st emergency lighting engineering specification...2000/10/23 · as 1627.4 metal finishing –...

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LV TUNNEL SERVICES BOARD

EP 23 10 00 01 SP

Engineering Specification Electrical

Version 2.1

Issued April 2013

Owner: Chief Engineer, Electrical

Approved by:

Neal Hook Chief Engineer Electrical

Authorised by:

Neal Hook Chief Engineer Electrical

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 14

RailCorp Engineering Specification — Electrical LV Tunnel Services Board EP 23 10 00 01 SP

© RailCorp of 14 Issued April 2013 UNCONTROLLED WHEN PRINTED Version 2.1

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Document control

Version Date Summary of change May 2008 Last Technical Review

2.0 May 2010 Application of TMA 400 format. 2.1 April 2013 Template update



Contents

1 Introduction .............................................................................................................................4 2 Scope and Application ...........................................................................................................4 2.1 General......................................................................................................................................4 2.2 Application.................................................................................................................................4 3 References...............................................................................................................................4 3.1 Australian Standards.................................................................................................................4 3.2 RailCorp Standards...................................................................................................................5 3.3 RailCorp Drawings ....................................................................................................................5 4 Background .............................................................................................................................5 5 Functional Characteristics.....................................................................................................6 6 Technical Requirements.........................................................................................................6 6.1 General......................................................................................................................................6 6.2 Incomer and Automatic Transfer Switch ...................................................................................7 6.3 Distribution Section ...................................................................................................................7 6.4 Lighting Control and Monitoring Section ...................................................................................7

6.4.1 Normal lighting Controls ............................................................................................8 6.4.2 Emergency Lighting Controls ....................................................................................8 6.4.3 Local indication ..........................................................................................................8 6.4.4 Selector Switches ......................................................................................................8 6.4.5 Pushbuttons...............................................................................................................8 6.4.6 Contactors .................................................................................................................9 6.4.7 System Monitoring .....................................................................................................9

6.5 PLC Requirements....................................................................................................................9 6.5.1 Hardware ...................................................................................................................9 6.5.2 Software.....................................................................................................................9 6.5.3 Functional requirements ............................................................................................9

6.5.3.1 Normal lighting .........................................................................................10 6.5.3.2 Emergency lighting...................................................................................10

6.6 SCADA Interface.....................................................................................................................11 7 Maintenance ..........................................................................................................................11 8 Testing....................................................................................................................................11 9 Data Set Associated with the Equipment ...........................................................................11 Appendix A Technical Schedule ...............................................................................................12 Appendix B RFT Checklist.........................................................................................................13 Appendix C Requirements for Technical Aspects of Tender Evaluation .............................14

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1 Introduction This document describes the whole of life performance requirements for the purchase and maintenance of low voltage tunnel services distribution boards. The document covers design the minimum design, manufacturing, documentation and maintenance requirements and practices

2 Scope and Application

2.1 General This document sets out the minimum requirements for design and manufacture of Tunnel Services Boards deployed in RailCorp’s infrastructure. It includes requirements relating to the equipment as a whole and components used in the equipment.

A Tunnel Services Board provides protection and power distribution to normal and emergency lighting and miscellaneous small power within the tunnel. The board is configured to connect to two independent incoming supplies and includes an automatic transfer switch. The board also interfaces with push button control stations for control of normal lighting and provides indication of the mode and status of tunnel lighting, including individual battery maintained emergency light fittings.

Tunnel Services Boards do not supply sump pumps or vent fans within the tunnel. These are supplied separately.

2.2 Application The requirements of this document apply when a new tunnel services board is purchased or installed in the RailCorp network from the date of issue that this specification is approved.

The requirements of this document apply when an existing tunnel services board is modified or refurbished.

The requirements of this document are not applicable to the configuration of existing tunnel services boards currently in service in the RailCorp network.

3 References The following documents contain provisions which, through reference in this text, constitute provisions of this Standard.

At the time of publication, the editions indicated were valid.

3.1 Australian Standards The following Australian Standards are either referenced in this document or can provide further information.

AS 1102 Graphical Symbols for Electrotechnical Documentation AS 1627.4 Metal finishing – Preparation and pre-treatment of surffaces –

Abrasive blast cleaning AS 1939:1990 Degree of Protection provided by Enclosures for Electrical Equipment

(IP code)

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AS 2700 Colour Standards for General Purposes AS/NZS 3000:2007 Electrical installations – known as the Australian/New Zealand

wiring rules AS/NZS 3439.1 Low Voltage Switchgear and Controlgear Assemblies – Type

tested and partially type tested assemblies AS/NZS 3100 Approval and test specification – General requirements for electrical

systems AS 60898.1 Electrical accessories – Circuit Breakers for Overcurrent Protection for

household and similar installations AS60947 Low Voltage Switchgear and Controlgear

3.2 RailCorp Standards Key RailCorp Standards:

Several significant sets of requirements applicable to tunnel services boards are common to other classes of equipment and are set out in the following RailCorp standards. The equipment shall comply with the relevant requirements set out therein.

EP 00 00 00 12 SP Electrical Power Equipment – Integrated Support Requirements EP 00 00 00 13 SP Electrical Power Equipment – Design Ranges of Ambient Conditions EP 00 00 00 15 SP Common Requirements for Electrical Power Equipment The following RailCorp documents are either referenced in this document or can provide further information.

EP 00 00 00 00 MP Electric Power Technical Maintenance Plan EP 17 00 00 06 SP Installation Inspections ESC 340 Tunnels

3.3 RailCorp Drawings The following drawings form part of this specification:

EL 0413476 Tunnel Services Board Tunnel Lighting Panel Schematic Diagram EL 0413477 Tunnel Services Board Lighting Control Panel Schematic Diagram EL 0413478 Tunnel Services Board Change Over Power DB Schematic Diagram EL 0413479 Tunnel Services Board Change Over Control Circuit DB Schematic Diagram

4 Background The RailCorp network includes a significant length of tunnels, in some cases connecting underground stations in underground railways and on other cases discrete tunnels connecting sections of surface rail lines. RailCorp’s rail Tunnels are both single and double track configurations. The majority of the rail lines in RailCorp’s rail tunnels are electrified. The overhead electric traction system operates at 1500V DC with negative return via the rails. The rails are near earth potential but are not earthed.

Tunnel services boards are usually located in stations for underground railways and outside tunnel portals for discrete tunnels. In longer tunnels or sections of underground railway, the services within the tunnel will be supplied from two tunnel services boards, one at each end. In such cases there is no connection between the services supplied from one end and those supplied from the other end.

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In underground railways, the Tunnel Services Board will be installed within a room or an enclosure with a minimum fire rating of two hours.

Power supplies to tunnel services boards will normally be derived from two independent RailCorp supplies or from one RailCorp supply and one supply from the local electricity distributor. The tunnel services boards should be connected to distribution main switchboards and not to a railway station installation main switchboard or a sub-board within a railway station installation.

The RailCorp supply is normally derived from a RailCorp 11kV feeder which in turn is derived from a RailCorp sub-transmission (traction supply) feeder. The traction rectifier loads result in significant harmonic distortion on some parts of the RailCorp HV network and this is may be see on the LV supply connected to the tunnel services board.

In order to prevent traction leakage current from the rails from flowing in the earth conductor the RailCorp LV distribution systems are generally earthed at one point only and an insulated earth conductor is reticulated with the phase and neutral conductors.

5 Functional Characteristics Tunnel Services Boards covered by this standard shall:

• Provide separate isolators for each of two incoming supplies. • Provide an automatic transfer switch to automatically select between the two

incoming supplies. • Provide for distribution and circuit protection for:

– Normal tunnel lighting – Emergency tunnel lighting – Power outlets – Marker lights for refuges equipped with phones – Provide controls for normal tunnel lighting – Provide controls for emergency tunnel lighting

• Provide monitoring for individual battery maintained emergency tunnel light fittings. The monitoring unit will be a free issue item.

• Provide local indication of system status. • Provide interface to the electrical SCADA for indication of status.

6 Technical Requirements

6.1 General The Tunnel Services Board shall be a 3 ph. +N +E board of Form 1 construction to AS3439.1 and shall have a degree of environmental protection of IP65 to AS1939.

The Tunnel Services Board shall be suitable for both top and bottom entry cables.

The Tunnel Services Board shall be supplied complete with all internal wiring

A document pocket shall be provided on the door of the cubicle.

The Tunnel Services Board shall consist of the following segregated sections:

• Incomers and changeover switch • Distribution Section • Controls, PLC, indications and alarms • SCADA interface

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6.2 Incomer and Automatic Transfer Switch An automatic transfer switch shall switch to the backup supply on failure of the normal supply. Phase failure relays shall be installed on both incoming supplies and on the load side of the transfer switch.

The Transfer Switch shall be Schneider BTS or RailCorp approved equivalent. By means of a selector switch on the front of the panel, it shall be possible to bias the supply to select either of the incomers as the Normal Supply.

Note:

As it is more important to maintain supply to the lights than ensuring power quality, phase failure relays with a voltage tolerance of a minimum of 75% to 125% of nominal voltage shall be selected. The effect of possible harmonic distortion on the phase failure relays shall also be considered and appropriate units selected.

6.3 Distribution Section The power distribution section shall be based on a standard, commercially available distribution board. The distribution board shall have provision for a minimum of 25% spare circuit breakers and contactors. Pole fillers shall be fitted to all spare poles.

Distribution board shall be one of the following types:

DB Type 1 2 3 4 Number of 1 phase poles 24 36 48 60 Number of poles fitted with RCD’s for GPO’s 3 6 9 9

Main Switch Rating – Amps 250 250 250 250 Busbar Rating – Amps 250 250 250 250 Minimum number of PLC inputs/ outputs 32/16 32/16 64/32 64/32

Circuit breaker ratings shall be rated at 16A. GPO circuit breakers shall be equipped with Residual Current Devices rated at 30mA. Circuit breakers shall meet the requirements of AS 60898.1.

The distribution board shall be rated for a fault current of 30kA for 0.1 seconds.

6.4 Lighting Control and Monitoring Section The control functionality shall be in accordance with the Schematic Diagrams listed in Section 3.3 above.

The control section shall include all relays, contactors, indicating lights, switches, pushbuttons and terminals associated with tunnel services.

The required functionality shall be achieved by means of a Programmable Logic Controller.

Power supplies to the control section shall be from a dedicated circuit breaker sourced downstream of the Automatic Transfer Switch.

Control functionality shall conform with Sections 6.4.1 to 6.4.3 below.

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6.4.1 Normal lighting Controls Power to normal tunnel lighting shall be supplied by means of a number of single-phase circuit breakers. Each tunnel or portion of a tunnel shall be supplied by a group of three circuit breakers spread across the three phases.

Under normal operating conditions only one phase within a group will be energised and every third light in the tunnel will be switched on. The set of active lights will rotate between the three phases at regular intervals, nominally one week.

Outputs to the lights shall be wired to terminals in the tunnel services board via a normally closed contactor contact which will be controlled by the PLC. For 2 out of every 3 lights, the contactor will be energised and the tunnel lights will be off. An external input, initiated by pushbuttons at the tunnel entrances shall cause the contactor to de-energise and turn all groups on, nominally for two hours.

Bypass selector switches, one per tunnel shall be installed on the front of the Tunnel Services Board. When selected bypass the circuit breakers will connect directly to the output terminals turning on the lights.

6.4.2 Emergency Lighting Controls Controls shall be implemented in PLC logic.

All emergency lighting circuits shall be wired in series with a normally closed contactor contact. Test pushbuttons (one per 3 circuits) shall be provided to test the test the emergency lighting batteries. On operation of the test button the PLC shall open the contactor supplying the emergency lights and cause the batteries to commence discharging. After 4 hours the PLC will cause the contactor to de-energise and the batteries will re-commence charging.

A reset pushbutton shall be installed which will end the timing cycle when operated.

6.4.3 Local indication Indicating lights shall be installed for the following

• Normal supply available • Emergency supply available • Normal supply ON • Emergency supply ON • Output ON • Normal lights on full i.e. all lights within a group turned on • Emergency lights on test (per group of 3 emergency lighting circuits)

Indicator lights shall be LEDs, 22mm diameter.

6.4.4 Selector Switches Selector switches shall be provided for:

• Bypass ON-OFF

6.4.5 Pushbuttons The following pushbuttons shall be installed on the front of the panel:

• All normal lights ON pushbutton

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• Lights OFF pushbutton. • TEST emergency lighting • RESET emergency lighting test

Pushbuttons shall be to 22mm diameter to AS 60947.5.1.

6.4.6 Contactors Contactor shall be single phase and rated at 240V 40A for normal lights and 415V 40A three phase for emergency lights.

6.4.7 System Monitoring Space shall be provided to install an approved emergency light monitoring unit. Approximate dimensions are 315mm long x 55mm high x 125 mm deep. Ducting shall be provided on two sides of the unit to enable running of wiring connections. The emergency light monitoring unit will be a free issue item. Allowance shall be made to wire 2 potential free contacts to suitably labelled terminals for future external use.

A suitable mounting plate shall be installed for mounting the monitoring unit into the switchboard without drilling into the switchboard.

6.5 PLC Requirements

6.5.1 Hardware The PLC shall be a standard commercially available product. The PLC shall be of modular design, and shall be capable of expansion by the insertion of additional cards in spare I/O slots. The PLC shall operate from a single phase 240V 50Hz supply. Other voltages required for the operation of the PLC and I/O shall be derived from the 240V single phase supply.

Inputs shall operate from a 24V dc. supply generated internally by the PLC.

PLC outputs shall be voltage free contact outputs and shall be sized to operate the inrush current of the contactors but shall in any event be capable of switching 2A at 240Volts. If required, outputs shall be equipped with interface relays to achieve the required current rating. PLC outputs shall be fail safe. i.e if the power supply or the PLC fails, the output shall revert to an OFF state (output contact open).

6.5.2 Software The PLC programme shall be supplied with the PLC in accordance with the functional requirements set out below. A full listing of the programme shall be supplied. By plugging in a laptop into a suitable port of the PLC it shall be possible to download the PLC programme to the laptop and modify the programme as dictated by requirements (e.g. upon installing additional lights). The necessary software required to perform the modification shall be supplied. All software shall become the property of RailCorp.

A watchdog timer alarm output shall provide visual indication of PLC operational status. The alarm shall also be wired to a set of terminals for external use

6.5.3 Functional requirements PLC functionality shall fulfill the requirements as set out below.

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6.5.3.1 Normal lighting Each group of 3 normal lighting circuits shall be equipped with the following inputs and outputs

• Lights ON (input from a pushbutton on front of panel). Initiates the normal operating mode by switching on the first set of lights, E.g. lights connected to the red phase. After a period of nominally 1 week and adjustable from 0.5 to 4 weeks the operating circuits will change over to the white phase, and a week later to the blue phase. The cycle is then repeated. Note: It shall be possible to adjust the cycle time without stopping the PLC. Suppliers shall provide details of the proposed method of achieving this. i.e. HMI panel, potentiometer etc.

• Lights ON (Momentary external input from pushbutton station in tunnel). This is a maintenance requirement. All the normal lights in that tunnel or section of the tunnel will be switched ON and remain ON for a period of 2 hours, or until RESET. At the end of the two hour period the system shall revert to the Normal mode of operation, (Refer to bullet point 1 above).

• OFF/RESET (input from pushbutton on front of panel). Terminates the maintenance mode and reverts back to the normal mode of operation.

• Contactor output. Operates the relevant contactor associated with each set of lights

Active circuits shall as far as possible be spread across the three phases. Active circuits shall rotate at periodic time intervals of nominally one week.

The table depicts the desired switching sequence.

1st GROUP OF LIGHTS

2ND GROUP OF LIGHTS

3rd GROUP OF LIGHTS

PHASE R W B R W B R W B WEEK 1 ON OFF OFF OFF ON OFF OFF OFF ON WEEK 2 OFF ON OFF OFF OFF ON ON OFF OFF WEEK 3 OFF OFF ON ON OFF OFF OFF ON OFF

Switching for the fourth group of lights will be as per the first group etc.

After week 3, the cycle is repeated

The above sequence shall be automatically advance to the next period when the input power supply to the PLC is switched off and on.

6.5.3.2 Emergency lighting Each set of 3 emergency lighting circuits shall be equipped with the following inputs and outputs. Note that normally all emergency lights will be left on continuously.

• Lights TEST (Input from pushbutton on front of panel). Switches off the output to the lights and initiates the 4 hour backup battery test. At the end of 4 hours normal operation is resumed.

• RESET (Input from pushbutton on front of panel). Terminates the battery test and resumes normal operation.

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6.6 SCADA Interface Status and alarms monitored by the SCADA system shall have one normally open and one normally closed voltage free contact wired to a set of terminals for external use. The contacts shall have a minimum rating of 1 Amp at 120V d.c.

The following condition shall be monitored:

• Phase failure relay for normal supply • Phase failure relay for alternate supply • Emergency lights on test • Luminaire failure (output from lighting monitoring system)

7 Maintenance The equipment must be suitable for operation with only limited periodic routine maintenance comprising tasks falling into the following categories:

• Testing of functionality • Cleaning • Lubrication of locks and hinges • Replacement of Circuit Breakers • Replacement of control circuit components including relays, contactors,

pushbuttons and indicating lights • Replacement of distribution board.

8 Testing Factory tests shall include the following:

• Inspection in accordance with AS3439.1 Section 8.3.1 • Insulation resistance test • Continuity (point to point) testing of all wiring. • Function test of all logic and interlocks • Phasing of power circuits • PLC logic functionality shall be demonstrated • The Tunnel Services Board shall be energised and tested prior to delivery. • Copies of final inspection and equipment test reports shall be provided and comply

with EP 00 00 00 12 SP

9 Data Set Associated with the Equipment Drawings and documentation shall be supplied in accordance with the requirements of EP 00 00 00 15 SP “Common Requirements for Electrical Power Equipment”.

The PLC programme shall be supplied in ladder logic format.

Detailed documentation relating to the Maintenance tasks shall be supplied for inclusion in RailCorp’s Electrical Technical Maintenance Plan.

All documentation shall remain the property of RailCorp.

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Appendix A Technical Schedule The supplier shall complete the following data sheets:

Distribution board dimensions Height

− Length .………………............ mm

− width .………………............ mm

− depth .………………............ mm

Distribution board fault level .………………............ kA

Busbar rating .………………............ Amps

Main switch rating .………………............ Amps

Number of poles supplied .………………............

Main switch manufacturer/type number .………………............

Circuit breakers make/type .………………............

Contactors make/type .………………............

Selector switch make/catalogue number .………………............

PLC manufacturer/model .………………............

Number/ of inputs supplied .………………............

Number of outputs supplied .………………............

Maximum number of I/O that the PLC can be expanded .………………............

Input card type/catalogue number .………………............

Output card type/catalogue number .………………............

Communication protocol .………………............

General Arrangement and equipment mounting .………………............

Recommended spares .………………............

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Appendix B RFT Checklist Application

The following material is for guidance in the preparation of a Request for Tender for this type of equipment. This checklist itself is not intended to directly form part of any contract.

This section is to be read in conjunction with the RFT Checklist in specification EP 00 00 00 15 SP, Common Requirement for Electrical Power Equipment.

Information to be supplied to the Tenderer

Where this document is used as the basis for procurement of equipment for a particular location, in addition to the general requirements in this specification the following information related to the particular site will need to be supplied.

• Distribution board type (as defined in Section 6.3 above) • Incoming feeder cable size • Site location • Number of sets of documentation required

Information to be Sought from the Tenderer

• Integrated Support information as per RailCorp Standard • Tenders to complete and submit Appendix A

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Appendix C Requirements for Technical Aspects of Tender Evaluation

Evaluation of tenders

Tender submissions will be evaluated based on a number of criteria. One constant criterion is compliance with this specification. The Chief Engineer Electrical requires that persons evaluating the technical aspects of this tender have sufficient technical competence for the task.

Tender evaluation committees shall forward details of persons evaluating the technical aspects of the tender to the Chief Engineer Electrical for concurrence. This will normally be in the form of an email and is to include sufficient detail of the tender and the person to enable the Chief Engineer Electrical to satisfy themself of the merits of the evaluating person. A minimum of 4 weeks notice is required prior to the evaluation of the Tenders.

The Chief Engineer Electrical will advise within 5 working days only if the person is considered technically unsuitable for the technical evaluation.

Acceptance of product

A number of the specifications require acceptance of product at both the factory and at site. The purchaser is to advise the Chief Engineer Electrical the details of the person carrying out the acceptance testing for the concurrence of the Chief Engineer Electrical. A minimum of 4 weeks notice is required prior to the evaluation of the acceptance testing.

The Chief Engineer Electrical will advise only if the person is considered unsuitable for the acceptance testing.

The Chief Engineer Electrical reserves the right to nominate a representative to review and/or attend such acceptance.

Record Keeping

Where product is purchased against this specification, the Chief Engineer Electrical requires that relevant detail be provided so that it can be logged against this specification.

For RailCorp purchases, all records are recorded in Ariba.

Where this specification is utilised by parties external to RailCorp (Alliance parties, etc) then copies of all relevant technical information and evaluation shall be forwarded to the Chief Engineer Electrical for filing against the specification. In addition copies of selected commercial information pertaining to the ongoing support of the product as follows is also required.

• Warranty details • Spare parts and associated availability • Product support information.

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st emergency lighting engineering specification...2000/10/23 · as 1627.4 metal finishing –...

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