Local Authority
standards.
Turning radii shall be designed to accommodate entry of the proposed largest item to
be transported to the substation.
The depth of roadbase shall be designed to suit the traffic loads during construction
and operation of the Substation, but shall not be less than 200mm.
All internal roads (within the Substation fenced enclosure) shall be provided with
either a 2-coat bitumen seal or a minimum of 40mm thick asphaltic concrete (A.C.)
seal.
All edges of internal roadways shall be clearly marked by an approved means.
7.5.3
DOORS
a)
b)
External doors shall be heavy duty, self closing doors fitted with pinned
hinges inside of the building, cover plate for locks or heavy duty metal
roller doors with lockable chains.
c)
All internal and external doors shall be provided with keyable locks
(Lockwood type - barrels) that adhere to a classification of D2S3K4 or
better as per AS 4145.2.
d)
Doors shall have a fire resistance level equal to the walls in which they
are situated, and shall be in accordance with AS 1905.1.
e)
Doors through which equipment must pass shall be of such a size, and in
such location(s) that the largest item of equipment can be removed without
disassembly. Removable fanlights above doorways are acceptable to
allow equipment through otherwise standard height doorways.
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f)
g)
The designated normal access into the building need only be provided with
an externally accessible lock. All separate compartmented rooms shall all
have locked accessibility and emergency egress being provided by means
of panic bars fitted to locks.
7.5.4
FENCING
The substation shall be bounded by a security fence with lockable entrance gates.
All external equipment including the substation building shall be enclosed in a
compound (or switchyard) using a chain link fence. Fencing shall be earthed, and
shall maintain clearances from equipment as specified in A.S. - 2067, or as
necessary to provide truck access to any item of equipment, whichever is greater.
The fence or enclosure shall be a minimum of 3m away from the substation
buildings.
One or more sets of matching gates with a minimum length of 3600mm shall allow
access to the compound. The gates shall be equipped with heavy duty & vandal
proof means of securing the substation. Robust drop bolts, locking chains and
padlock shall be provided for each gate.
The fencing and gate design shall be such that the largest item of plant in the
substation can be transported out without the need to dismantle any part the fence or
gate.
Where the substation is prone to vandalism a concrete panel enclosure or a palisade
type fence shall be used instead of a chain link fence.
7.5.5
ALARM SYSTEM
All areas of the substation shall be covered by heat and smoke detection and an
alarm system. The alarm system shall be activated by quad sensors with motion and
IPR activation.
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14
EQUIPMENT LAYOUT
b)
c)
d)
e)
f)
g)
h)
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i)
8.2
15
Where such information is not available from the System Design Data Sheets, the
designer shall obtain the information from individual equipment manufacturer(s).
The Substation equipment will be remotely operated by a SCADA system, with
provision for local operation of all equipment. The Remote Terminal Unit of the
SCADA system will be provided and installed by the Departments representative.
The designer shall coordinate with the Department regarding the provisions to be
made in the building for SCADA equipment.
The substation, complete with electrical equipment shall be designed for minimum
whole of life costs. To this end, characteristics such as efficiency availability,
accessibility, maintainability, reliability and compatibility with the existing System are
the criteria used in the determination of minimum whole of life costs. Equipment
selected needs to be supportable for at least twenty five years after commissioning
with spare parts and technical support available.
Equipment selected shall be proven in service in a railway environment where
possible.
As per AS 3439 each switchgear assembly shall be provided with one or more
nameplates that are durable, visible and legible when the assembly is installed.
The Designer is responsible for the identification and documentation of all training,
training support, materials handling and tools, maintenance plan and maintenance
manuals which will be required by the Department's staff to effectively operate and
maintain the substation equipment throughout its economic life.
The following substances are not to be used in any part of the traction power supply
installations:
Asbestos
Polychlorinated biphenyls (PCBs)
Sulphur Hexafluoride (SF6)
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AC Bus
b)
AC Switchgear
c)
d)
Rectifier Transformer
Auxiliary Transformer
Signal Transformer (Voltage is dependent on rail corridor characteristics2)
Rectifier
e)
Rectifier Cubicle
Rectifier Control Cubicle
DC Switchgear
f)
g)
415v/240v AC Switchboard
110v DC Switchboard
Signal Power Supply Switchboard
Selection of 22kV or 11kV is determined by the distribution voltage of the supplying electrical network
operator.
3
The voltage of the signaling equipment will vary dependent on the rail corridor the work is being carried
out on. Single phase voltages of 6.6kV, 2.2kV, 1kV or 0.65kV are used in the Melbourne Metropolitan
Rail Network. ( The frequency used for signaling is 50Hz except for 2.2kVequipment which may have
50Hz or 25Hz) The preferred system for signaling is a 1kV, single phase, 2 wire, unearthed, 50Hz AC
system.
4
Indoor Dry type equipment is preferred by the Department.
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The incoming supply feeder to the bus shall be located in the middle of the
switchboard. The outgoing feeders supplying the upside 5 track signalling
equipment shall be located to the left of the incomer circuit breaker when viewed
from the front of the switchboard. The leftmost circuit breaker shall be designated
No.1.
The circuit breaker numbering shall increase to the right of the
switchboard.
All feeders supplying the downside 6 track signalling equipment shall be to the
right of the incomer circuit breaker when viewed from the front of the switchboard.
Incoming supply
2
1
To up side
To down side
SCADA
i)
j)
The preference is for 48V DC supply to power the protection and control
equipment. However specific equipment may necessitate a different supply
voltage. The secondary preference is for a 110V or 125V DC supply.
Negative Bus
k)
Earthing System
8.3
INTERCONNECTING CABLES
8.3.1
CABLING - GENERAL
8.3.1.1
As per AS 3000 section 3.9.8 the following categories of cables shall be run in
separate ducts or conduits whether they are inside or outside the substation building.
1
High Voltage.
5
6
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2
3
4
8.3.1.2
All wiring shall be to AS 3000 or AS 3008 unless otherwise approved by the
Department.
8.3.1.3
All cabling shall be multi-stranded, including those for control circuitry and light and
power.
8.3.1.4
The cables sizes shall be selected such that it does not compromise the type tested
temperature rise capability of the switchboard it is connected to.
8.3.1.5
All cables shall be of manufacture approved by the Department and shall comply with
all appropriate AS standards.
8.3.1.6
Cabling design requirements shall be shown in a Cable Schedule
which shall allocate each cable and each core (of multi core cables) a specific
number - (see AS 2067).
8.3.1.7
The Cable Schedule shall list each cable number, type, size, insulation details, cable
start and destination points, function and core numbers.
8.3.1.8
The Cable Schedule shall be read in conjunction with the Terminal Strip
Interconnection Drawing.
8.3.1.9
Cables shall not be forced into a radius less than that specified by the manufacturer.
Conduits, ducts, cables and trays and support systems shall be designed to ensure
this.
8.3.1.10
The selection of the cable shall be dependent on the fault level, load current,
temperature, voltage drop and method of installation.
8.3.1.11
In areas which could present possible future problems such as difficult access areas,
the provision of spare cables and spare cores in multi core cables or pull wires is
required.
8.3.1.12
Underground conduits and other forms of wiring enclosures shall be selected as to
AS3000 appendix C6.1 so that cables and circuits may be installed without damage.
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8.3.1.13
The design shall provide for the preparation of cable, lug and busbar termination
point in an approved manner. See AS 2067. App B.
8.3.1.14
Plans for Underground cables are required and details of location, depth,
obstructions over or under the cable route and other relevant data shall be provided
in the design.
8.3.1.15
Cables shall be installed so that they can be withdrawn if relocation and/or rewiring is
required.
8.3.1.16
Cable entries and conduits shall be temporarily sealed during construction and then
permanently sealed after construction to prevent the ingress of foreign objects, water
and vermin. The sealing method used shall not hinder the requirements of 8.3.1.15.
8.3.2
These shall be run separately from H.V. power cables and light and power cables,
with preference that control cabling between items of equipment shall be designed to
be run in floor ducts/conduits passing through or below the Substation floor.
8.3.3
Light and Power cables shall be run separately from H.V. and control cables.
They shall be adequately supported along route lengths as required under AS 3000.
8.3.4
8.3.4.1
Cables shall be designed to be run according to AS 3000 or manufacturers data,
whichever is more stringent.
8.3.4.2
The minimum bending radius of HV cables depends on the type of insulation,
sheathing and conductors comprising the cable. The minimum radius specified by
the Manufacturer shall be adhered to.
8.3.4.3
The design for terminating of HV cables shall provide for approved heat shrinkable
plastic termination (22kV, 2.2kV) or for 1500V cables, completed as per the
departments drawings.
8.3.4.4
All HV 11kV and 22kV supply and 1500V DC positive cables shall be screened.
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8.3.4.5
As permitted by AS 3000 and AS 3008.1, cable de-rating factors shall be applied so
that the grouping, spacing, enclosure and location of cables are taken into account.
The specifications of the cables shall be specified such that the current rating of the
conductors after appropriate de-rating factors have been applied is not less than the
specified rating of the circuit breaker or fuse that protects the conductor.
8.3.4.6
For new substations insulated cabling shall be used between switchgear. The cable
shall be placed in ducting, conduit or cable tray depending on the best design
solution that provides safety to personnel, cost efficiency, efficient use of space and
maintainability. Cable trays shall be free of sharp edges in order to prevent damage
to cable sheaths.
8.3.4.7
Cabling from any outdoor switchgear to an indoor switchroom shall also use
underground cabling.
8.4
The specifications for protection equipment will be provided by the Department, after
it has evaluated system parameters and requirements. The Department shall be
consulted by the designer in order to obtain the specifications required of the fault
protection equipment to be selected.
8.5
ELECTROLYSIS MITIGATION
8.5.1
BACKGROUND
In brief, electrolysis is the process by which underground pipes, cables and other
metallic structures are corroded by electric currents.
Electrified railways in Victoria are operated on direct current with the overhead
contact wire at positive potential and rails at negative potential. The rails are not
directly earthed.
Not all return negative current flows through the rails, as some current leaks off via
the rail fastenings, through the sleepers and ballast into the ground. In the ground it
may enter insulated pipes, cable sheaths and similar underground metallic structures
and flows towards the substation. At some point that current leaves the underground
structures and returns to the rails and back to the substation negative bus bar.
Corrosion is likely to occur where the current leaves the underground structures to
return to rail.
The loss from pipes and cable sheaths is confined to small areas which quickly
become perforated to the detriment of the pipe or cable.
Tests shall be conducted by the Departments Representative on the in-service
substation to determine the active electrolysis conditions and whether there is a need
for Electrolysis Mitigation Equipment.
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21
The designer shall however make provision for the future installation of Electrolysis
Mitigation Equipment in the design.
8.5.2
b)
The cubicle shall be located either in the HV switch room or in the amenities
area. As the Electrolysis Mitigation Equipment is not normally serviced by the
Substation staff of the Department, it shall be located in an area well clear of
operational HV equipment.
c)
32A, 240-230 volt AC power supply from MCCB F438 and F439 on
switchboard shall be provided in the design.
d)
Provisions shall be made for SCADA control and indication of the Electrolysis
Mitigation Equipment.
e)
f)
g)
h)
8.6
METERING REQUIREMENT
AC supply is taken from the Electrical Network Operator and sometimes, the
department's feeders, either aerially or underground, usually at 22kV, 3 phase, 50Hz.
Power metering is to be installed as per the Electrical Network Operators
requirements 7 .
The designer shall provide the designs for the following:
Electrical Network Operator requirement.
a)
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22
Departments Requirements.
b)
c)
A feeder alive relay to be installed within the metering cubicle by the Electricity
Network Operator.
A multi-core cable for feeder alive and energy management generally to be
run underground in conduit from metering cubicle to the Remote Terminal
Unit.
8.7
LIGHTING - INTERIOR
An illuminance level of 200 Lux shall be provided within the substation building and
incorporate the following:
a)
c)
8.7.2
LIGHTING - EXTERIOR
b)
The following illuminance levels shall be provided for the external areas of the
substation.
All external areas of the substation including but not limited to the marshalling boxes,
power cubicles, operating points and near control building shall have an illuminance
of 20Lux.
Road/path leading to the substation shall have an illuminance of 10 Lux.
The exterior lighting shall incorporate the following.
a)
b)
c)
d)
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8.7.3
23
EMERGENCY LIGHTING
EMERGENCY SIGNAGE
The escape route signage shall be Photo-Luminescent signage that complies with
AS 2293.
Escape route signage shall be provided to show clearly and unambiguously the
emergency escape path out of the substation building
Escape route signage shall direct personnel to areas outside the building that is
preferably not locked off or to any area that the personnel is authorised to enter.
See section 7.5.1 for access authorisation requirements.
8.7.5
c)
8.7.6
A schedule for Light and Power shall be provided which shall be read in conjunction
with the light and power layout drawing. All lights, light switches, power points shall
be numbered. The schedule shall detail the light number, switch type, wattage,
location, mounting details, cable size and type and supply MCCB numbers.
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8.8
Given below are some general requirement for HV and 1500V DC Switchboards.
More detailed requirements are provided in the electrical specifications that are listed
in section SECTION 13.0.
8.8.1
Switchboards shall be of metal-clad construction and designed to comply with AS
3000 and AS 3439.
8.8.2
Switchgear is to be fully operational from ground level, without the need to work off
platforms.
8.8.3
The switchgear in service status shall be unambiguous and should be possible to be
determined with ease by an operator.
8.8.4
Interlocking of the operation of equipment shall be provided for in the design such as
to prevent the accidental contact of personnel with live equipment. For example any
equipment that has switchgear on both sides of that equipment shall make provision
for the interlocking of the operation of the switchgear on both sides to ensure
electrical isolation from both sides.
8.8.5
Access is required to visually inspect earth and short circuit connections and
unambiguously determine the status. Also the connection shall be possible to be
viewed in dark conditions using a photo luminescent strip or internal lighting.
8.8.6
The switchboard and all it components shall be type tested as per AS 2650.
8.8.7
The switchboard rating will be such as to be able to supply the rated load as well as
well as any future load that may be part of the station strategy as would be specified
by the Department.
8.8.8
The switchboard fault rating shall be such as to withstand the maximum prospective
fault level at the switchboard.
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25
8.8.9
If required the switchboard shall have a transport split to enable manoeuvring to its
designated location.
8.8.10
Lifting lugs shall be provided to lift the switchboard using a crane if necessary.
8.9
8.9.1
Switchboards shall be of Form 4 construction as per AS 3439.
8.9.2
Cubicles shall be vermin and insect proof, and constructed to IP55 as per AS 1939
8.9.3
Switchboards in areas of moisture and dust shall at minimum have an IP65 enclosure
as per AS 1939.
8.9.4
The 415/240V switchboard shall be supplied from the substation auxiliary transformer
during normal operation.
8.9.5
Each switchboard shall include sufficient space to allow for 30 percent extra capacity
for future additions.
8.9.6
Protective devices on each switchboard shall be MCCBs.
8.9.7
Each fuse, link, MCCB, relays, switches, indications etc shall be identified by its
correct label. The designer shall provide for self adhesive black lettering on white
traffolyte labels.
8.9.8
The designer shall provide an Auxiliary Supplies Schematic showing the wiring
requirements for each switchboard.
8.9.9
A detailed layout or specification drawing shall be made of each switchboard to
enable manufacture.
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26
8.9.10
There shall be the means to connect the switchboard to an emergency supply in the
event of a loss of supply from the auxiliary transformer.
8.9.10.1
The 415/240 switchboard shall have a manually operated changeover switch to
provide supply from a temporary single phase motor generator set during an outage
of the auxiliary transformer or upstream AC supply.
8.9.10.2
A single phase motor generator inlet socket shall be provided in close proximity to
the 415/240V switchboard.
8.9.10.3
The manual changeover switch when operated shall disconnect all three phases from
the normal AC supply and then connect the generator supply to the white phase and
neutral only.
8.9.10.4
The manual change over switch shall have three stable contact positions (Auxiliary
Transformer, OFF, Generator Position) and full circuit indications.
8.9.10.5
At a minimum the following circuits shall be connected to the white phase and neutral
phases of the 415/240V switchboard.
1. All battery chargers
2. Lighting to critical areas of the switchroom/switchyard.
3. Strategically placed General Power outlets. (these GPOs shall have
signage indicating that it can be supplied from the emergency supply)
4. Any other essential services.
8.9.10.6
The requirement for generator supply for critical systems such as communications
shall be coordinated with the respective authorities or design staff.
8.10
ERGONOMICS
NOTE:
a)
b)
Building and switchyard design shall allow for heavy loads and large
doors/gates.
c)
Allowance shall be
conduits/ducts/trays.
d)
made
for
pulling
heavy
cables
through
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27
f)
8.11
SAFETY CLEARANCES
b)
There shall be sufficient space at the front of the metal clad switchgear
to easily and comfortably carry out any inspections and routine
maintenance recommended by the manufacturer. For example there
shall be sufficient space in front of the DCCBs to rack in and out the
circuit breakers. There shall also be additional space for manoeuvring
of the circuit breaker earthing truck by a person.
c)
d)
e)
f)
Any deviation from these clearance requirements shall be subject to the approval of
the Department.
8.12
MAINTAINABILITY
8.12.1
Maintenance requirements are determined during the detailed design process. The
design of the Substation, the equipment selection and layout of equipment shall be
such as to permit ease of maintenance and emergency repairs.
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28
8.12.2
The substation will undergo routine and major maintenance in accordance with
planned preventative maintenance schedules, produced for each location and each
item of equipment, in accordance with manufacturer's recommendations. In addition,
it may be necessary for operators/maintenance gang to be on site for a considerable
period of time and allowance for such shall be considered in the design.
8.12.3
Aspects of Design that have an influence on future maintenance include the
following:
a)
The design shall specify enclosures, brackets, equipment and
steelwork generally (particularly where used outdoors), that are
corrosion resistant. Stainless steel shall be used where it can be
justified.
8.13
b)
The design and layout of plant and equipment shall facilitate ease of
access, minimum time and safety for routine maintenance and
emergency repairs.
c)
EARTHING REQUIREMENTS
GENERAL
A soil resistivity test shall be carried out prior to any earthing design.
The resistivity test shall be carried out using the ESAA Substation
Earthing Guide for guidance.
b)
Earthing for the substation shall be in the form of a grid beneath the
building and switchyard and shall be designed with reference to the
design procedure as set out in AS 2067, Appendix C.
c)
d)
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29
The earth grid shall continue under and around the switchyard and
be designed such that safe step, touch and transfer potentials are
achieved.
The design shall provide for the connection of the switchroom main
earth bar to the outside earth grid. Disconnection point for testing
shall be at the main earth bar. There shall be some means to
visually and electrically confirm the connection of the switchroom
earth bar to the external earth grid.
8.13.2
In accordance with AS 2067, all outdoor metal equipment, structures and fences
shall be earthed directly to the earth grid.
8.13.3
In accordance with AS 2067, galvanised mesh or steel plate earth mats shall be used
to ensure safety of personnel who are required to operate switchgear in the
switchyard.
8.13.4
8.13.5
Apparatus to be earthed via an earth leakage protection relay (64 A) to the earth bar:
NOTE:
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30
Rectifier Cubicle
Rectifier Control Cubicle
The switchyard shall be covered with 20mm blue metal to a depth of 200mm above
finished ground level. The designer shall ensure that this is sufficient to ensure safe
levels of step, touch and transfer potentials. The coverage depth of the blue metal
may have to be adjusted to maintain satisfactory levels of step, touch and transfer
potentials.
8.14
NEGATIVE REQUIREMENTS
b)
c)
d)
e)
Notes:
1 The DC switchgear shall be mounted on an insulated floor of at least 1
Megohm (500V megger) to earth.
2
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31
GENERAL REQUIREMENTS
9.1.1
The design shall provide oil bunding for substations that have oil filled equipment.
9.1.2
Present and future requirements for land in proximity to the substations location shall
be ascertained by the Designer.
9.1.3
Present or future residential usage may dictate that all equipment be installed within
a building or behind acoustic walls.
9.2
ENERGY CONSERVATION
9.2.1
The design of a traction power supply shall facilitate conservation of energy while
maintaining it's primary role. The function of the installation shall not be reduced
below standards specified by the Department.
9.2.2
Whole of life cost shall be the basis for selecting equipment for energy conservation.
9.2.3
The designer shall notify the Department if there is any adverse affect on the
environment due to any features of the design.
9.3
NOISE ABATEMENT
9.3.1
All electrical equipment shall comply with their respective Environment Protection
Agency standard in respect to meeting noise requirements.
9.3.2
The designer shall consider EPA rulings related to problems associated with
electrical equipment noise in close proximity to residential locations.
9.3.3
Within the substation the noise level shall not exceed 85dBa for a total duration of 8
hours.
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32
NOTE:
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33
DOCUMENTATION
NOTE:
a)
b)
Full instructions and drawings for the building works and electrical fitout.
c)
d)
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34
11.2
DETAILED DRAWINGS
Locality Plan (Site access from main roads, overview of Substation building
and switchgear and track location).
Cable conduits/pipes/pits/ducts/layout.
Transformer nameplate
transformers)
details
(for
Rectifier,
Auxiliary
and
Signal
NOTE:
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35
1500V Line Isolators - outline drawing, mounting location and earthing details.
Cubicle plinths to suit rectifier, rectifier control and remote terminal unit
cubicles.
Equipment schedule.
NOTE:
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36
11.2.1
The detail design instructions is a document produced to explain how to construct the
substation in a logical sequence. It refers consistently to the design drawings and is
used to amplify points about the design drawings.
The documentation is to be read and able to be understood by the construction
workforce.
11.2.2
SYSTEM RECORDS
In order to facilitate operation and ongoing maintenance of the traction power supply
location, the designer shall provide maintenance documentation for electrical
equipment not already existing within the Department's traction system. This
documentation shall include drawings, schedules and special requirements
necessary to maintain the equipment for its estimated life and will be included into
the MAINCO Technical Maintenance Plan (TMP). Refer appendix A of this standard
for the format to use for a Technical Maintenance Plan.
11.3
11.3.1
The final design at this stage allows the full construction of a substation. The final
design and documentation requires the completion of all designs, drawings,
specifications, schedules and documentation pertinent to proprietary items fully
detailed to enable the Department to invite public tenders for the construction works.
11.3.2
The final design and specifications shall comprise:
Scale plans and detailed drawings showing the works described in these
Design Standards in sufficient detail to permit construction.
NOTE:
Works Instructions that are required to describe the work, materials and
drawings required to permit construction. The work instruction shall
describe information such as tools to use, other ancillary equipment that
will be required to carry out the work, installation instructions and
procedures etc. The work instructions shall be of sufficient detail to
enable a construction contractor to carry out the work without requiring
additional clarifications.
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37
11.3.3
The designer shall provide to the Department or its representatives, full sets of the
detailed drawings, specifications, material schedules and documentation for review,
comment and approval.
11.3.4
Upon completion, the designer shall provide to the Department or its representatives,
the original of all final drawings and a master copy of all the specifications, schedules
and any other documentation. The designer shall also provide copies of the above
information on a CD in PDF and "Microsoft Office Word - Version 11.8" format for
documents and in PDF and "Intergraph" microstation dgn' format for all drawings.
The drawings shall also be submitted to the VicTrack Drawing Management System
(DMS).
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38
NOTE:
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39
ROA Code For the installation of other partys services and Pipelines within
Railway Boundaries.
Code of Practice for the Defined Interstate Rail Network, January 2003.
Australian Standards
AS Reference
AS 1028
AS 1033
AS 1104
AS 1170
AS 1243
AS 1306
AS 1384
AS 1428
AS 1429.1
AS 1675
AS 1746
AS 1767
NOTE:
Title
Power reactors and earthing transformers.
High voltage fuses (for rated voltages exceeding 1000 V).
Informative symbols for use on electrical and electronic
equipment.
Minimum design loads on Structures (Parts 1, 3 and 4).
Voltage transformers for measurement and Protection.
High Voltage a.c. switchgear and control gear
Disconnectors (isolators) and earthing switches.
Transducers for Electrical Measurement.
Design for Access and Mobility.
Electric cables Polymeric insulated.
Current transformers Measurement and protection.
Conductors Bare overhead Hard drawn copper.
Insulating liquids Specification for unused mineral
insulating oils for transformers and switchgear.
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40
AS Reference
AS 1795
AS 1824
AS 1939
AS 2005
AS 2006
AS 2024
AS 2053
AS 2067
AS 2086
AS 2264
AS 2293
AS 2374
AS 2481
AS 2650
AS 2676
AS 2732
AS 2735
AS 3000
AS 3008
AS 3011
AS 3017
AS 3100
AS 3116
AS 3137
AS 3147
AS 3198
AS 3439
AS 3600
AS 3660
NOTE:
Title
Sheets and boards for electrical purposes.
Insulation co-ordination (phase to earth & phase to phase,
above 1 kV).
Degrees of Protection provided by enclosures for electrical
equipment (IP Code).
Low voltage fuses Fuses with enclosed fuse links.
High Voltage a.c. switchgear and control gear circuit
breakers for rated voltages above 1000 V.
High voltage a.c. switchgear and control gear Switchfuse combinations.
Non-metallic conduits and fittings.
Switchgear assemblies and ancillary equipment for
alternating voltages above 1kV.
A.C Metal-Enclosed Switchgear and Controlgear for rated
voltages above 1 kV up to and including 72.5 kV.
A.C Insulated enclosed Switchgear and Controlgear for
rated Voltages above 1 kV and up to and including 38 kV.
Emergency Evacuation lighting for buildings.
Power transformers.
All-or-nothing electrical relays (instantaneous and timing
relays).
Common specifications for high-voltage switchgear and
controlgear standards.
Guide to the installation, maintenance, testing and
replacement of secondary batteries in buildings sealed
cells.
Guide to the lightning impulse and switching impulse
testing of power transformers and reactors.
Dry - Type Power Transformers.
Wiring Rules.
Electrical Installations Selection of cables.
Electrical Installations Secondary batteries installed in
buildings Sealed cells.
Electrical Installations Testing Guidelines.
Approval and test specification General requirements for
electrical equipment.
Approval and test specification Electric Cables
Elastomer insulated For working voltages up to and
including 0.6/1 kV.
Approval and test specification Luminaires (light fittings).
Approval and test specification Electric Cables XLPE
insulated For working voltages up to and including 0.6/1
kV.
Approval and test specification Electric Cables
Elastomer insulated For working voltages up to and
including 0.6/1 kV.
Low-voltage switchgear and control gear assemblies.
Concrete Structures.
Termite management - Assessment criteria for termite
management systems
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AS Reference
AS 3771
AS 4029.2
AS 4044
AS 4100
AS 4145.2
AS 4799
AS 60044.1
AS 60044.2
AS 60146
AS 61000.3
AS/ACIF
S008:2001
AS/ACIF
S009:2001
Title
Road lighting luminaries with integral control gear.
Stationary batteries Lead Acid Valve regulated type.
Battery chargers for stationary batteries.
Steel Structures.
Locksets. Part 2 : Mechanical locksets for doors in
buildings.
Installation of underground utility services and pipelines
within railway boundaries (2000)
Instrument transformer Current transformers.
Instrument transformer Voltage transformers.
Semiconductor converters General requirements and
line commutated converters Transformers and reactors.
Electromagnetic Compatibility (EMC) Limits.
Requirements for authorised cabling products Australian
Standard
Installation requirements for customer cabling (Wiring
Rules) Australian Standard
British Standards
British
Standards
Reference
BS EN 50163
BS EN
50122.1
41
Title
VicTrack Standards
VicTrack
Standards
TS-SP-013
TS-SP-015
Title
VicTrack cable installation specification.
VicTrack Communications Network Protection Plan.
VicTrack specifications are for use under this contract and are not to be used for
other purposes or copied into other specifications without the express approval of
Vic Track. Where the specification reads VicTrack Project Manager replace
with the Principal
VRIOG Standards
VRIOGS
VRIOGS 010.3
VRIOGS 010.4
VRIOGS 010.5
VRIOGS 010.7
NOTE:
Title
Railway Traction Substation Design Standard
Railway Traction Substation Construction Standard
Train Overhead Design Standards for the Electrification of
New Routes
Traction bonding, track circuit connections and traction
interfaces
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42
VRIOGS 010.8
VRIOGS 012.1
VRIOGS 012.2
MESP 0004
MESP 0005
MESP 0006
MESP 0008
MESP 0009
MESP 0011
MESP 0013
MESP 0016
MESP 0017
MESP 0018
MESP 0019
MESP 0020
MESP 0024
MESP 0026
MESP 0027
MESP 0029
MESP 0031
MESP 0032
MESP 0035
MESP 0037
NOTE:
Title
Technical Scope and Specification for 1500 Volt Rectifier
Assembly and Control System
Contact Wire Hard Drawn Copper 161mm2
Technical Scope and Specification for Electrical Cable
400mm2 Aluminium
Conductor 1.9kv XLPE Insulated (with Metallic Screen)
Transmission Wire Hard Drawn Copper 19/2.14 70mm2
Inspection and Testing of Electrical Equipment and
Systems (Substations)
Technical Specification for an Indoor Signal Switchgear
Assembly For Traction Substation
Technical Specification for an Indoor High Voltage Single
Phase Power Transformer
Technical Scope and Specification for 1500 Volt dc Railway
Traction Rectifier Transformer
Technical Specification for SCADA Cabling in Substations
Technical Specification for a 1500 V DC Switchgear
Assembly
Technical Specification for a Stationary Control Battery &
Battery Charger Set In a Railway
Traction Substation
Technical Specification for a 22kV Outdoor Circuit Breaker
Electrically Insulated and Very Flat Flooring System
Technical Specification for an Outdoor High Voltage Single
Phase Signal Power Transformer
Technical Specification for an Outdoor High Voltage Single
Three Phase Auxiliary Power Transformer
Portable Earthing Device For JR Type 1500V D.C. Circuit
Breakers
High Voltage Operating Sticks Extendable Sets
Insulating Gloves For High Voltage Operating On
Equipment Up To 22,000 Volts Phase To Phase
Insulating Mats For High Voltage Operating On Equipment
Up To 22,000 Volts Phase To Phase
Live Line Detectors For 1500v D.C. Equipment
Type Approval & Testing Specification For Dunham Model
DE-300-1 600v 1500v Live Line Detector
NON-CONTACT A.C. LIVE LINE DETECTOR FOR HIGH
VOLTAGE A.C. EQUIPMENT UP TO 22kv
Live Conductor Covers Rated Up To 22kv
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Procedure
MESP 0038
MESP 0039
MESP 0040
MESP 0044
MESP 0045
43
Title
Portable Earthing Device For 1500v Overhead To Rail
Portable Earthing And Short Circuiting Devices
Insulated Live Line High Voltage Operating Tools
Switchyard Specifications
Portable Earthing Device for 650V Metal Clad Signal
Switchgear
Mainco specifications are only provided under a specific contract and are not to
be used for other purposes or copied into other specifications with the express
approval of Mainco.
13.2
NOTE:
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44
POSITION
NAME
SIGNATURE
Approval
Changes made to this procedure since its last revision, which affect its scope or
sense, are marked in the left margin by a vertical bar ( | ).
DATE
REV
A
AMENDMENT DESCRIPTION
Original Issue
NAME
INITIALS
PURPOSE
The purpose of this Instruction is to describe the.
SCOPE
This Instruction applies to all.. in the Melbourne Metropolitan Rail Network
area.
SPECIAL TOOLS
SPECIAL MATERIALS
SAFETY
TASK DESCRIPTION
RE-INSTATEMENT ACTION
NOTE:
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