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Issue 3 1/6/2015

Infrastructure & Asset Management Specification E1322

Specification E1322: Specification for the Installation of Pipelines on Railway Land

Table of Issues

Issue Number Prepared (P)

Reviewed (R)

Amended (A)

Date Issued

1 Michael Berry (P) Not numbered E1322

19 April 2004

2 Michael Berry (A) Not numbered E1322

18 July 2007

3 Michael Berry (A) 28 February 2011

4 Michael Berry (A) 1 June 2015

SPECIFICATION FOR THE INSTALLATION OF PIPELINES ON RAILWAY LAND - E 1322

KiwiRail document E1322 of 22 1 June 2015

SCOPE This specification sets out the conditions governing the installation of pipelines under railway tracks or elsewhere on or under Railway Land. The relevant sections of Parts 1 & 2 also apply to aerial electrical and telecommunication conductors. Further requirements for aerial services can be obtained from KiwiRail’s Professional Head of Traction & Electrical Engineering which shall be considered on an individual basis. This specification does not supplant or override any conditions imposed by KiwiRail in entering into an agreement or executing a licence with the pipeline owner. Where Public Statutes, Local Government Ordinances, Bylaws or Orders of a Public Authority prescribe a higher degree of protection, than specified herein, then the higher degree of protection so prescribed shall be deemed a part of this specification. This specification is specific to KiwiRail and is for use on the KiwiRail network and connected private sidings where KiwiRail vehicles operate. KiwiRail takes no responsibility for its application to non-KiwiRail railways. Significant amendments to this Specification since issue 3 are shown by a vertical line thus:

INDEX PART 1: GENERAL REQUIREMENTS AND CONDITIONS

1.1 Definitions 1.2 Grant of Right 1.3 Renewal or Replacement of Pipelines 1.4 Pipes carrying Toxic or Corrosive Substances 1.5 Entry onto Railway Land 1.6 Markers 1.7 Identification 1.8 Warning Tape 1.9 After Installation

PART 2: APPLICATION FOR GRANT OF RIGHT

2.1 Application 2.2 Submission of Design

PART 3: DESIGN REQUIREMENTS

3.1 Location of Pipelines 3.2 Depth of Pipelines 3.3 Protection against Electrolysis or Corrosion 3.4 Loading 3.5 Encasement Pipes 3.6 Multiple Pipes 3.7 Reinforced Concrete Pipes 3.8 Steel Pipes 3.9 Polyethylene Pipes 3.10 Poly Vinyl Chloride Pipes 3.11 Ductile Iron Pipes 3.12 Ceramic Pipes 3.13 Bedding

PART 4: ADDITIONAL REQUIREMENTS FOR PIPELINES CARRYING NON-INFLAMMABLE SUBSTANCES

4.1 Pressure Pipelines 4.2 Gravitational Pipelines 4.3 Telecommunication Pipelines 4.4 Irrigation Pipes



PART 5: ADDITIONAL REQUIREMENTS FOR PIPELINES CARRYING INFLAMMABLE SUBSTANCES

5.1 Strength Requirements for Pipelines 5.2 Pipelines laid Below Ground Level 5.3 Pipelines laid Above Ground Level 5.4 Leakage of Inflammable Substances from Pipelines 5.5 Low Pressure Gas Pipelines 5.6 Location of Pipelines

PART 6: ADDITIONAL REQUIREMENTS FOR PIPELINES CARRYING ELECTRICAL CABLES

6.1 General 6.2 Segregation between pipelines 6.3 Restoration of Thermal Fill

PART 7: INSTALLATION

7.1 Safety 7.2 Disposal of Excavated Material 7.3 Backfilling of Excavations 7.4 Trenching or Tunnelling under Tracks 7.5 Trenchless Pipe Installation 7.6 Carrying out the Works

APPENDICES

Drawing 100 600 – Pipes carrying non-inflammable substances

Drawing 100 601 – Pipes carrying inflammable substances



PART 1: GENERAL REQUIREMENTS AND CONDITIONS 1.1 DEFINITIONS

Asset Engineer - shall mean the local Asset Engineer of KiwiRail responsible for the location of the pipeline Cable - shall mean a conductor which carries electrical power or telecommunications signals. Encasement - shall mean an external concrete (or approved other) surround to the pipe. Encasement Pipe - shall mean a protective pipe through which the pipeline is placed. Engineer - shall mean KiwiRail’s Professional Head of Civil Engineering or the Professional Head of the appropriate discipline to whom he may defer. KiwiRail - shall mean KiwiRail Limited. Owner (Service Provider) - shall mean the authority, body, applicant or licensee, or any party applying for, being granted, installing, using or maintaining any pipeline or crossing in or on Railway Land. Pipeline - shall mean a pipe or group of pipes that carry a liquid, gas, water, sewage or other conveyable substance. Rail level – Rail level shall mean the top surface of the rail on which train wheels run. On curves, this means the lower rail. Railway Land - shall mean any Land leased to KiwiRail Limited by the Crown and NZRC pursuant to the memorandum of lease dated 20 December 1991, as varied from time to time. Track – shall mean the construction on which railway vehicles run that comprises two rails on individual sleepers or within a slab. The track centreline is the point halfway between the two rails. Where a track has been removed or is yet to be placed the position of the track shall be as defined by the Engineer.

Note:

From this point forward, unless specifically noted, reference to “pipeline” shall also include the interpretation of a conduit containing a “cable” as defined in the above.

1.2 GRANT OF RIGHT

1.2.1 The owner of a Pipeline to be placed in or over Railway Land will be required to apply for and obtain a Grant of Right from KiwiRail prior to construction works commencing.

1.2.2 The Grant of Right states the conditions under which the Pipeline may be installed

and remain within Railway Land and is an agreement to pay to KiwiRail such fees that may be fixed by KiwiRail from time to time.

1.2.3 There is a one-off application fee and a documentation fee followed by an on-going

annual fee that are determined by KiwiRail’s Grants Administrator based on the nature of the proposed work.



1.3 RENEWAL OR REPLACEMENT OF PIPELINE

1.3.1 A renewal or replacement of an existing Pipeline or encasement Pipe shall be

considered as a new installation and shall be subject to the requirements of this specification.

1.4 PIPES CARRYING TOXIC OR CORROSIVE SUBSTANCES

1.4.1 A risk analysis and construction impact assessment is to be carried out by the owner for consideration by the Engineer before the pipeline alignment is finally determined.

1.4.2 Pipelines carrying toxic or corrosive substances shall comply with such

requirements as specified by the Engineer.

1.5 ENTRY ONTO RAILWAY LAND

1.5.1 Investigations and surveys leading to the design of the pipeline may require entry onto Railway Land. Persons may only enter Railway Land when they have a Permit to Enter. Unauthorized people on Railway Land without a Permit to Enter are trespassing.

1.5.2 A Permit to Enter is required to be able to enter to undertake work on Railway Land. No work may commence until a permit has been obtained.

1.5.3 Where traction overhead wires are present (Auckland metro area, Wellington metro area and Palmerston North to Hamilton), a separate and additional Electrical Safety Permit may also be required by third parties entering Railway Land. Persons working near or within 4 metres of the electric overhead wires must receive specific Electrification Awareness instruction. Note: In some locations, wires on poles that may appear to be telephone wires are actually 3.3kV power wires.

1.5.4 Permits to Enter and Electrical Safety Permits are issued by the Asset Engineer from offices located in Auckland, Hamilton, Palmerston North, Wellington, Christchurch and Dunedin. The reason for requiring a permit is to ensure that essential rail safety requirements are observed.

1.5.5 The Permits will specify the conditions applicable (including site induction, site rules and hazards) and any requirements to contact additional parties. KiwiRail will charge an administration fee and other fees depending on the services required (e.g. protection from trains).

1.5.6 Permission to enter rail freight terminals, shunting yards, sidings, rolling stock maintenance depots and other railway facilities should be sought from the site manager of the facility.

1.6 MARKERS

1.6.1 Markers shall be provided at the location of: (a) all pressure pipes 50 mm and over (b) all pipelines carrying an inflammable substance (c) Electrical cables (d) adjacent piers where a pipeline passes underneath a bridge (e) any pipeline that the owner wishes to have marked.



1.6.2 Markers shall have clear wording that adequately describe the nature of the

pipeline, the depth of the pipeline below ground level and contact details of the owner.

1.6.3 Markers shall be of robust construction of incombustible material as approved by

the Engineer. They may stand at least 600 mm out of the ground or be a tablet fixed in the ground as appropriate. They shall be located above the pipeline as follows:

a) At points of entering and leaving railway land; and b) At angles and points along the route within railway land.

Also in no case shall the distance between two consecutive markers be greater than 40 metres.

1.7 INDENTIFICATION

1.7.1 All pipelines shall bear identification by means of colour or lettering. It is appreciated that surface applied identification is not practicable for a pipe that is installed by a trench less method.

1.7.2 Standard colours are:

Water Blue or White Sewer Light grey Stormwater Dark grey Electricity Orange Gas Yellow Telecommunications Colour adopted by Company e.g. Chorus = light green

1.7.3 Identification colours may be stripes on pipes that are manufactured in a neutral

colour 1.8 WARNING TAPE

1.8.1 A plastic warning tape shall be laid 500mm above Pipelines that have been

installed in trenches. The tape shall be about 75mm wide, distinctly coloured and carry a warning about the presence of the pipeline below it.

1.9 AFTER INSTALLATION

1.9.1 A pipe carrying liquid or gas shall pass a leak test to prove its worthiness before

the pipe is put into service.

1.9.2 A drawing of the work as built shall be supplied by the owner to KiwiRail on completion of the pipeline installation.



PART 2: APPLICATION FOR GRANT OF RIGHT

2.1 APPLICATION

2.1.1 Please email the address [email protected] to obtain an application form for a Grant of Right.

2.1.2 There will be a one off non-refundable application fee payable at the time of application that is determined by KiwiRail’s Grants Administrator based on the nature of the proposed work.

2.1.3 Submit your application form and supporting documentation by email to

[email protected] The supporting documentation should include a letter giving the general background to the proposal and the items identified in section 2.2 based on the size and complexity of the proposed work.

2.2 SUBMISSION OF DESIGN

2.2.1 The application for a pipeline shall include sufficient detail to show the location, size, depth, configuration and construction methodology to enable KiwiRail to determine its compliance with this specification and suitability to enter Railway Land.

2.2.2 Pipelines smaller than 299mm diameter of normal utilities in a straight forward

installation will not require more than the items identified in clauses 2.2.1 and 2.2.5

2.2.3 Pipelines between 300 and 599mm diameter will require the submission of the

specification for the work, geotechnical information and construction methodology. Calculations may be requested by KiwiRail, if required.

2.2.4 Applications for pipelines 600mm diameter and over or for complex or unusual

projects shall have a Construction Management Plan that shall identify the proposed construction methods, structure type, plant and equipment, timeframes and external construction constraints. Detailed specifications, engineering calculations, ground investigations and, where applicable, Producer Statements should be submitted with the application.

2.2.5 Drawings shall show:

a) An appropriate title, an identification number and an issue date or code. b) The relationship (as surveyed) of the proposed pipeline to railway track (rail

and sleepers), other facilities, property boundaries and abuttal’s; c) Location of valves, pits and other relevant details; d) The names of adjacent streets and the Territorial Authority; e) A long-section of the pipeline in relation to the actual profile and levels of the

ground and railway track; f) A cross section if a multiple configuration is used or to show any special

features of the installation; g) The complete description of the pipe’s size and material; h) The details of any temporary sheeting, tunnel timbering or other construction

works; i) Location and description of markers. Drawings should preferably be lodged as .pdf files created from CAD originals rather than scans of printed versions. Hand drawn and computer sourced sketches are acceptable for simple proposals provided they are clear and are correctly proportioned.



PART 3: DESIGN REQUIREMENTS

3.1 LOCATION OF PIPELINES

3.1.1 Pipelines shall be located so that, where practicable, they cross railway tracks at

approximately right angles. In special cases, approval may be given to cross the tracks at other angles such as where pipelines are laid in a road that makes an oblique crossing with the railway.

3.1.2 Pipelines shall be laid clear of structures, cattle pits or stops, drains, signalling

equipment, overhead masts, buildings, points and crossings.

3.1.3 Pipelines may only be laid under bridges or through culverts under conditions that will be determined by the Engineer for each particular application.

3.1.4 Pipelines laid longitudinally in Railway Land shall be located within the following

parameters:

a) Less than 3 metres from the boundary of railway land but not less than 500mm from a fence.

b) More than 5 metres from the track centreline. c) More than 2 metres from the toe of formation embankments. d) More than 3 metres from the top edge of cuttings.

It will be essential for the length of each individual Pipeline proposal to be checked for obstructions, train and signal vision protection and to determine clearances and points of conflict. This should be done in conjunction with the Asset Engineer.

3.1.5 Special consideration shall be given to Pipeline locations in station yards to

minimise subsequent alterations to the Pipeline resulting from the expansion of railway facilities and possible siding connections to adjoining land.

3.1.6 Pipelines shall be designed to avoid the need for manholes or access pits on

Railway Land. If they cannot be avoided then they shall be located: a) More than 1.5 metres from the boundary of the railway land to provide

clearance to road vehicles and not to undermine a fence; b) More than 5 metres from the track centreline. c) More than 2 metres from the toe of formation embankments; and d) More than 3 metres from the top edge of cuttings.

3.2 DEPTH OF PIPELINES

3.2.1 The top of the pipeline or encasement pipe, where required, shall be at least 1500mm below rail level of main lines, loops and running lines and 1000mm below rail level in the case of sidings.

The pipeline shall be maintained at that depth for not less than 3.5 metres beyond track centreline, measured at right angles thereto.

3.2.2 The top of the pipeline or encasement pipe, where required, shall be at least

600mm beyond the toe if under an embankment 3.2.3 The top of the pipeline or encasement pipe, where required, shall be not less than

600mm below the bottom of drainage channels or shall be at such additional depth as directed/approved by the Engineer. This requirement may result in a greater depth below rail level in some situations than required in the above clauses.



3.2.4 Elsewhere on railway land, the top of the pipeline or encasement pipe where applicable, shall be not less than 900mm below ground surface,

3.2.5 The owner is to check the proposed route and existing cable depth(s) prior to

submitting the design for approval and prior to commencing works (KiwiRail experience suggests the ground sonar may be of assistance in this work).

3.3 PROTECTION AGAINST ELECTROLYSIS OR CORROSION

3.3.1 Protection against electrolysis or corrosion shall be provided and maintained by the owner to the satisfaction of the Engineer, if required by KiwiRail.

3.3.2 In electrified traction areas, all metallic services and metal pipelines in a network

(i.e. not just an encasement pipe) within Railway Land shall be provided with an electrical insulating coating approved by the Engineer.

Note: All new pipelines immediately beyond the current electrified Metro Areas should be electrically insulated to allow for the future extensions of electrification of the railway.

3.4 LOADING

3.4.1 A pipe which crosses under a railway line (or potential site of a railway line) must be able to withstand design railway loading at its installed depth.

3.4.2 For pipes less than 3.0m below rail level the design railway loading is 3 No.

250kN axles at 1.6m spacing plus an impact factor of 1.6. 3.4.2 For pipes more than 3.0m below rail level the design railway loading is an array of

250kN axles. A diagram of the spacing will be provided on application. 3.5 ENCASEMENT PIPES

3.5.1 The purpose of the encasement pipe is to divert liquid under pressure away from beneath the railway in the event of the carrier pipe leaking so that it does not wash out the railway formation or cause pollution. It also provides additional protection to the carrier pipe.

3.5.2 The encasement pipe shall extend at least 5 metres beyond track centre line,

measured at right angles to the track. This is so that the installation pit is beyond the limits where a protection person would be required to be provided for rail safety purposes.

3.5.3 Where the pipe goes beneath an embankment, the installation pit shall be at least

2 metres from the toe of the embankment to prevent instability of the embankment.

3.5.4 The inside diameter of the encasement pipe shall be greater than the outside

diameter of the carrier pipe, its joints or couplings by at least the following ratio:

Carrier pipe maximum OD Proportional increase to encasement pipe ID Up to 249mm 1.40 250 to 400mm 1.33 Greater than 401mm 1.25



3.5.5 Encasement pipes shall be provided for pipes larger than 55mm inside diameter carrying liquid under pressure (e.g. pumped) and pipes carrying hazardous material. Encasement pipes are not required for power and telecommunications ducts but may be used to contain multiple ducts.

3.5.6 Where an encasement pipe is used, the encasement pipe will become the criteria

for which all requirements will be addressed. Therefore, the carrier pipe may continue as the same material through the Railway Corridor.

3.6 MULTIPLE PIPES

3.6.1 Multiple pipes carrying compatible contents may share an encasement pipe. The encasement pipe internal diameter shall be 100mm greater than the combined outside diameters of the carrier pipes over their couplers to allow for removal of an individual pipe.

3.6.2 Multiple pipes over 200mm internal diameter and less than 3 metres below ground level shall be spaced apart by the same distance as the their depth below ground to avoid large settlement occurring under the railway.

3.6.3 A matrix of up to 100mm nominal diameter pipes that are only carrying cables may be placed in a bored hole that is then filled with slurry cement around the pipes.

3.7 REINFORCED CONCRETE PIPES

3.7.1 Reinforced concrete pipes shall comply with AS/NZS 4058:2007 “Pre-cast concrete pipes (pressure and non-pressure)”.

3.7.2 Concrete pipes that are within 5.0 metres of the track centreline or within the

formation embankment shall be Class 4 (old Class Z) pipes. 3.7.3 Elsewhere, other than described in paragraphs 3.7.2 above, concrete pipes shall

be Class 2 (old Class X) unless otherwise directed by the Engineer. 3.8 STEEL PIPES

3.8.1 Steel pipes shall be manufactured from steel complying with an approved specification and have a minimum yield stress of 240 MPa.

3.8.2 Steel pipes shall have a means of corrosion protection such as galvanizing,

specialist coating system, Denso tape, Polyken wrap or similar unless a thicker unprotected option is used. Pipes that are laid in open trench must be protected.

3.8.3 Steel pipes shall have a minimum wall thickness as follows:

Outside Diameter (mm) Minimum Wall Thickness (mm)

Protected Unprotected 100 mm and under Heavy wall Not permitted Over 100 mm and under 340 mm 6 mm 7 mm 356mm, 406mm, 457mm 7.9 mm 9.5 mm 508 mm, 559 mm 9 mm 12.7 mm 610 mm, 660 mm 10 mm 14.2 mm 711mm, 762 mm 12.7 mm 15.8 mm 813mm, 864mm, 914 mm 15.8 mm 17.4 mm > 950mm Subject to Engineering review/approval



3.9 POLYETHYLENE (PE) PIPES

3.9.1 PE pipes shall comply with AS/NZS 4130:2009 “Polyethylene (PE) pipes for pressure applications”.

3.9.2 PE pipes must be less than 320 outside diameter if they are under a railway track. 3.9.3 PE pipes shall be a minimum of PN10 ( = SDR13.6 as PE80 or SDR 17 as PE100)

if they are under a railway track. 3.9.4 PE pipes that are inside an encasement pipe or are not in an area subject to heavy

loading may be of a lower strength grade.

3.10 POLY VINYL CHLORIDE (PVC) PIPES

3.10.1 PVC pipes must be less than 320 outside diameter. 3.10.2 For non-pressure applications uPVC pipes shall be a minimum of class SN16.

They shall comply with either AS/NZS 1254:2010 “PVC-U pipes and fittings for stormwater and surface water applications” or AS/NZS 1260:2009 “PVC-U pipes and fittings for drain, waste and vent applications”.

3.10.3 For pressure applications uPVC and mPVC pipes shall be a minimum of class

PN16. They shall comply with AS/NZS 1477:2006 “PVC pipes and fittings for pressure applications” or AS/NZS 4765:2007 “Modified PVC (PVC-M) pipes for pressure applications”.

3.10.4 PVC pipes that are inside an encasement pipe or are not in an area subject to

heavy loading may be of a lower strength grade. 3.11 DUCTILE IRON PIPES

3.11.1 Ductile iron pipes shall comply with AS/NZS 2280:2004 “Ductile iron pipes and fittings”.

3.12 CERAMIC PIPES

3.12.1 Ceramic pipes are not permitted within 5 metres of the track centre line or under areas subject to heavy loads.

3.13 BEDDING

3.13.1 Bedding of encasement pipes and of pipelines within the formation but not requiring encasement shall be in accordance with bedding type HS2 of AS 3725.

Note: Dimensions are given to track centreline. On site measurements may be taken to the outside face of the rails and 0.5m subtracted from the specified figure. Rails may have an electrical current running through them which would be shorted out by a metal tape between them. Non-metallic tapes must be used when measuring to rails. Metallic tapes must not be used where overhead wires are present.



PART 4: ADDITIONAL REQUIREMENTS FOR PIPELINES CARRYING NON-INFLAMMABLE SUBSTANCES

(see Drawing CE No. 100600) 4.1 PRESSURE PIPELINES

4.1.1 Pipelines carrying liquid or other substances under pressure shall be placed inside an encasement pipe for at least 5 metres each side of track centreline measured at right angles to the track. Refer to Clause 3.5.

4.1.2 The pipeline designer must verify that the carrier pipe can cope with being un-

confined inside the encasement pipe; i.e. not requiring surrounding soil for support or restraint for thrust loads (e.g., thermal, water hammer). The annulus between the carrier pipe and the encasement pipe may be packed or filled if required.

4.1.3 If allowed by the Engineer, the encasement may take the form of a solid reinforced

concrete encasement of such cross-sectional dimensions and with such reinforcement as approved by the Engineer.

4.1.4 Pipelines less than 55 mm inside diameter will not require an encasement pipe.

4.2 GRAVITATIONAL PIPELINES

4.2.1 Pipelines operating under gravity have no additional requirements to those in Section 3.

4.2.2 Where a drainage pipe is connected to unlined drains on railway land, an end wall

and apron shall be provided where directed and be to the approval of the Engineer. 4.3 TELECOMMUNICATIONS PIPELINES

4.3.1 Pipelines containing telecommunications cables have no additional requirements to those in Section 3.

4.4 IRRIGATION PIPES

4.4.1 Unless otherwise specifically approved by the Engineer, the pipe shall be reinforced concrete Class 4 (old Class Z) bedded in accordance with Clause 3.13. The pipe shall have an end wall brought up to 600 mm above full supply level of the approach channel.

4.4.2 The full supply level of the approach channel within Railway Land shall be at least

600 mm below rail level. 4.4.3 Provision shall be made for the free flow of drainage along railway land. 4.4.4 Where any irrigation pipe flows full, is under head or acts as a siphon, the pipe

shall have flexible rubber ring joints. 4.4.5 End walls and an apron shall be provided where any irrigation pipe under the track

connects to unlined channels on railway land.



PART 5: ADDITIONAL REQUIREMENTS FOR PIPELINES CARRYING INFLAMMABLE SUBSTANCES (see Drawing CE No. 100601)

5.1 STRENGTH REQUIREMENTS FOR PIPELINES

5.1.1 Pipelines carrying oil, liquefied petroleum gas, natural or manufactured gas and other inflammable substances shall conform to the requirements of the American Standard Codes ASA B31.4, Code of Oil Transportation Piping, ASA B.31.8, Code of Gas Transmission and Distribution Piping Systems, and other applicable American Standard Codes, except that –

For steel pipes within an encasement pipe under a railway track and across railway land, the hoop stress shall not exceed:

i) Seventy-two percent of the specified minimum yield strength, multiplied by the

appropriate longitudinal joint factor, for oil pipelines. ii) Fifty percent of the specified minimum yield strength, multiplied by the

appropriate longitudinal joint factor, for pipelines carrying liquefied petroleum gas and other inflammable liquids with low flashpoint.

iii) Sixty percent of the specified minimum yield strength, multiplied by the

appropriate longitudinal joint factor, for gas pipelines.

For steel pipe laid longitudinally along railway land, hoop stress should not exceed: i) Sixty percent of the specified minimum yield strength, multiplied by the

appropriate longitudinal joint factor for oil pipelines. ii) Forty percent of the specified minimum yield strength, multiplied by the

appropriate longitudinal joint factor, for oil pipelines.

5.1.2 Strength requirements for pipelines under railway tracks shall apply for a minimum distance of 15 metres beyond outer rails measured at right angles thereto, or 7.5 metres beyond the ends of encasement pipe, whichever is greater. The pipeline shall be laid with sufficient slack so that it is not in tension.

5.1.3 Where, in the above mentioned Codes, a reference is made to other American Codes or Specifications, the equivalent NZS or ESS Code or Specification, if any, shall be applicable.

5.2 REQUIREMENTS FOR PIPELINES CARRYING INFLAMMABLE SUBSTANCES LAID

BELOW GROUND LEVEL

5.2.1 Where the pipeline passes under a railway track, it shall be encased in a steel encasement pipe complying with the requirement of Clauses 3.5 & 3.8.

5.2.2 Encasement pipes shall be so constructed as to prevent leakage of any substance

from the casing throughout its length, or through any portion of the vent pipes other than at the outer end of the vent pipe. The ends of the encasement pipe shall be suitably sealed to the outside of the pipeline.

5.2.3 The inside diameter of the encasement pipe shall be such as to allow the pipeline

to be removed subsequently without disturbing the encasement pipe. All joints or coupling supports, insulators or centering devices for the pipeline within an encasement pipe under railway tracks shall be taken into account.



5.2.4 In addition, a minimum vertical deflection of the encasement pipe of 3 percent of its own diameter, plus 12 mm clearance shall be provided so that so loads from the roadbed track traffic or encasement pipe itself are transmitted to the pipeline.

5.2.5 When insulation is used on the pipeline, the inside diameter of the encasement

pipe shall be at least 50mm greater that the outside diameter of the pipeline for pipes less that 200mm in diameter; at least 80mm greater for pipes 200mm to 400mm inclusive in diameter, and at least 112 mm greater for pipes 450 mm in diameter and over.

5.2.6 Encasement of pipelines under railway tracks shall extend to the greater of the

following distances, measure at right angles to the track: a) 600 mm beyond toe of bank; and b) A minimum distance of 8 metres from centreline of track.

5.2.7 Pipelines and encasement pipes shall be suitably insulated from underground

conduits carrying electric wires or power cables within Railway Land. 5.2.8 Encasement pipes shall be properly vented. Vent pipes shall be of sufficient

diameter, but not less than 50 mm, shall be attached near each end of the encasement pipe and project through ground surface hard against the boundary fence or not less than 15 metres measure at right angles from the centre of the nearest track.

5.2.9 Vent pipe, or pipes, shall extend not less that 1200 mm above ground surface.

Top of vent pipe shall be fitted with a relief valve or down turned elbow and in either case shall be properly screened and flame-trapped. Unless otherwise approved by the Engineer, vent pipes, other than those hard against the boundary fence, shall not be located within 4.5 metres of the boundary fence or within 3.5 metres of the top of a cutting of the toe of a bank.

5.2.10 Vents, in locations subject to high water, shall be extended to the maximum

elevation of high water, and shall be supported and protected in a manner approved by the Engineer. Vent pipes shall be at least 4.5 metres measured horizontally from aerial wires.

5.2.11 All piping above ground, valves, fittings and attachments shall be subject to regular

inspection and testing by the owner. The whole of the installation shall be subject, at intervals as prescribed by the Engineer, to an approved pressure test, in which the pressure shall be not less that 1.1 times the approved working pressure. The owner shall thereupon certify in writing that the whole of the installation is in sound order, safe for the purpose for which it is designed, and that all automatic valves and safety devices are operating satisfactorily.

5.2.12 Accessible emergency shut-off valves and reflux valves shall be installed within

effective distances each side of the railway as approved by the Asset Engineer. Such valves shall have permanently fixed to them instructions relative to their operation. Where pipelines are provided with automatic control stations at locations and within distances approved by the Engineer, no additional valves shall be required. The location of all valves shall be subject to the approval of the Asset Engineer.

5.2.13 Pumping stations will not be permitted within or on Railway Land unless especially

authorised by the Engineer.



5.3 REQUIREMENTS FOR PIPELINES CARRYING INFLAMMABLE SUBSTANCES LAID

ABOVE GROUND LEVEL

5.3.1 Pipelines shall be adequately supported on non-combustible pedestals, and the supports shall be of such design as to prevent mechanical abrasion of the pipe and seating.

5.3.2 The areas beneath, and for a distance of at least 2 metres outside, the outer limits

of any installation shall be kept clear by the owner of all inflammable substance. The method of vegetation control and disposal of inflammable substance shall be subject to the approval of the Asset Engineer.

5.3.3 Piping, fittings, attachments and pedestals shall be protected against corrosion and

mechanical damage. 5.3.4 Piping, valves, fittings and attachments shall be subject to regular inspections and

testing by the owner. The whole of the installation shall be subject, at intervals as prescribed by the Engineers, to an approved pressure test, in which the pressure shall be not less that 1.1 times the approved working pressure stated in Clause 1.6. The owner shall thereupon certify in writing that the whole of the installation is in sound order, safe for the purpose for which it is designed, and that all automatic valves and safety devices are operating satisfactorily.

5.3.5 Accessible emergency shut-off valves and reflux valves shall be installed within

effective distances each side of the railway as approved by the Engineer. Such valves shall have permanently fixed to them instructions relative to their operation. Where pipelines are provided with automatic control stations at locations and within distances approved by the Engineer, no additional valves shall be required. The location of all valves shall be subject to the approval of the Asset Engineer.

5.3.6 Pumping stations will not be permitted within or on railway land, unless especially authorised by the Engineer.

5.4 LEAKAGE OF INFLAMMABLE SUBSTANCES FROM PIPELINES

5.4.1 In the event of any leakage of inflammable substances from any pipeline on railway land, the owner shall immediately confer with the Asset Engineer on action to be taken to dispose of such leakage, and to prevent further leakage, and shall take such action at such times, and with such precautions as are approved by him.

5.4.2 Actions required to manage, contain, and remediate the leakage event and

remediate any affected areas, maybe undertaken by KiwiRail at the owners cost. 5.5 LOW PRESSURE GAS PIPELINES

5.5.1 Gas pipelines not greater than 75 mm in diameter and with pressures not

exceeding 70kPa may be installed without any encasement pipe.

5.6 LOCATION OF PIPELINES

5.6.1 Pipelines carrying inflammable substances will not be permitted through railway

culverts or bridges, nor closer than 15 metres to any portion of any railway bridge, building or other important structure, except in special cases and then only when



the Pipeline is encased and where the design and condition are specifically approved by the Engineer.

5.6.2 Pipelines carrying inflammable substances laid above ground level shall be located

not less than 15 metres from the outer rail of the nearest adjacent track or of the nearest part of any bridge or any other important structure, or less than 4.5 metres from the boundary fence unless with the approval of the Engineer. The pipe shall be placed underground at points of entry and access roadways for Track maintenance and where otherwise required by the Asset Engineer.



PART 6: ADDITIONAL REQUIREMENTS FOR PIPELINES CARRYING ELECTRIC CABLES

6.1 GENERAL

6.1.1 Electric cables shall be contained in pipes whilst passing through Railway Land. 6.1.2 Electric cabling shall comply with AS/NZS 3000:2000 “Electrical Installations”.

6.2 SEGREGATION BETWEEN PIPELINES

6.2.1 Pipelines carrying electric cables shall be separated from other pipelines by the

following minimum amounts:

Low voltage power, signals and telecommunications 150mm High voltage (>650 V) power 450mm Low and medium pressure gas 150mm High (> 2000 kPa) pressure gas 600mm Water mains 450mm

6.2.2 Pipelines installed by a trenchless method shall be 500mm from any KiwiRail or railway operator’s cable.

6.2.3 A minimum lateral clearance of 1 metre applies to any Communications fibre optic

cable running along the railway corridor. 6.2.4 Other party’s earth pegs shall have a minimum lateral clearance of 3 metres from

any KiwiRail or railway operator’s earth peg or railway line and 1 metre from any KiwiRail or railway operator’s cable.

6.3 RESTORATION OF THERMAL FILL

6.3.1 Where a power cable is replaced or disturbed, the thermally stable backfilling shall

be restored with matching backfill.



PART 7: INSTALLATION 7.1 SAFETY

7.1.1 The safety of the persons undertaking the work, railway staff and the general public is paramount. A site specific safety plan shall be prepared and observed.

7.1.2 People and machines must not approach closer than 5 metres from track centreline

or 4 metres from overhead wires without the supervision of designated railway staff. A machine’s potential maximum reach must not be capable of encroaching within 5m from track centreline. Machine operators must be particularly alert to the approach of trains and shall cease operating unless permitted to continue by the railway protection person.

7.1.3 Red or green flags shall not be displayed on Railway Land. Persons working near a

railway track shall wear high visibility clothing and must avoid red or green garments. 7.1.4 Barriers shall be erected around open excavations and access pits adjacent to

access ways provided that they are 3 metres away from the track centreline. Warning lights must be placed around open excavations during darkness but must not be placed so as to be confused with railway signals. Excavations that are closer than 3 metres to track centreline must not be left open during darkness.

7.2 DISPOSAL OF EXCAVATED MATERIAL .

7.2.1 Material from excavations shall be deposited in a position and manner approved by

the Asset Engineer and shall be kept clear of track ballast so as to avoid fouling of ballast and blocking of track drainage.

7.2.2 Under no circumstances shall excavated soil be thrown directly on to the track

ballast. 7.2.3 Where it is necessary to place such material between the rails or upon the ballast

shoulders, a suitable screen of hessian, timber or other approved material shall be used to protect the ballast and such screen and material shall be removed on completion.

7.3 BACKFILLING OF EXCAVATIONS

7.3.1 All excavations under tracks and for a distance of at least 3 metres beyond the outer rails, and including the whole of any embankment and under roadways, shall be backfilled and compacted with fine crushed rock, gravel or other approved material to the satisfaction of the Asset Engineer.

7.3.2 All other excavations shall be backfilled with approved material, properly

compacted. The property of KiwiRail shall be left in a clean and tidy condition. 7.4 TRENCHING OR TUNNELLING UNDER TRACKS

7.4.1 Where pipelines or pipes are installed by trenching or tunnelling under tracks, the excavations shall be adequately timbered, as specified by the Engineer. The top of the tunnel timbering shall be at least 2 metres below rail level.

7.4.2 Temporary supports (e.g. sheet piling) to the tracks shall be at the cost of the

Owner at the sole discretion of the Asset Engineer.



7.4.3 The cavity between the tunnel wall and the pipeline shall be filled with properly

compacted fine crushed rock, sand gravel or by other material approved by the Asset Engineer.

7.4.4 Monitoring of track settlement and any remedial actions, shall be as determined by

the Asset Engineer. 7.5 TRENCHLESS PIPE INSTALLATION

7.5.1 Where pipes are installed under railway tracks by a trenchless method, the diameter of a bored hole shall not exceed the diameter of the pipe by more than 10%. The cavity between the pipe and the hole shall be filled with material approved by the Engineer. Excess bentonite shall be disposed of at an approved disposal site and shall not be discarded on Railway Land.

7.5.2 A settlement study may be required for pipelines greater than 300mm diameter.

The study shall predict the amount of settlement that will occur as a result of the work taking into account the nature of the ground and the method of installation.

7.5.3 For pipes greater than 300mm diameter a system for monitoring the track for

settlement shall be undertaken by the owner. Before commencing work under the railway line, levels are to be measured on the head of one rail of each track immediately above the centre of the pipeline and at a distance of 2 metres each side and recorded with the Asset Engineer. Measurements shall be made at every 3 metres of progress of the pipes installation or hole boring under the railway line. Should any change in track alignment or rail level exceed +/- 10mm from the initial measurement, the work shall be halted and the Asset Engineer notified immediately.

7.5.4 A railway protection person shall be present on site through out the period that a

pipe greater than 900mm diameter is being installed. That person will be responsible for halting all rail services should any change exceeding the above mentioned limits occur. All work shall cease while the Asset Engineer reviews the situation and undertakes any work required to reopen the railway lines. All costs associated with this shall be at the Owner's expense.

7.6 CARRYING OUT THE WORKS

7.6.1 No work shall be commenced on Railway Land for the installation, maintenance or

removal of any pipeline until details of the proposal have been submitted to and approved by KiwiRail and a Grant of Right issued for the work or other written notice stating the conditions to be imposed that have been agreed to in writing by the Owner.

7.6.2 The work shall be carried out only in the manner and at such times as directed by

the Asset Engineer and to his entire satisfaction. Adequate notice must be given prior to commencement of the work. Blasting shall only be carried out in accordance with the condition laid down by the Asset Engineer.

7.6.3 Any work within 5 metres of the track centreline or any other portion of the work so

determined shall be carried out only in the presence of the Asset Engineer’s representative and in accordance with his directions.

7.6.4 Pipes shall be installed in accordance with AS/NZS 2566 or the relevant NZ

Standard Specification. Encasement pipes shall be installed so as to prevent leakage of any substance from the encasement pipe throughout its length.



7.6.5 The use of mechanical appliances for excavating or lifting under overhead structures or aerial cables is prohibited, unless the owner has first established to the satisfaction of the Asset Engineer, that adequate clearance exists.

7.6.6 The Asset Engineer shall have power to order the suspension of work if he

considers that it is being performed in an unsafe or unsatisfactory manner.

specification for the installation of pipelines e1322 3nov ) for the... · specification for the...

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