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Victorian Rail Industry Operators Group Standards

VRIOGS 010.3
Railway Traction Substation Design
Standard
Revision:

Issue Date:

08/09/2009

ii

VRIOGS 010.3 Revision A

VRIOGS 010.3 Railway Traction Substation Design Standard


Revision A
Issue Date:
APPROVAL STATUS
APPROVER

STATUS

DATE

QUALIFICATIONS

Document Developer
VRIOG
Infrastructure Sub
Committee

Approved

All Sections

Accredited Rail Operators


Metropolitan Train
(Metro Train
Melbourne)
Intrastate Train
(V/Line)

Not Applicable

Interstate Train
(ARTC)

Not Applicable

Tram

Not Applicable

(Yarra Trams)

For any queries please contact vriogs@transport.vic.gov.au.

NOTE:

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Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.3 Revision A

iii

PURPOSE OF THE STANDARD


The Standard has been created through the collaboration of members of the
Victorian Rail Industry Operators Group (VRIOG) for the purpose of establishing
standards which, if implemented throughout the Victorian Rail Network, will facilitate
the interoperability of infrastructure.
The use of the Standard is not prescribed by law but, if adopted, conformity with the
provisions of the Standard is mandatory in order that the purpose of the Standard be
achieved.

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.

NOTE:

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Any other copy of this document is uncontrolled, and the content may not be current.

iv

VRIOGS 010.3 Revision A

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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VRIOGS 010.3 Revision A

SECTION 1.0 CONVENTIONS


1. Words or phrases that appear capitalised out of context are defined within the
definitions section of this VRIOG Standard.
2. The word Shall is to be understood as mandatory.
3. The word Should is to be understood as non-mandatory i.e. advisory or
recommended.
4. Uncontrolled Standards may not be referenced within the VRIOG Standards.
These include former PTC Standards, Franchisee Standards, Franchisee
Subcontractor Standards and Infrastructure Lessee Standards.
5. Controlled Standards, including Australian Standards and other VRIOG
Standards, may be referenced but only if:
The referenced item can not be adequately explained with an amount of
text that could not reasonably be inserted into the body of the Standard.
The reader is not referenced to another Controlled Standard necessary
for the item to be adequately explained i.e. one document link only.
The referenced document is a Figure or table and could not reasonably
be included in the appendices of the Standard.
6. The format employed in the VRIOG Standards is compatible with Australian
Standards, and will be used from this point on.
7. The numbering system for the VRIOG Standards is chronologically sequential
from the point of introduction, and is not based on any form of interpretive
system.
8. The VRIOG Standards contain engineering information necessary to operate a
safe Railway. VRIOG Standards will not contain any information that can be
construed as a work instruction, procedure, process or protocol. This
information forms the basis of each individual entitys Safety Accreditation
Certification, and, as such, is outside the scope of VRIOG Standards.

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VRIOGS 010.3 Revision A

SECTION 2.0 DEFINITIONS


Terminology used and/or applied in this Standard is defined as follows:
DOT

Department of Transport

Department
High Voltage (HV)

DOT or its representative.


For the purpose of these Standards, High Voltage is defined
as a voltage exceeding 650V AC and 1500V DC.

MAINCO

Infrastructure Maintenance provider for the Victorian Rail


Traction Power Supply Assets.

Traction
Power
System (TPS)

Assets required to supply, switch and protect the 1500V DC


supplies to electrified trains. Assets may take the form of:

SCADA
(Supervisory
Control and Data
Acquisition System)
VRIOG

Substations

An Electrical Installation equipped to


transform and rectify HV AC supplies
before distributing it through 1500V DC
Circuit Breakers to the overhead system.

Tiestation

An Electrical Installation not equipped to


transform and rectify HC AC supplies,
but equipped with 1500V DC circuit
breakers to distribute traction power
through the overhead system.

Switching Station

An Electrical Installation equipped with


more than one HV AC circuit breaker, but
not to transform and rectify traction
power.

Term used to describe a system of remote control and


indication of substation equipment. SCADA systems involve
one or more Control rooms, communication systems and
substation-based Remote Terminal Units.
The Victorian Rail Industry Operators Group comprising the
following members:

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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VRIOGS 010.3 Revision A

SECTION 3.0 SCOPE AND GENERAL


3.1

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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VRIOGS 010.3 Revision A

3.2

APPLICATION

In addition to the fundamental standard of designing installations in accordance with


the best engineering practices with full regard being paid to personnel and general
public safety, economic factors, energy conservation and maintenance requirements,
the design shall comply with the relevant standards and recommendations. All
equipment and installation instructions shall conform with the applicable clauses of
recognised Standards, rulings and recommendations. Wherever a conflict exists in
the requirements of these Standards, rules and recommendations, the following
order of precedence will be observed in ascending order:

Victorian Rail Industry Operators Group Standards (VRIOGS), this Design


Standard and related rail industry standards.
The Victorian Service and Installation Rules.
Most recent relevant Australian Standards.
Most recent relevant British and European Standards.
Most recent relevant US Standards.
Most recent recommendations of the International Electro-technical
Commission.

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.

The Building Control Act.


Melbourne and Metropolitan Board of Works Act.
Town Planning and Environment Act.

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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VRIOGS 010.3 Revision A

SECTION 4.0 TRACTION POWER SUPPLY SYSTEM DESIGN


The Department in consultation with key stakeholders determines the configuration,
capacity and locations of the rail traction power supply assets. These outcomes are
provided to the designer as inputs to the detailed design.
These are advised in the form of:

Proposed changes to infrastructure.

Proposed changes to traction system.

Nominal ratings and configuration of substation equipment.

Location of substation and layout of HV & DC connections.

The designer shall use the above mentioned information in determining the
requirements for the substation detailed design.

NOTE:

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Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.3 Revision A

SECTION 5.0 SAFETY IN DESIGN


Safety in design is the integration of hazard identification and risk assessment
methods in the design process to eliminate or minimise the risks of injury or damage
throughout the life of the item being designed
The designer shall ensure that the design of the substation incorporates safety to
humans during construction, installation, commissioning and throughout the
operational life of the substation.
The following general process shall be adhered when carrying out the design of the
substation:
Identification of all safety related issues that would affect humans during the
construction, installation, commissioning and throughout the life of the
substation.
Elimination of as many as possible safety related issues that have been
identified. The elimination of the hazards shall be by designing out the
hazards.
All affects of hazardous issues that can not be designed out shall be
minimised by way of further design.
Due to the multi-disciplinary nature of a substation design, the affects on the
operational safety shall be examined for potential hazards. A number of
alternative review processes or methodologies may be used to identify any
hidden safety issues with the overall design.
In addition to the above the following specific requirements shall be incorporated in
the design, but not limited to:
Provision of Residual Current Devices in areas of the substation where there
is significant risk of an electric shock due to the failure of other protection
measures and operator carelessness.
Signage, warning signs or instructions shall be displayed where there is a
potentially ambiguous or dangerous situation.
The safety of vandals or children who may breach the security fences shall be
considered.
In addition to the above requirements the designer shall look to the following
documents for guidance:
The Australian Safety and Compensation Council (ASCC) Guideline on the
Principles of Safe Design (provides references to the relevant legislation and
codes of practice in Australia)
WorkSafe Victorias guide on Designing safer buildings and structures.

NOTE:

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Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.3 Revision A

SECTION 6.0 RISK MANAGEMENT


The designer shall maintain a risk management process that includes works from the
planning phase until the completion and handover of the substation design. The risk
management process shall comply with AS 4360. The following essential aspects of
risk management shall be included in the designers risk management process.

Communicate and Consult with the Department, Maintenance Contractor, sub


consultants and any other stakeholder
Establish the context in which the risk management process is to be carried
out
Identify when, where, why and how undesirable events could occur to
jeopardise the design and subsequent construction, operation and
maintenance of the substation
Analyse the identified risks, consequences, level of risk and evaluate how to
control them
Evaluate the levels of risk against pre-established criterion and decide on
extent, treatment and priorities of the risks
Develop strategies and action plans to reduce risks
Monitor the effectiveness of the risk management process and review the
risks and strategies and action plans.

Risks related to safety, environmental impact, quality of design, reliability, on time


delivery and future construction & maintainability should be among the risks
considered by the contractor.
The contractor shall document its risk management process and also maintain an up
to date risk register that documents the risks as per its risk management process.

NOTE:

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VRIOGS 010.3 Revision A

SECTION 7.0 BUILDING DESIGN


The design and sizing of the building shall only proceed once the equipment to be
housed has been selected and it is confirmed what specific equipment will be used.
The building design shall take in to account the confirmed equipment dimensions, all
required clearances as well as any other spatial considerations.
The design of the building to house the electrical installation shall consider the
following:
7.1

BUILDING LOCATION CONSIDERATIONS

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

Availability of incoming HV AC supply.


Site access - all weather heavy vehicle access for construction and
future maintenance requirements
Space availability and site topography
Location from track and orientation to track
Amenities require stormwater and sewerage connections.
Site parameters current and future industrial/residential
Electrical sectioning location of 1500V overhead sectioning point. (
the existing sectioning points may have to be changed to facilitate the
location of sectioning points adjacent to substations)
Security considerations
Susceptance of site to adverse whether conditions
Site specific environmental requirements and considerations
BUILDING DESIGN

a)

The construction of the substation building shall comply with all relevant
clauses of the Australian Standards and/or the Building Code.

b)

The substation building shall be of solid brick construction or tilt up


concrete slab construction and shall be built to last for at least 75 years
without requiring any major maintenance.

c)

All structures, buildings and footings shall be designed as per AS 1170


together with the following additional loadings:
Short Circuit Forces
Operational Loads
Manufacturers specified loading data, and
Any other relevant loads.

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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VRIOGS 010.3 Revision A

e)

Stormwater Drainage - The drainage system shall be designed for a


minimum return period of 20 years for the local area. The drainage system
shall be sufficient to collect and discharge water which is trapped by site
features such as footings, cable trenches, buildings and fences. Internal
guttering is not permitted.
All stormwater shall be collected and
discharged beyond the site of the substation to the satisfaction of the local
Drainage Authority. The design shall also adhere to the requirements of
section SECTION 9.0 with respect to oil containment.

f)

Sewerage Installation The substation sewerage shall be connected to


the local sewer network and shall be carried out to the satisfaction of the
Sewerage Authority.

g)

It is mandatory to have a water supply to the substation. The preference is


for mains connected water supply. If mains water supply is not available a
rainwater tank shall be used.
The rainwater tank if required shall have a capacity of 7 kilolitres with
corresponding galvanized steel framed tank stand base. The rainwater
tank shall be positioned such that it can be supplied from the Substation
Building gutters. The water tank shall be reticulated to the Amenities
Building toilet and sinks by means of a suitable pump. The pump shall be
located in a secure, concealed position such that any discharge of water
from failure of the pump shall be adequately drained. The rainwater tank
shall be provided with a vermin proof stainless steel fine mesh screen with
galvanized finish over the top opening and an overflow outlet. The
overflow outlet shall be connected to the stormwater drainage system.

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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10

VRIOGS 010.3 Revision A

k)

Walls shall be capable of fastening electrical conduits, electrical cables,


switches and other equipment thereto.

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)

The building shall be designed and constructed to prevent entry of water.


Equipment mounted within the switchyard shall be designed for outdoor
use.

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)

No ceiling lining is required. Birdwire supporting double sided foil


insulation with mineral wool to meet R3 rating is sufficient.

p)

No windows are permitted in substation walls. Light and ventilation shall


be achieved by other approved means.

q)

The design and specification of electrical equipment shall be based on


ambient air temperature range - 4C to 45C in shady, wind-free conditions

r)

Flooring under both AC and DC switchgear shall meet manufacturers


recommended tolerances. In addition, it is a system requirement that the
flooring under the DC switchgear be insulated to 1 Mega ohm from earth.

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)

Preference is given to an epoxy floor to reduce dust within the building.

u)

Building floor and sub floor may contain conduits and ducts to facilitate
power and control wiring to equipment.

v)

Equipment mounted within a switchyard shall be mounted on reinforced


concrete pads.

7.3

AMENITIES AND ANCILLARY EQUIPMENT AREA

An amenities area with unrestricted floor area of 3m x 4m is required to


accommodate a team of 5 people. A desk shall be placed in the area for the
purposes of login in and out, report writing and having lunch
Adjacent to the
amenities room shall be a sewered toilet with a hand wash facility.

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VRIOGS 010.3 Revision A

11

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 Contractor shall design a system of forced ventilation in order to maintain an


ambient condition that is within the operating parameters of the substation
equipment. A forced ventilation system shall include a filtered intake to keep the
building reasonably dust free. Fans should be arranged to provide positive pressure
(blowing air into the building at low level) with exhaust air discharging at a high level.
Anti-condensation control shall be incorporated if either specific equipment or site
conditions require it.
All ventilation breather slots shall be vermin proofed with fine gauze. There shall be
no roof penetrating ventilation ducts or any other ducts located above any electrical
equipment.
The noise requirements shall adhere to section 9.3.
The Contractor will submit for approval computations which demonstrate compliance
with these requirements.
7.5

SECURITY AND ACCESS REQUIREMENTS

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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12

VRIOGS 010.3 Revision A

substation. The access authorisation is as follows;

All personnel can gain access to the amenities room.


HV Personnel can gain access to any part of the substation.
Signalling personnel can gain access to only the signalling room and amenities
room.
Communications personnel can gain access to only the communications rooms
and amenities area.
The appropriate personnel can gain access to only the external LV supplies
switchgear room and amenities area.

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)

External doors and frames should be of solid construction. These doors


should be fitted with quality locksets, which comply with the Building Code
of Australia (Fire Regulations) and AS 4145.2

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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VRIOGS 010.3 Revision A

13

f)

A minimum of two emergency doors shall be provided from all High


Voltage and 1500V DC areas, generally located diagonally opposite each
other and purposely located to allow ready emergency exit.

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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VRIOGS 010.3 Revision A

SECTION 8.0 TRACTION POWER SUPPLY DETAIL DESIGN


There are many requirements that the designer shall adhere to. Some specific
requirements have been presented in this section. Also presented in this section are
issues that the designer shall consider in the design.
8.1

EQUIPMENT LAYOUT

The design of electrical equipment layout shall consider:


a)

What equipment is to be mounted/located within the substation building.

b)

Whether an outdoor switchyard is to be provided. The aesthetics, noise


and environmental impact of equipment together with costs and land
availability shall determine whether the switchyard is to be outdoor or
indoor. The preference of the Department is for an indoor substation with
all equipment enclosed within the building.

c)

Specific details of each equipment item (i.e. rating, physical dimensions,


weight, exact location of incoming/outgoing cables etc.)

d)

Grouping arrangement of equipment (i.e. Similar or related items should be


grouped together).

e)

It is a requirement of the Department that the High Voltage and 1500V DC


Traction Substation equipment, the signal switchgear, toilet and mess
areas are in separate rooms separated by 120/60/60 Fire Resistance Level
Walls. If these levels cannot be met the achievable levels of fire resistance
shall be submitted for approval by the Department.

f)

Layout of equipment in a logical sequence from input to output with a


minimum number of crossovers.

g)

Clearances from equipment to building walls/switchyard fences and other


equipment.
a. Clearance sufficient to allow for future maintenance requirements
dependent on the individual equipment. The clearances shall be such
that maintenance personnel have unrestricted access to carry out
inspections, maintenance and removal of equipment.
b. Sufficient substation entry space is required for the entry and removal
of equipment in and out of the building.
c. The layout of the switchroom/switchyard will be such it enables
efficient movement of equipment in or out of the area. The layout
shall not be such that in service equipment requires temporary
relocation.

h)

NOTE:

Provision of sufficient area/access for installation, maintenance, operating,


inspections and earthing functions so that all switchgear can be operated
from ground level without th need to work off platforms.

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VRIOGS 010.3 Revision A

i)
8.2

15

As a guide only, existing layouts of traction power supply installation may


be perused. A concept layout drawing may be provided on request.
EQUIPMENT REQUIREMENTS

For each item of electrical equipment it is imperative to obtain specific information


such as:

Performance characteristics - mechanical/noise.


Performance characteristics - electrical/protection requirements.
Physical size, mounting details.
Terminal connections - (heavy current, control wiring)
Recommended spares and their availability.
Maintenance requirements and procedures.
Environmental impacts and requirements.
Required clearance from other equipment.
Required clearance for maintenance and inspections.

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)

In conjunction with the Substations System Design requirements the completed


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VRIOGS 010.3 Revision A

traction substation will comprise of one or more of the following equipment:


a)

AC Bus

b)

AC Switchgear

c)

Rectifier AC Circuit Breaker (22kV or 11kV) 2


Feeder AC Circuit Breaker (22kV or 11kV)1
Auxiliary Transformer Fuse Switch (22kV or 11kV) 1
Signal Transformer Fuse Switch (22kV or 11kV) 1
Signal Switchgear (Voltage is dependent on rail corridor characteristics 3 )
Transformers

d)

Rectifier Transformer
Auxiliary Transformer
Signal Transformer (Voltage is dependent on rail corridor characteristics2)
Rectifier

e)

Rectifier Cubicle
Rectifier Control Cubicle
DC Switchgear

f)

Rectifier DC Circuit Breaker (1500v)


Feeder DC Circuit Breaker (1500v)
DC Line Isolators (1500v)
Switchboards

g)

415v/240v AC Switchboard
110v DC Switchboard
Signal Power Supply Switchboard

One Incoming Supply Circuit Breaker.


Two or more outgoing Feeder Circuit Breakers.

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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VRIOGS 010.3 Revision A

17

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

Figure 8-A : Signalling Switchboard Requirements


h)

SCADA

Remote Terminal Unit(s)


Ancillarys PABX Phone, Communications, Pilot entry termination .

i)

Battery Charger and Sealed Battery Bank (48V)

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

Upside is the direction towards Melbourne CBD


Downside is the direction away from the Melbourne CBD
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VRIOGS 010.3 Revision A

2
3
4

1500V DC power cables. (Negative and Positive cables in separate


conduits or trenches)
Light and power cables.
Local and remote control, telephone and communication cables.

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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VRIOGS 010.3 Revision A

19

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

LOCAL CONTROL AND SCADA CABLES

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.

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

HEAVY POWER/HIGH VOLTAGE AND 1500V DC CABLES

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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VRIOGS 010.3 Revision A

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

FAULT PROTECTION EQUIPMENT AND SETTINGS

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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VRIOGS 010.3 Revision A

21

The designer shall however make provision for the future installation of Electrolysis
Mitigation Equipment in the design.
8.5.2

ELECTROLYSIS MITIGATION CUBICLE

The Electrolysis Mitigation Cubicle is designed and installed by one of the


Departments Representatives. To enable the installation of electrolysis mitigation
equipment in the Substation, the designer shall make the following provisions in the
design.
a)

Provision for freestanding type cubicle with minimum internal dimensions of


1000mm wide, 800mm deep and 2000mm high. The cubicle will have front
access by a full height door. The designer shall obtain the most current
drawing for this cubicle from the Department.

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)

Connection of potential leads to the shunt on the negative bus.

f)

Provision of an appropriate number of 100mm P.V.C. conduits between this


equipment and the track side of the substation.

g)

Installation of an electrolysis drainage bus bar to enable connection of


electrolysis feeders.

h)

Interconnecting cables between the E.M.E. and above busbars.

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)

A metering cubicle, in accordance with the Victorian Service & Installation


rules.

Refer to the Victorian Service and Installation Rules.


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VRIOGS 010.3 Revision A

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

SUBSTATION LIGHTING AND POWER REQUIREMENTS

No lighting or power fixtures are to be located within 2.4m of live exposed HV


switchgear or conductors. Those fixtures shall be accessible for maintenance without
de-energising the HV apparatus.
8.7.1

LIGHTING - INTERIOR

An illuminance level of 200 Lux shall be provided within the substation building and
incorporate the following:
a)

c)

Lighting shall be provided on a minimum of two circuits within the HV


area(s).
Light switches shall be easily accessible and located near entrances to
room(s).
Fluorescent lighting is mandatory in substations.

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)

Lighting shall be provided on a minimum of two circuits within the HV area(s).


Vandal proof and weather proof exterior type fluorescent fittings shall be used
to illuminate the external areas.
The lighting fittings shall not be accessible from outside of the substation
perimeter.
The switching to external lighting shall be inside the main entrance door of the
substation and have bright neon indication of the ON position.

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8.7.3

23

EMERGENCY LIGHTING

Emergency route lighting and signage shall comply with AS 2293.


Emergency lighting shall be provided with an illumination level of at least 20 Lux
sufficient to allow staff to move safely to exit doors after loss of normal lighting. Such
lighting should only be activated if normal lighting has been switched on and the
supply to the normal lighting has subsequently been lost.
The Emergency lamps shall be powered by the battery system. The batteries shall
not run dry if the normal lighting has inadvertently been left on.
Escape route lighting shall be provided to show clearly and unambiguously the
emergency escape path out of the substation building.
8.7.4

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

POWER OUTLET REQUIREMENTS SHALL INCLUDE.


a)
b)

c)

8.7.6

GPO outlets of sufficient quantity and located to allow ease of


construction and maintenance works.
A special heavy current power outlet shall be provided in a suitable
location for operating transformer oil filtering equipment. The outlet
shall be compatible with the electrical characteristics and physical
connection of the oil filtration equipment.
Residual Current Devices shall be used in areas that may become wet
such as the amenities area or close to the substation entries.

LIGHT & POWER SCHEDULES

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

VRIOGS 010.3 Revision A

HV AND 1500V DC SWITCHBOARDS

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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VRIOGS 010.3 Revision A

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

SWITCHBOARDS 415V/240V AND 110V DC

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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8.9.10

VRIOGS 010.3 Revision A

CONNECTION TO AN EMERGENCY GENERATOR

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

The designer shall consider the following:

NOTE:

a)

Lifting/manoeuvring of heavy equipment to and from the building and


switchyard.

b)

Building and switchyard design shall allow for heavy loads and large
doors/gates.

c)

Allowance shall be
conduits/ducts/trays.

d)

All electrical equipment shall be capable of being operated and

made

for

pulling

heavy

cables

through

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VRIOGS 010.3 Revision A

27

maintained by a 5 to 95 percentile person.


e)

Safe and unrestricted access to all parts of equipment where


operations and settings have to be carried out.

f)

Safe and unrestricted access to all maintainable parts for inspection


and maintenance.

8.11

SAFETY CLEARANCES

Clearances from electrical equipment, to other electrical equipment, to building walls,


switchyard fences and other equipment shall be at least to AS 2067.
In addition, sufficient clearances to allow for initial construction and future
maintenance, operating and earthing as outlined below shall be observed:
a)

At least 900mm from rear of metal clad switchgear to walls. This


space shall be sufficient to allow for maintenance and inspections by
personnel.

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)

A break of at least 900mm in a metal clad switchgear bus, or an


alternative means of egress, where it is considered that the total
assembled length of the bus may present a hazard to the operators.

d)

The minimum clearance between the metal clad 1500V DC Circuit


Breaker Bus and any earthed structure shall be 2000mm.

e)

The minimum clearance between the metal clad 1500V DC circuit


breaker that is in the isolated position and AC circuit breakers that has
been racked out shall be 2000mm.

f)

At least 1200mm of unobstructed space between equipment (other


than cable trays, cables and cable terminations) to ceiling lining or
greater if so stipulated by equipment manufacturers.

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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VRIOGS 010.3 Revision A

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)

Generally, standard products (or products accepting standard stock


lines) shall be used to allow for minimum spares to be carried into
stock.
Where superior performing products or equipment are
available, they shall be referred to the Department for prior approval.

EARTHING REQUIREMENTS

The designer shall be responsible for designing a complete earthing system,


providing safety (both within and outside the substation fence) to all personnel
(including the public), as well as protecting all HV Plant and equipment from damage,
during fault conditions.
8.13.1.1
a)

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)

The combined earthing principle of providing an earth bar as per AS


3000 shall be adopted to which each piece or group of electrical
equipment shall be terminated and suitably identified.

d)

Earthing for the substation shall observe the following:

NOTE:

Bare copper earth grid conductors with a cross sectional area of


70mm2 shall be used in the earth system to minimise corrosion and
mechanical strength. The Copper earthing electrodes shall have a
minimum diameter of 16mm and a length of 3m.

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29

The earth grid system shall be designed for installation at a nominal


depth of 500mm below foundations level.

The earth grid shall continue under and around the switchyard and
be designed such that safe step, touch and transfer potentials are
achieved.

Sub-ground jointing shall be by cadwelding or brazing.

The total earth grid resistance shall be less than 1 ohm.

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.

The design shall provide for connection of earth grid to building


reinforcing bars.

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

APPARATUS TO BE EARTHED THROUGH EARTH BAR

Apparatus to be Earthed Through Earth Bar:

AC HV switchgear enclosures and HV current transformer windings, if indoor


Main transformer tank, if indoor
Auxiliary transformer tank and Auxiliary Transformer Neutral Terminal, if indoor
Signal transformer tank
Signal switchgear
AC HV bus structures and anchorages for AC HV aerials, if provided.
The screen of HV AC cables.
415V/240V switchboard
110V battery negative
Remote Terminal Unit of SCADA system.

8.13.5

APPARATUS TO BE EARTHED VIA AN EARTH LEAKAGE


PROTECTION RELAY (64A) TO THE EARTH BAR

Apparatus to be earthed via an earth leakage protection relay (64 A) to the earth bar:

NOTE:

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30

VRIOGS 010.3 Revision A

Rectifier Cubicle
Rectifier Control Cubicle

Note that the Rectifier and Control cubicles shall be at least


1 Megohm (500V megger) to earth - normally achieved by mounting the cubicles on
dressed hardwood plinths.
Note that the DC switchgear cubicles shall not be earthed.
8.13.6

SWITCHYARD CRUSHED ROCK

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

The following connections are required as part of the Negative requirements.

The connection between the rectifier negative terminal and substation


Negative Bus Bar.
Connection between Negative Bus Bar and Negative Pillar
Connection between Negative Pillar and rail track (designed by others and
located between Substation building and track).

The negative busbar shall be designed such that:


a)

A substation shunt may be installed for recording substation loadings as


per the departments drawing.

b)

It allows for power cable connections from the Rectifier Cubicle.

c)

It allows for negative cable connections to the negative track pillar.

d)

It allows for connections to the Electrolysis Mitigation Equipment, DC


switchgear cubicles and base steelwork of wall mounted 1500V line
isolators.

e)

It allows for the connection of 1500V DC switchgear panels.

Notes:
1 The DC switchgear shall be mounted on an insulated floor of at least 1
Megohm (500V megger) to earth.
2

The screens of the 1500V DC positive cables shall be connected to the


negative strip on the 1500V DC switchgear bus only.

The DC switchgear enclosures shall be connected to the Negative Bus bar.

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VRIOGS 010.3 Revision A

31

SECTION 9.0 ENVIRONMENTAL IMPACT


9.1

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.
NOTE:

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32

VRIOGS 010.3 Revision A

SECTION 10.0 ALTERATIONS AND ADDITIONS TO EXISITING


PLANT
Where there is a need for altering or extending existing plant in a substation, this
standard as well as the relevant provisions in AS 3000 shall be followed. Every
alteration or addition to an existing installation shall be deemed to be a new electrical
installation.
In existing installations where JR12 or Whipp & Bourne DC circuit breakers are
installed and additional circuit breakers are to be installed, then the latest generation
of metal clad switchgear shall be used to replace the existing equipment. All
electrical equipment from the output of the rectifier to the line isolator shall be
replaced.
Any exemptions to these requirements shall be submitted to the Department for
approval.

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VRIOGS 010.3 Revision A

33

SECTION 11.0 DOCUMENTATION AND RECORDS


The design, purchase of equipment, installation and operation of the traction power
supply location entails the preparation of documents, maintenance schedules and
system records as detailed below.
Whilst the Department may review drawing arrangements and format, the designer
shall be solely responsible for the creation, supply and certification of all substation
drawings that are:
Technically and functionally correct, reflecting accurately the installed plant,
equipment and associated circuits,
Prepared in a format consistent with the appropriate standards and the
Department requirements detailed in this standard,
Processed, signed and distributed through an approved Quality Assurance
process.
The designer shall be responsible for the development of all new drawings and
modifications to existing drawings where necessary.
11.1

DOCUMENTATION

The designer shall provide all necessary documentation, including drawings, to


enable the construction and electrical fit-out works to be completed in exact
accordance with the design. This documentation shall include:

NOTE:

a)

Documentation including specifications and drawings as appropriate, to


enable purchase of major equipment through appropriate tender
processes. Refer to the electrical specifications listed in section
SECTION 13.0 for detailed equipment requirements.
The
documentation shall require the equipment tenderer to provide the
following information;
A recommended list of tools and spares, with prices for each item,
which the manufacturer considers will be required to satisfactorily
install and maintain the plant.
The Tenderer shall state whether such tools and spares as the
manufacturer recommends are available ex-stock in Australia for
the next thirty years.
Maintenance requirements for all equipment shall also be specified.

b)

Full instructions and drawings for the building works and electrical fitout.

c)

A description of the salient points of the installation for the information


of the other parties concerned.

d)

Equipment Maintenance Procedures and Schedules for all equipment


in the traction power system shall be created, unless explicitly
exempted by the Department. The procedures and schedules shall be
prepared to a format and standard of a MAINCO Electrical
Maintenance Instruction, refer Appendix A for the format to be used.

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34

VRIOGS 010.3 Revision A

11.2

DETAILED DRAWINGS

The use of a consistent device function designation numbering system throughout


the TPS ensures ease of verification, installation, commissioning and maintenance.
All electrical drawings shall use a device function designation numbering system
approved by the Department.
Detailed drawings shall be produced at an appropriate scale to commensurate with
the detail necessary to achieve the final product. The drawings produced shall be
consistent with the current drawing practice of the Department which is provided in
VRIOG standard 007.2-2006.
The following is a minimum list of general drawings and diagrams required to enable
installation of electrical equipment, for operator training and for fault finding prior to
and following commissioning and in-service running of the completed substation.
General Drawings and Diagrams (minimum requirement)

Locality Plan (Site access from main roads, overview of Substation building
and switchgear and track location).

Architectural, civil and structural details to a standard required for Building


Approval to a level of detail which would enable the tendering of substation
building and switchyard works. Where a Conflict exists between these
Standards and the Substation Building Design Standard, that conflict shall be
resolved by the Department.

Equipment Layout (Electrical equipment).

Earthing Layout - Subfloor/External/Building interior.


The earthing sub floor layout shall show all assets 50m from the substation
including water, drainage, sewer pipes, communications cables, fibre optic
cables and other non rail assets such as fuel pipes.

Equipment earthing connections.

Cable conduits/pipes/pits/ducts/layout.

Cable route details - power and control cable routes.


Ground.

Main Circuit Diagram.

Power Circuit Diagram. (from incomer HV bus to rectifier DC terminals)

Transformer nameplate
transformers)

details

(for

Rectifier,

Above and below

Auxiliary

and

Signal

Installed Equipment Details (minimum requirements)

NOTE:

AC switchgear - outline drawing and control schematic.

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VRIOGS 010.3 Revision A

35

DC switchgear - outline drawing and control schematic.

Rectifier cubicle - outline drawing and control schematic.

Rectifier control cubicle - outline drawing and control schematic.

Battery charger - outline drawing and circuit schematic.

Battery bank - outline drawing and circuit schematic.

Rectifier Transformer - outline drawing, connection details and earthing.

Auxiliary transformer - outline drawing, connection details and earthing.

Signal transformer - outline drawing, connection details and earthing.

1500V Line Isolators - outline drawing, mounting location and earthing details.

Switchboards and Hardware Details (minimum requirement)

415V/240V switchboard layout.

110V DC switchboard layout.

Cubicle plinths to suit rectifier, rectifier control and remote terminal unit
cubicles.

Negative -Busbar - Layout and Details.

HV Cabling Detail - Methods and Specialised Hardware for Support of HV


Cables.

Transformer to rectifier connections - Layout and Details.

Schedules (minimum requirement)

Cable Schedule - Power and Control Cabling.

Lighting and Power layout and schedule.

Equipment schedule.

Circuit and Wiring Diagrams (minimum requirement)

Rectifier power circuit diagram

Rectifier control circuit diagram

Auxiliary supplies circuit diagram (415/240/110V DC circuits).

Equipment interconnection drawing - to show the interconnecting cables and


wiring to all equipment.

NOTE:

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36

11.2.1

VRIOGS 010.3 Revision A

DETAIL DESIGN SPECIFICATION (INSTRUCTIONS)

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

FINAL DESIGN AND DOCUMENTATION

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.

Works Instructions for the manufacture and supply of major items of


material or prefabricated structures.

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VRIOGS 010.3 Revision A

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).

NOTE:

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38

VRIOGS 010.3 Revision A

SECTION 12.0 REVIEW AND APPROVAL PROCESS IN


DESIGN
The Department requires that all designs of the rail traction power supply assets
meet the objectives of functionality and minimum "Whole of Life" costs while
maintaining the highest standards of personnel and general public safety.
A further consideration is the need to take advantage of "best world practice" in rail
traction power supply technology while maintaining system, operational and
maintenance compatibility with the existing traction power supply infrastructure of the
Department.
To that effect, the overall review and approval process is described in the VRIOG
Design, Construction and Handover Process document.

NOTE:

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VRIOGS 010.3 Revision A

39

SECTION 13.0 REGULATIONS AND PUBLISHED STANDARDS


Substation Design requirements will comply with the requirements of the Departments
Traction Substation Design Standard 2007, unless noted otherwise.
All designs shall comply with all relevant regulations of Government and Semi
Government Authorities.
In particular, the proposed designs shall comply with the provisions of current editions
of the following acts, codes, regulations and standards.
13.1

ACTS, CODES, REGULATIONS AND PUBLISHED STANDARDS

Historic Building Act.

Occupational Health & Safety Act.

Building Code of Australia.

Victorian Building Regulations.

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.

Victorian Service & Installation Rules.

Electricity Distribution Code - Essential Services Commission - Victoria

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

VRIOGS 010.3 Revision A

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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VRIOGS 010.3 Revision A

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

Railway application Supply voltages of traction systems.


Railway Application Fixed Installations Part 1
Protective Provisions relating to Electrical Safety and
Earthing.

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 010.3 Revision A

VRIOGS 010.8

Railway Traction Electrical Network Study Standard.

VRIOGS 012.1

Signalling Design and Documentation Specification

VRIOGS 012.2

Specification for Signalling Supply, Construction and


Installation

MAINCO - Electrical Equipment Specifications


Procedure
MESP 0001
MESP 0002
MESP 0003

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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VRIOGS 010.3 Revision A

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

APPLICATION & INTERPRETATION


Reference to Standards or Codes of Practice shall mean the latest issue, and
to such specifications, rules, codes, supplements and amendments associated
with such Standards or Codes at the date of invitation to tender.
Where no Australian Standard or Code of Practice exist then the appropriate
British, American or International Standard shall be adopted, subject to the
written consent of the Department.

NOTE:

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44

VRIOGS 010.3 Revision A

SECTION 14.0 APPENDIX A: ELECTRICAL MAINTENANCE


INSTRUCTION - PRO-FORMA
ELECTRICAL NETWORKS MAINTENANCE INSTRUCTION
<TITLE NAME OF EQUIPMENT>
Operational Check
Approval
FUNCTION
Reviewed By:
Approved By:

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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