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Engineering Specification Signals Equipment Specification

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SPG 1010

CABLES FOR RAILWAY SIGNALLING APPLICATIONS -

GENERAL REQUIREMENTS

Version 1.2

Issued 28 September 2010

Owner: Chief Engineer Signals

Approved by:

Warwick Allison Authorised by:

Paul Szacsvay Principal Engineer Signalling Technology

Chief Engineer Signals

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

UNCONTROLLED WHEN PRINTED of 29

RailCorp Engineering Specification — Signals — Equipment Specification Cables for Railway Signalling Applications - General Requirements SPG 1010

© RailCorp of 29 Issued 28 September 2010 UNCONTROLLED WHEN PRINTED Version 1.2

Document control

Version Date Summary of change

1.0 September 2005 Replaced SC 11 11 00 00 SP Cables for Railway Signalling Applications – General Requirements

1.1 May 2010 Application of TMA 400 format 1.2 28 Sept 2010 App C, items 32-39 – SPG 1015 changed to SPG 1014



Contents 1 Scope and Application ...........................................................................................................4 2 General .....................................................................................................................................4 3 Applicable Standards .............................................................................................................4

RailCorp Specifications..............................................................................................4 Australian Standards .................................................................................................4 International Standards..............................................................................................5

4 Environmental Conditions .....................................................................................................5 5 Types of Cables.......................................................................................................................5

5.1 Cable suitable for outdoor use...................................................................................5 5.2 Cable suitable for indoor use.....................................................................................6 5.3 Cables Suitable for laying directly on the ground ......................................................6 5.4 Composite Cables .....................................................................................................6

6 Ratings of Cables....................................................................................................................6 7 Insulation Material...................................................................................................................6 8 Construction............................................................................................................................7

8.1 Termite Barrier (Protection against termites, insects and rodent attack on the cables) ............................................................................................................7

8.2 Screening...................................................................................................................7 9 Packaging (Reels) ...................................................................................................................7 10 Identification (Marking)...........................................................................................................8

10.1 Marking on Cables.....................................................................................................8 10.2 Reels and Marking on Reels .....................................................................................8

11 Information to be provided by the Tenderer ........................................................................9 12 Information to be provided by manufacturers (Verification of manufacture

as specified by the Tenderer) ................................................................................................9 13 Warranty...................................................................................................................................9 14 Quality Assurance & Inspection..........................................................................................10

14.1 Production deviations from specifications ...............................................................10 15 Testing....................................................................................................................................11

15.1 Acceptance Testing Procedure ...............................................................................11 15.1.1 Suppliers with quality management systems ...........................................11 15.1.2 Suppliers without quality management systems ......................................11

16 Supplier Test and Certification Agreement........................................................................11 17 Witness Testing Procedure..................................................................................................12 18 Inspection at Time of Delivery .............................................................................................12 19 Test Certificates ....................................................................................................................13 Appendix A Information to be provided by the Supplier ........................................................14 Appendix B Technical Report – Cable Inspection and Test...................................................18 Appendix C Cables for use on RailCorp Network for Railway Signalling

Applications...........................................................................................................................22 Appendix D Insulation resistance - Temperature correction factors for most

common insulation materials ..............................................................................................29



1 Scope and Application This Specification describes the general requirements for cables for use on the RailCorp Network for signalling applications.

2 General This Specification provides the general requirements for cables covered in the specifications as listed in Clause 3.1.

A complete specification for a particular cable is formed by Specification SPG 1010 in conjunction with one of the specifications as listed in Clause 3.1. In case of any conflicts the latter series of specifications shall take precedence over Specification SPG 1010 Cables for Railway Signalling Applications - General Requirements.

Any conflicts are to be brought to the attention of the RailCorp Representative.

3 Applicable Standards

RailCorp Specifications This Specification refers to the following RailCorp Specifications under the heading “ Cables for Railway Signalling Applications”. Specific applications are:

SPG 1011 Multi-Core Signalling Cables SPG 1012 Single and Twin Conductor Cables SPG 1013 Single Conductor Cables for Indoor Use SPG 1014 Traction Return Bonding and Track Connection Cables SPG 1015 High Frequency Screened Track Circuit Cables SPG 1016 Fire Safe High Frequency Screened Track Circuit Cables SPG 1017 Fire Safe Multi- Conductor Cables SPG 1018 Fire Safe Single and Twin Conductor Power Cables SPG 1019 Fire Rated Twin Conductor Power Cables for Emergency Services

Australian Standards This Specification refers to the following Australian Standards

AS 1125:1993 Conductors in Insulated Electric Cables and Flexible Cords. AS 1660.3:1998 Test Methods for Electric Cables, Cords and Conductors-Electrical

Tests. AS 1746:1991 Conductors-Bare-Overhead-hard drawn copper. AS 1802/1995 Reeling and Trailing Electrical Cables for Underground Coal Mining

Purposes. AS 2837.1986 Wrought Alloy Steels – Stainless Steel Bars and Semi-Finished

Products AS 3100:1999 Approvals and Test Specification- General Requirements for

Electrical Equipment. AS 3158:1995 Approval & Test Specification-Fibrous Insulated Electric Cables for

Working voltages up to and including 0.6/1KV AS 3178:1991 Approval & Test Specification-Electric Cables - Silicone Rubber

Insulated-For working voltages up to and including 0.6/1KV AS 3191:1996 Approval & Test Specification-Electric Flexible Cords



AS 3569:1989: Steel wire ropes AS 5000-1999 Electric Cables – Polymeric insulated for working voltages up to and

including 0.6/1KV

International Standards BS 174/1970: Specification for Hard Drawn Copper and Copper/ Cadmium wire for

telegraph & telephone purposes.

4 Environmental Conditions Cables shall be suitable to be used under the following environmental conditions.

a) Humidity: RH up to 100%

b) Temperature: -10C to +75C unless otherwise specified

c) Direct exposure to UV radiation in certain applications which shall be specified in particular Specifications.

d) Total Immersion in water, acidic solutions with low concentration, salty media, etc.

e) Exposure to toxic materials, dirt, dust, grease, oil, hazardous gases, etc.

f) Abrasion as a result of vibration and shock (Abrasion within cables due to vibration and shock shall also be taken into consideration)

Field testing shall be performed for a reasonable period of time to evaluate the performance and suitability of these cables for the conditions specified above.

Environmental conditions applicable to specific use shall be described in the following sections.

5 Types of Cables Shall be as specified in particular specification as listed in Clause 3.1 which is summarised in Appendix 3:(Cables for use on RailCorp Network for Railway Signalling Applications)

Performance requirements of cables used for specific applications and subject to different environmental conditions are detailed below.

5.1 Cable suitable for outdoor use a) Laid directly in the ground, ash ballast or concrete at depths up to one metre at

the side of and under the railway tracks without protective covering of any kind if specified to be suitable for direct burial.

b) Laid in PVC under-ground conduit at depths up to one metre at the side of and under railway tracks.

c) Laid in galvanised steel or PVC or concrete ducts.

d) Exposed to atmospheric conditions at rail level or at the tops of poles where it will be joined to aerial cables.

e) Exposed to acids and salts which may be present in concrete structures and soils



5.2 Cable suitable for indoor use a) Laid indoors in steel cable trays, concrete or PVC ducts.

b) Exposed to atmospheric conditions including indirect sunlight and the various substances present in industrial and seaside areas.

5.3 Cables Suitable for laying directly on the ground Cables under this category are intended to be laid direct on the ground surface and the metal ballast of the track. It will be subjected to a particularly severe environment including lubricating and diesel oil from trains, insecticides from mobile spraying operations, weather conditions encountered in the state of New South Wales, temperature rise due to the sun heating of the rock ballast, heavy vibration due to the passage of trains and mechanical abrasion of cables due to dragging equipment, movement of personnel, tools, material, equipment including rubber tyred mobile machinery, etc.

In respect of mechanical damage it is recognised that the protection offered cannot guard against all possible contingencies but the material and construction shall provide the greatest possible protection against abrasion and penetration.

Construction shall be in accordance with the best procedures and practices for the most severe applications in mine trailing cables except that metallic armouring is not permissible for electrical reasons.

CSP cables have proven success in the NSW rail network. However alternate cables such as “Flexolex “ cables will be considered.

5.4 Composite Cables Composite cables are acceptable for some specific applications that would require cable cores that can be used for power circuits and separate control wiring in the same cable that can be used for control circuits.

In a composite cable each of the components shall comply with the applicable specification.

Typical examples are the cable runs for train stops and point machines, that would require 3-4 power circuits and up to 6 control circuits.

6 Ratings of Cables Cables shall be rated to 0.6/1KV unless otherwise specified in the particular cable specification (the operating voltage for signalling equipment is 120V AC 50Hz, which is derived from 240V AC 50Hz power supply).

7 Insulation Material Unless otherwise specified in the particular specification, V-75 PVC or V-90 PVC insulation, in conformance with AS 5000 shall be used.

The average thickness of primary insulation and supplementary insulation (sheath), shall not deviate by more than + (0.1 x Specified average thickness + 0.1mm), unless otherwise specified. (Refer AS 1660 for methods specified in determination of insulation thickness.)



The nominal thickness of primary and supplementary insulations, are specified in specifications as listed in Clause 3.1 and in Appendix 3 of this Standard, as a summary.

Minimum thickness of the nylon covering shall preferably be within the range of specified nominal value + 0.1mm

8 Construction Material, design and workmanship generally shall be of the highest possible standard. No jute, fabric, or material which deteriorates when exposed to atmospheric conditions shall be used. All material used in the construction of the cable shall be non hygroscopic as detailed in AS3100.

8.1 Termite Barrier (Protection against termites, insects and rodent attack on the cables) Where specified, cable shall be mechanically protected against termite, insects and rodent attack on the cables.

Presently used signalling cables possess two layers that have been used against termite, insects and rodent attack.

The outermost nylon jacket serves as the primary protection. This also serves as a mechanical protection and provides sufficient slipperiness.

Nylon type 11 or 12 shall be used. Thickness of the nylon jacket shall be as detailed in the particular specifications.

Secondly, the copper tapes are used as a shield against termite attack to serve as the secondary protection, while it also provides electrical shielding for the cable.

Between the two supplementary insulations (sheaths), two layers of copper tape each 0.08mm thick with a gap, shall be provided. The centre of the second layer shall be located accurately over the centre of the gap of the first layer.

The width of copper tapes shall not exceed 2 x (the outer diameter of the inner sheath) & shall be within 1 to 2 times the OD.

Alternate cable designs such as PVC/PVC/nylon jacket/sacrificial PVC or/and other designs that will protect the cable against termite attack, will be considered.

8.2 Screening Where specified, cables shall be protected against electro-magnetic and electrostatic interferences. A metallic screening tape along with a drain wire shall be provided whenever requested.

9 Packaging (Reels) Cable shall be supplied on wooden reels with lagging. The wooden reels and lagging shall protect the cable or wire adequately while in transport or in storage.

Shrink-wrapped metal spools may be used for smaller sizes of cables and electrical wires if stated at the time of tender or quotation.

The manufacturer shall indicate if steel drums are available. In these cases details shall be provided of the drum.



Lagging shall be provided and securely fastened on all drums and reels to protect the cables during transportation and storage. Lagging shall preferably be full wooden battens with two steel straps. Three steel straps are required on drums wider than 900mm or of gross weight greater than 1 tonne. Polypropylene (corrugated) continuous sheet, or 3.2mm Masonite sheeting, with 1 steel strap may be used on drums not exceeding 750mm in diameter or 500mm in width. Alternative material may be used on approval.

Aerial wires (bare copper) shall be supplied on drums with impervious lining and external lagging.

10 Identification (Marking)

10.1 Marking on Cables The following information shall be permanently marked or embossed on the outer sheath (not the nylon jacket) of the cable in a legible format not less than 3mm high at intervals not exceeding 0.5 metres. On cables less than 6mm in diameter the tenderer shall indicate the height of lettering that can be applied. Lettering shall be not less than 1.8mm in height.

a) The manufacturer's name with the year of manufacture.

b) Any additional legend as specified.

In addition to the above, unless otherwise specified, cables shall be marked at 1metre intervals on the outermost sheath or covering of the cable with the progressive length starting from the inner end on the drum.

Length marking shall be in yellow or white numerals on a black background or black numerals on an orange or red background. Numerals shall not be less than 3mm in height.

On cables and wires less than 9mm in overall diameter the metre marking is not required unless otherwise specified. (For Item number - Cable 7/0.85mm to Specification SPG 1012 Single and Twin Conductor Cables, metre marking shall be provided.)

The following information shall also be printed or embossed along with metre marking on the cable

A x B/Cmm/X/Y/Z Rated Voltage

Example: 2x (7/0.85 Red, Blk PVC) / Blk PVC / Nyl 0.6/1KV

10.2 Reels and Marking on Reels The following information shall be indelibly marked on the side of the reel. Nail on tags are not permitted. Alternatively printed labels as approved by the RailCorp Representative may be used. These shall be stapled to the drum using staples 8mm or less in length.

a) Manufacturer's name, month and year of manufacture of the cable and the manufacturer's identification of the reel.

b) Rated voltage.

c) The inscription "RailCorp" and the RailCorp Item number.

d) The length of cable on the reel.



e) The legend "A x B/Cmm/X/Y/Z" as applicable.

A shall indicate the number of conductors provided.

B shall indicate the number of strands per conductor.

C shall indicate the diameter of each strand in millimetres.

X type of insulation (including the colour of insulation).

Y type of cover (including Colour).

Z type of additional covering.

Example: Railway Signalling CABLES Pty Ltd Manufacture Code: Sept 1992 2x (7/0.85 Red, Blk PVC)/Blk PVC/Nyl 0.6/1 KV Manufactured for "RailCorp - Signals" RailCorp Item No Contract # /Item#: 11 Order No: ####### Quantity = 1000 Metres Gross Weight =100 Kg

11 Information to be provided by the Tenderer Tenderers shall supply complete information concerning the cable offered. Reasonable deviations from the specifications which do not nullify the intent of the clause concerned, will be considered but such changes shall be fully described as part of an offer, and will not be permitted after an offer is accepted.

Tenders shall provide all the information as listed in schedule in Appendix 1 of this specification.

This shall also apply to all cables supplied to a contractor undertaking work on railway signalling systems.

Tenderers shall state the time required for delivery after placing of an order for cable.

12 Information to be provided by manufacturers (Verification of manufacture as specified by the Tenderer) Manufacturers shall supply complete technical details on the cable offered. Any component of the cable not mentioned in the Specification shall be fully detailed regarding type, composition, dimensions, tolerance, minimum thickness and colour.

For multi-conductor cables, a large scale drawing shall be provided on A4 size paper showing a cross section of the cable, giving the arrangement and length of lay of all cores and layers and showing the disposition of all material in the cable together with dimension tolerances.

13 Warranty For cables, with the exception of CSP insulated cables, the manufacturer shall guarantee that the insulation resistance when measured with an insulation tester with applied voltage of 500 volt DC, shall be not less than the values indicated below.



Cable type Insulation Resistance @ 20C Core-Core (MOhm.Km)

Core-Earth (MOhm.Km)

Core-Screen* (MOhm.Km)

Screen*-Earth (MOhm.Km)

Multi-conductor New Cables 60 60 60 5 After 10 years 40 40 40 2 Single conductor New Cables 10 5* 5* After 10 years 5 2* 2*

* - Whenever applicable (either the shield or screen).

The manufacturer shall guarantee that the cable meets this requirement for a period of 10 years from despatch of the cable. Where the insulation resistance of the materials used is temperature dependent the manufacturer shall indicate the temperature correction required to convert measured readings to a standardized reading at 20C

The manufacturer shall undertake to replace at his expense any length which fails to withstand these tests or give satisfactory service during this period. This obligation does not extend to cable which has been subject to misuse, negligence, or accident after delivery.

Manufacturers shall indicate their agreement to guarantee the cable for 10 years against damage by ants and termites, or otherwise the period they will guarantee the cable against such an attack.

14 Quality Assurance & Inspection The contractor or nominated representative shall have such access to the works of the manufacturer as is reasonable and necessary to enable him to determine the quality of the material and workmanship.

The person shall reject any part of the cable, which may appear to be defective either in material or workmanship. The reason for rejection of the cable shall be forwarded to the manufacturer in writing and the manufacturer shall replace, free of cost, such rejected parts by others of a satisfactory character without unnecessary delay.

14.1 Production deviations from specifications When the manufacturer finds that a cable in production does not comply with the specification, but the deviation does not significantly affect the quality and performance of the cable, the purchaser may elect to accept the cable, subject to such conditions as the purchaser may impose.

To obtain acceptance of the out-of-specification cable, the manufacturer should forward a Specification Deviation/Concession Request to the Contractor for determination by the RailCorp Representative.

This request shall provide details of the cable involved, the nature and effects of the deviation, the cause of the deviation, and the changes implemented in production procedures to prevent a recurrence of the effect.

Each Deviation/Concession request shall bear a unique identifying number, allocated from a register maintained by the manufacturer.



The RailCorp Representative may elect to reject or accept the cable, with or without any discount in price. In any case the deviation request should be submitted immediately the deviation occurs, to minimize costs to the manufacturer arising from any possible rework or disposal required.

When a cable is supplied subject to an approved Specification Deviation/Concession Request, the serial number of the request, and a brief description of the deviation shall be shown on the test certificate.

15 Testing A high voltage spark-over test as specified in AS 1660.3, shall be carried out on the completed cable in addition to the tests laid down in AS 5000.

15.1 Acceptance Testing Procedure For acceptance of cables the following documents shall be provided with cable drums.

a) Test Certificate with each drum of cables, which shall be enclosed in a transparent envelope and attached to the drum.

b) Conformance Certificate with every order/delivery

Acceptance testing procedure depending on the Supplier's level of quality control facilities shall be as follows:

15.1.1 Suppliers with quality management systems (See Section 16 - Supplier Test and Certification agreement.)

No inspections shall be carried out by the RailCorp Representative for the cables supplied, unless for random inspections, if required.

15.1.2 Suppliers without quality management systems The methods of inspection for this type shall be as specified in Section 18 and 19.

Samples of every production batch of cable drums shall be tested and inspected according to the requirements of particular specification and in accordance with CheckList in Appendix 2 and information in Appendix 3.

Step 1: Manufacturer will submit a conformance certificate (and test reports if requested) to the nominated representative declaring that the cable manufactured is in accordance with the specification and ready for inspection.

Step 2: Inspection officer checks(verifies the results of test report) against the specifications and CheckList in Appendix-2 and passes or rejects the cables. Any conflicts are to be brought to the attention of the Contractor.

A copy of the RailCorp Representative’s inspection note shall be despatched along with other certificates mentioned.

16 Supplier Test and Certification Agreement Where a manufacturer is producing these cables under a Quality Assurance system, which is accredited to AS/NZS 9001, 9002 or a recognized equivalent, the purchaser will enter into an agreement for Supplier Test & Certification. Under this agreement all



inspections and certification of cables covered by this Specification is carried out by the manufacturer.

Each drum of cable shall be delivered with a test certificate to a format agreed between the manufacturer and RailCorp or the contractor.

All other test records shall be retained by the manufacturer as part of the standard QA documentation. Production and test records shall be made available for audit as and when required by the Contractor. The Technical Report, specified under the Witness Testing Procedure described below, is not required for any cables manufactured subject to a Supplier Test and Certification Agreement.

Random inspections for these cables will be performed by the nominated representative.

17 Witness Testing Procedure Every drum of cable shall be inspected and tested according to the test procedure as attached to the specification describing the detailed requirements. The results of this test procedure shall be recorded in the Technical Report.

The manufacturer shall supply a set of the complete test report as in Appendix 2, for each reel of cable to be supplied. The manufacturer shall complete all relevant details of the report and present the report to RailCorp or its nominated representative, if requested, prior to delivery being accepted.

18 Inspection at Time of Delivery Where the point of manufacture is outside the metropolitan area of Sydney, pre-delivery inspections may be carried out. In some cases, inspections for the purpose of acceptance may be arranged by officers of other railway administrations or Supply authorities or a nominated representative of RailCorp. Any charges shall be borne by the manufacturer. Alternatively, inspection can be carried out after delivery but in this case transport cost arising from rejection shall be borne by the manufacturer. In the absence of approved specific arrangements for inspection at the point of manufacture, this alternative provision shall apply and the company shall inform the Contractor or the nominated person when the cable will be delivered and can be inspected. Along with this advice the company's test certificate shall be presented.

Certificates of inspection and tests may be accepted from recognized testing laboratories. The purchaser reserves the right to carry out its own tests and to reject the whole or any portion of the cable if in the opinion of the purchaser, it is unsatisfactory when delivered.

The purchaser may require that a selection of cables and wires be presented for pre-delivery tests in accordance with the conditions as described in the detailed specifications.

The manufacturer shall provide two cable tails for testing, readily accessible from outside the cable drum. These tails shall be 500mm long. They shall be securely fixed to the drum by means of galvanized saddles. The cable is not to be punctured in any way. The position of the outer end of the cable is to be marked on the side of the reel. The ends of the cable tails shall be sealed to prevent the ingress of moisture or other contaminants. For all multi-core cables heat shrink caps are required; for all other cables and electrical wires mastic sealing compound or tape or fitted caps are required.



19 Test Certificates Test certificate shall include at least the details shown below:

a) Test certificate number and cable identification drum No.

b) Description of the cable.

c) Relevant order number and company works codes.

d) Conductors resistance, tested (or corrected) at 20C

e) Screen resistance (if applicable).

f) High voltage test.

g) High Voltage Spark-over test.

h) Insulation resistance as applicable

i) Between Cores

ii) Between Cores and Screen/Shield

iii) Between Cores and Earth

iv) Between Screen/Shield and Earth

i) Core numbering tested? (For multi-conductor cables) (Yes/No)

Specification Deviation/Concessions (references, if applicable).



Appendix A Information to be provided by the Supplier Note

This is a standard sheet for all cables and wires. For items that are not applicable to certain types of cable or wires the response by the

Tenderer/Supplier shall be "Not applicable".

a) Cable Description:

b) RailCorp Identity Number:

c) RailCorp Specification Number: Specification SPG 1010 Cables for Railway Signalling Applications - General Requirements:

d) Contract Schedule Number: Schedule No: Item No:

e) Major Contract Specification Number:

f) Name of principal Contractor:

g) Other Relevant Specifications or Standards:

h) Reel

i) Material:

ii) Lagging:

iii) Number of steel straps:

iv) Length of cable per reel:

v) Gross weight of reel:

vi) Refund on reels:

vii) Drum diameter and width:

i) Identification

i) Are full details shown on the drum?:

ii) Cable marking method:

iii) Information shown on the cable:

iv) Metre marking on cable:

v) Information shown on the cores:

Construction

a) Cable

i) Number of cores:

ii) Number of conductor strands per core:

iii) Size of conductor strands:

iv) Conductor material:



v) What is the length of twist of cable:

vi) Relevant specifications or standards:

vii) Is A4 drawing showing construction of cable appended?:

b) Insulation

i) Material type:

ii) Temperature Rating

iii) Thickness:

iv) Colour:

c) Innermost sheath.(supplementary insulation)

i) Material type:

ii) Temperature Rating:

iii) Thickness:

iv) Colour:

d) Metallic Shield or Barrier

i) Material type:

ii) Material size and number:

iii) Thickness:

iv) Construction:

e) Outermost Sheath (supplementary insulation)

i) Material type:


iii) Thickness:

iv) Colour:

f) Covering or Jacketing

i) Material type:


iii) Thickness:

iv) Colour:

g) Cable

i) Overall diameter: min: max:

ii) Minimum bending radius:

iii) Weight per metre:



Materials

a) Have any compounds been added to the insulation or sheath or covering materials:

If so give full details:

b) Has a lubricant been used between any layers:


c) Has a water repellant compound been used between any layers:


d) Is fire retardant compound included in the cable:


Testing

a) Manufacturer's Tests

i) What tests does the manufacturer undertake: If so give full details:

(Attach a copy of testing specification)

ii) Does the manufacturer have any testing accreditation:(Yes/No)

iii) What quality assurance procedures are in operation at the manufacturer's plant:

iv) Is technical support available in Australia:

b) Guarantee

i) Is guarantee provided as per Specification SPG 1010 Cables for Railway Signalling Applications - General Requirements:

ii) If not what conditions apply:

c) Witnessed Tests

i) Where is the cable available for witnessed tests (if required):

Commercial

a) Delivery time from placement of order:

b) Australian Manufacturing content:

i) Total Australian content:

ii) Percentage of price subject to copper variation:

iii) Index for copper variation:

iv) Index for variations other than copper:

v) Technical support available in Australia:



Manufacturer Details

a) Manufacturer:

b) Address:

c) Place of Manufacture

i) Where is the cable manufactured:

ii) Name of the company that manufactures the cable:

iii) Where is the cable available for testing:

d) Contact Person: Tele

Supplier Details

a) Supplier:

b) Address:

c) Contact Person: Tele

d) Signature of Representative Date:



Appendix B Technical Report – Cable Inspection and Test CABLE INSPECTION CHECK LIST

NOTE: This report has been designed to assist quality assurance inspections conducted by RailCorp. Manufacturer’s/Supplier's representative shall complete this report, and sign at the end of the report. Any additional reports to be included, as applicable to particular Specifications. Representative of RailCorp will witness the testing of the manufactured cables, or verify the results in the test report, and then sign at the end of the report. Supplier shall provide this report upon request.

CABLE INSPECTION CHECK LIST

ORDER DETAILS Customer : Manufacturer : Address : Contract No.: Order No.: Contact person & Phone No: Dispatch To Test Location : Manufacturer's Ref: CABLE DETAILS Description : Manufacturer's Iden: RailCorp Spec.: Drum No.: RailCorp ID (MI#):

Drum length:

Ordered length: Test Certificate No: VISUAL CHECKS Details Drum Construction: Timber Steel Ply Other: Drum Lagging Timber battens Corflute Ply Wrapper Other: Drum Strapping Number of straps = Drum Markings Label Metal Plate Direct on Drum Other: Labelling Labelling indelibly marked Y/N Drum Identification Number Y/N "RailCorp " Y/N Length of Cable on Reel Y/N MI Number Y/N Position of Cable Outer End Y/N Cable deailCorpiption Y/N RAILCORP order number Y/N Manufacturer's Name Y/N Roll Direction Y/N Month & Year of manufacture Y/N



Information indented on Outer sheath: Every 500mm Y/N Manufacturer's Name: Year of manufacture: "RailCorp” Y/N Cable Description: Outer Nylon Jacket Appearance: Smooth, glossy, free from wrinkles or pinholes Y/N Marked at 1m intervals with progressive length yellow or white numerals 3mm high Y/N Markings: {Cable Description, 0.6/1KV} with Metre marking Y/N Height of ID marking on sheath Spec. : mm Actual: mm Screening tape: (if applicable) Y/N Shield/Copper Tapes Two Layers of Copper Tape 0.08 thick between Sheaths: (Y/N) Width of metal tapes: mm Specified value is > 1x OD of Supplementary insulation and < 2x OD Cable Cores Colours, Indelibly numbered with 2mm numerals every 200mm or less Y/N Core "1" on Inside Layer Y/N Core Numbering Sequential Y/N Adjacent Layers Wound in Opposite Directions Y/N MEASUREMENTS Physical Measurements (For multicore cables(>2 core) - individual core O/D's detailed on the attached Page. The measurements of core insulation in the table below is for the core with the smallest O.D.)

Core # Bare Conductor

Primary Insulation

Supplemen-tary Insulation

2nd supplem. Insulation

Nylon Jacket

Spec. O/D Actual O/D Point 1 Point 2 Point 3 Point 4 Point 5 Point 6 Ave.Radial Thickness Spec.Ave. Rad. Wall Spec. min.Point



Electrical Measurements Readings of C.R. & I.R. for individual cores. HV Test : ______________, KV AC 50Hz for ____ mins , Temp. at time of testing: Correction factors: C.R: __________ I.R.: _____________ Length:______metre Conductor Resistance

Ohms Reading Ohms@ 20C Ohms/Km@ 20C Spec. value Ohms/Km @20C

C.R. min C.R. max Insulation Resistance I.R MOhm/ Km@ 20C (or corrected value) Core core Core Screen/Shield Core Earth Scr/Shield Earth Resistance

Core No. Resistance Ohms

Equivalent Ohm/Km

Resistance of Cores

Resistance of Drain wire Insulation Resistance Between Cores( 6 Random checks) Test No. From Core To Core I.R. MegOhm/Km 1 2 3 4 5 6 From Cores to Screen (3 random checks. Not less than 60 Mohm.km when tested with a 500V DC Megger Core No. I.R. MegOhm/Km



Resistance of Cores (3 random checks) (Should be < 14 Ohm/km for 7/0.5) Core No. Ohm/Km

Manufacturer's representative RailCorp Representative (for inspection & testing)

Signature Date: / / Signature Date: / / Name: Name: Title Title


© RailCorp of 29 Issued 28 September 2010 1.2 UNCONTROLLED WHEN PRINTED Version

Appendix C Cables for use on RailCorp Network for Railway Signalling Applications

CONTENTS This section will summarize the technical specification of cables, that fall into the following categories, depending on applications of these cables, for signalling use: * Single conductor cable for indoor use * Signalling cables for underground use * Single and twin-conductor cables * Aerial cables * Earthing conductor used for lightning and surge protection * Track connection cables & traction return bonding cables * Fire safe cables * Fire safe multi-conductor signalling cables * Fire safe single and twin-conductor power cables * Fire rated twin conductor power cables for emergency services


RAIL CORP ITEM #

DESCRIPTION OF THE ITEM

NOMINAL THICKNESS OF INSULATION (mm)

NOMINAL THICKNESS OF SHEATH (mm)

NOMINAL THICKNESS OF NYLON (mm)

NOMINAL OVERALL DIA. OF (mm)

NOMINAL LENGTH (Metres)

REMARKS

Single conductor cable for indoor use

1 Cable 7/0.4 plain Copper /Wht PVC/Blk Nyl 0.6 - 0.15 2.9 1000 ± 10 (Spec SPG 1013)

Signalling cables for underground use

2 Cable, 6x(7/0.5 Blk PVC)/Blk PVC/DCT/ Blk PVC/Nyl 0.8 2.0,3.0 0. 4 21.2 (±0.6) 1000 ± 10 (Spec SPG 1011)




6 Cable, 2x(7/0.5 Wht, Blk PVC) / (Al Shield +Drain wire) / Blk PVC / Nyl

0.8 2.0 0.3 1000 ± 10 For AF Track Circuits (Spec SPG 1014)

Single & Twin-conductor cables

7 Cable, 7/0.5 Red, PVC)/ Blk PVC/Nyl 0.8 1.4 0.3 1000 ± 10 (Spec SPG 1012)

8 Cable,2x(7/0.5 Red, Blk PVC/ Blk PVC) (Twin Twist-2 individual cables twisted)

0.8 1.4 1000 ± 10 For overhead telephone circuits (Spec SPG 1012)

9 Cable, 7/0.85 Red PVC/ Blk PVC/Nyl 1.0 1.4 0.3 8.1 (±0.2) 1000 ± 10 (Spec SPG 1012)

10 Cable, 7/0.85 Blk PVC/ Blk PVC/Nyl 1.0 1.4 0.3 8.1 (±0.2) 1000 ± 10 (Spec SPG 1012)

11 Cable,2x(7/0.85 Red, Blk PVC) /Blk PVC/DCT/ Blk PVC/Nyl (Core colours Red & Blk)

1.0 1.4, 1.4 0.3 16.3 (±0.4) 1000 ± 10 Twin cable (Spec SPG 1012)








REMARKS

RAIL CORP ITEM #


Cable,2x(7/0.85 Blu, Yel PVC)/ Blk PVC/Nyl (Core colours Blue & Yeliow)

12 1.0 1.4, 1.4 0.3 16.3 (±0.4) 1000 ± 10 Twin cable-Staff line (Spec SPG 1012)

13 Cable, 1/1.70 Red PVC/ Blk PVC/Nyl 0.8 1.4 0.3 6.9 1000 ± 10 (Spec SPG 1012)

14 Cable, 1/1.70 Blk PVC/Blk PVC 0.8 1.4 1000 ± 10 (Spec SPG 1012)



17 Cable,2x(7/1.70 Red, Blk PVC) /Blk PVC/DCT/ Blk PVC/Nyl 1.0 1.4, 1.4 0.4 21.6 (±0.6) 1000 ± 10 Twin cable

(Spec SPG 1012)

18 Cable, 19/1.78 Red PVC/ Blk PVC/Nyl 1.4 1.4 0.3 15.2 (±0.4) 1000 ± 10 (Spec Spg 1012)


20 Cable,2x(19/1.78 Red, Blk PVC)/Blk PVC/DCT/ Blk PVC/Nyl 1.4 1.4, 1.4 0.4 30.3 1000 ± 10 (Spec SPG 1012)


22 Cable, 37/1.78 Blk PVC / Blk PVC/Nyl 1.6 1.5 0.4 19.5 (±0.5) 500 ± 10 (Spec SPG 1012)

23 Cable, 37/1.78 Red PVC/Orange PVC 1.6 1.5 - 18.7 500 ± 10 Tuning Unit Connect

(Spec SPG 1012)

24 Cable, 37/2.03 Red PVC/Orange PVC 1.6 1.5 - 20.4 500 ± 10 (Spec SPG 1012)









REMARKS

RAIL CORP ITEM #


Cable, 37/2.03 Blk PVC/ Blk PVC/Nyl 26 1.6 1.5 0.4 21.3 (±0.6) 500 ± 10 (Spec SPG 1019)

Aerial Wires

27 Wire Aerial 1/2.85 PVC Hard drawn Copper to BS 174 and AS 1746/91

0.8 - - 4.5 1000 ± 10

28 Wire Aerial 1/2.5 PVC Hard drawn Copper to BS 174 and AS 1746/91

0.8 - - 4.2 1000 ± 10 42.28 Kg/Km

29 Wire Aerial 1/2.85 PVC Bare Hard drawn Copper to BS 174 - - - 1000 ± 10

56.3 Kg/Km (to be supplied with wooden lagging)

30 Wire Aerial 7/1.70 (16 mm2) Copper HD Blk PVC / Blk PVC 1.0 1.4, 1.4 - 500 ± 10 Signalling power cable,

aerial Earthing conductor used for lightning/surge protection 31 Wire 1/2.0 mm Stainless Steel - - - 75 Kg coil Track connection cables & Traction return bonding cables

32 Cable, 7/19/0.26 Steel galvanized/ R-90-CSP (Orange) or equivalent

see ASC81-67, supl AS1802/92

- - - 500 ± 5 Track connection cable (Spec SPG 1014)

33 Cable, 7/19/0.26 Stainless Steel R-90-CSP (Orange) or equivalent

see ASC81-1967 - - - 500 ± 5 Track connection cable

(Spec SPG 1014)

34 Cable, 84/0.3 Tinned Copper / R-90-CSP(Orange) or equivalent 3.5 - - - 500 ± 5 Track connection cable

(Spec SPG 1014)








REMARKS

RAIL CORP ITEM #


Cable, 608/0.5 R-90-CSP (Orange) or equivalent 35 3.5 - - - 250 ± 1

Traction return bonding cable (Spec SPG 1014)

36 Cable, 962/0.5 R-90-CSP (Orange) or equivalent 3.5 - - - 100 ± 1

Traction return bonding cable (Spec SPG 1014)

37 Cable, 91/1.32, Bare Cu - - - - 250 ± 1 Traction return bonding cable

38 Cable Aluminium flexible 925/0.5 (185 mm2) R-90-CSP (Orange) or equivalent 3.5 - - 26.8 (±0.7) 100 ± 1

Traction return bonding Alumin. Alloy (Spec SPG 1014)

39 Cable Aluminium flexible 1525/0.5 (300 mm2) R-90-CSP (Orange) or equivalent 3.5 - - 32.3 (±0.7) 100 ± 1

Traction return bonding Alumin. Alloy (Spec SPG 1014)

Fire Safe Cables

40 Cable,fire safe 2x(7/0.5 Nat.XLPE) / (Al scrn+Drain wire)/Red HFS-90-TP (Core colours Blk & Wht

0.7 1.8 - 6.3 approx 1000 ± 10 (Spec SPG 1016)

Fire safe multi-conductor signalling cables

41 Cable,fire retardant 6x(7/0.5 Nat.XLPE) / HFS-90-TP/ DCT/Red HFS-90-TP

0.7 2.5 , 2.5 - 1000 ± 10 (Spec SPG 1017) - (6 core)


0.7 2.5 , 2.5 - 1000 ± 10 (Spec SPG 1017) - (15 core)








REMARKS

RAIL CORP ITEM #


Cable,fire retardant 25x(7/0.5 Nat.XLPE) / HFS-90-TP/ DCT/Red HFS-90-TP

43 0.7 2.5 , 2.5 - 500 ± 10 (Spec SPG 1017) - (25 core)


0.7 2.5 , 2.5 - 500 ± 10 (Spec SPG 1017) - (50 core)

Fire safe single and twin conductor power cables

45 Cable,fire safe 7/0.85 Nat.XLPE / Red HFS-90-TP/ DCT/Red HFS-90-TP

0.7 1.4 , 1.4 - 1000 ± 10 (Spec SPG 1018)

46 Cable,fire safe 2x(7/0.85 Red & Blk.XLPE) / Red HFS-90-TP/ DCT/Red HFS-90-TP

0.7 1.4 , 1.4 - 1000 ± 10 (Spec SPG 1018)

47 Cable,fire safe 7/1.7 Blk.XLPE / Red HFS-90-TP/ DCT/Red HFS-90-TP

0.7 1.4 , 1.4 - 10.2 approx 1000 ± 10 (Spec SPG 1018)

48 Cable,fire safe 2x(7/1.7 Red & Blk.XLPE)/ Red HFS-90-TP/ DCT/Red HFS-90-TP

0.7 1.4 , 1.4 - 18.1 approx 1000 ± 10 (Spec SPG 1018)


1.0 1.5 , 1.5 - 18.7 approx 1000 ± 10 (Spec SPG 1018)


1.0 1.5 , 1.5 - 18.9 approx 1000 ± 10 (Spec SPG 1018)

Fire rated twin conductor power cables for emergency services


ering Specification — Signals — Equipment Specification way Signalling Applications - General Requirements SPG 1010

© RailCorp of 29 Issued 28 September 2010 Version 1.2






REMARKS

UNCONTROLLED WHEN PRINTED

RAIL CORP ITEM #


51 Cable,fire rated 2x(7/0.85 Red & Blk.XLPE)/ HFS-90-TP/ DCT/Red HFS-90-TP

0.7 1.4 , 1.4 - 1000 ± 10 (Spec SPG 1019)

52 Cable,fire rated 2x(7/1.70 Red & Blk.XLPE)/ HFS-90-TP/ DCT/Red HFS-90-TP

0.7 1.4 , 1.4 - 1000 ± 10 (Spec SPG 1019)

RailCorp EngineCables for Rail



Appendix D Insulation resistance - Temperature correction factors for most common insulation materials

Based on 20° C

RUBBER CPR CSP/HYP SIL PVC H/R PVC Temp 0 C

R-60 R-75

R-EP-90 R-CSP-90 R-S-

150 V-60 V-75

V-90 V-105

Polythene (Refer Note 1&2)

10 0.46 0.56 0.27 0.51 0.39 0.27 0.67 11 0.5 0.59 0.31 0.55 0.42 0.31 0.7 12 0.54 0.63 0.35 0.58 0.47 0.35 0.73 13 0.58 0.67 0.4 0.62 0.51 0.4 0.76 14 0.63 0.71 0.46 0.67 0.57 0.46 0.79 15 0.68 0.75 0.52 0.71 0.62 0.52 0.82 16 0.74 0.79 0.59 0.76 0.68 0.59 0.86 17 0.79 0.84 0.68 0.82 0.75 0.68 0.89 18 0.86 0.89 0.77 0.87 0.83 0.77 0.93 19 0.93 0.94 0.88 0.93 0.91 0.88 0.96 20 1.0 1.0 1.0 1.0 1.0 1.0 1.0 21 1.08 1.06 1.14 1.07 1.1 1.14 1.04 22 1.17 1.12 1.3 1.15 1.21 1.3 1.08 23 1.26 1.19 1.48 1.22 1.33 1.48 1.13 24 1.36 1.26 1.69 1.31 1.46 1.69 1.17 25 1.47 1.34 1.93 1.4 1.61 1.93 1.22 26 1.59 1.42 2.2 1.5 1.77 2.2 1.27 27 1.72 1.5 2.5 1.6 1.95 2.5 1.32 28 1.85 1.59 2.85 1.72 2.14 2.85 1.37 29 2.0 1.69 3.25 1.84 2.35 3.25 1.42 30 2.16 1.79 3.71 1.96 2.59 3.71 1.48 31 2.34 1.89 4.23 2.1 2.85 4.23 1.54 32 2.52 2.01 4.82 2.25 3.13 4.82 1.6 33 2.73 2.13 5.49 2.4 3.44 5.49 1.66 34 2.95 2.25 6.26 2.57 3.79 6.26 1.73 35 3.18 2.39 7.13 2.75 4.16 7.13 1.8 36 3.44 2.53 8.14 2.94 4.58 8.14 1.87 37 3.71 2.68 9.28 3.15 5.04 9.28 1.95 38 4.01 2.84 10.6 3.57 5.54 10.6 2.02 39 4.33 3.01 12.1 3.6 6.09 12.1 2.1 40 4.68 3.19 13.7 3.86 6.7 13.7 2.19

Note:

1. These values were obtained from tests carried out on polythene film 0.012mm thick with test potential of 50 volts

2. Considering (a) high resistivity of polythene (greater than 1x1017 Ω.cm at 200 C) and (b) the relatively low temperature co-efficient per 0 C. It is suggested that resistance value of cables/cores be recorded as megohms per 1000m at the appropriate test temperature and not be corrected to 200 C.

equipment specification engineering specification · pdf file15.1 acceptance testing procedure...

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