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Part E (Technical Requirements) Page - 1

PART E

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TECHNICAL REQUIREMENTS

RFT No. 08/08056 Design and Construction of Upgrading Works for Lawson Electrical Substation

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Table of Contents

1 2

EXECUTIVE SUMMARY ................................................................................................................................................................4 SCOPE OF WORKS ..........................................................................................................................................................................4

2.1 DESIGN SCOPE OF WORKS ............................................................................................................ 4 2.1.1 General Design Requirements .................................................................................................. 5 2.1.2 Architectural / Civil / Structural Design ................................................................................... 6 2.1.3 Electrical Design....................................................................................................................... 8 2.2 DESIGN MATTERS ....................................................................................................................... 11 2.2.1 Engineering Design Management Procedures........................................................................ 11 2.3 TECHNICAL REVIEW ................................................................................................................... 13 2.3.1 Detail Design Review.............................................................................................................. 13 2.4 DELIVERABLES ............................................................................................................................ 13 2.4.1 Detailed Design....................................................................................................................... 13 2.5 SCOPE OF CONSTRUCTION WORKS ............................................................................................ 16 2.5.1 Extent of Work......................................................................................................................... 16 2.5.2 Application of Standards......................................................................................................... 18 2.5.3 Project Plan ............................................................................................................................ 18 2.5.4 Access to Site........................................................................................................................... 18 2.5.5 Site Compound ........................................................................................................................ 18 2.5.6 Temporary Demarcation Fence .............................................................................................. 19 2.5.7 RailCorps Access to its facilities ........................................................................................... 19 2.5.8 Working Hours........................................................................................................................ 19 2.5.9 Works Programme and Staging .............................................................................................. 19 2.5.10 Subsurface Conditions........................................................................................................ 20 2.5.11 Protection of Existing Infrastructure.................................................................................. 20 2.5.12 Coordination of Works with Others ................................................................................... 20 2.5.13 Railway Worksite Protection.............................................................................................. 20 2.5.14 Setting out the Works.......................................................................................................... 20 2.5.15 Services Search .................................................................................................................. 20 2.5.16 Occupational Health & Safety ........................................................................................... 21 2.5.17 Protection of the Environment ........................................................................................... 21 2.5.18 Signage............................................................................................................................... 22 2.5.19 Hot Work Authority ............................................................................................................ 22 2.5.20 Electrical Permits............................................................................................................... 22 2.5.21 Documentation and As-Built Drawings.............................................................................. 22 2.5.22 Quality Standards............................................................................................................... 22 2.5.23 Concrete Works .................................................................................................................. 22 2.5.24 Drainage Works ................................................................................................................. 23 2.5.25 66kV Structures .................................................................................................................. 23 2.5.26 High Voltage Electrical Work ............................................................................................ 23 2.5.27 Low Voltage Electrical Work ............................................................................................. 24 2.5.28 RailCorp Standards and Specifications.............................................................................. 26 2.5.29 Civil .................................................................................................................................... 26 2.5.30 Electrical : High and Low Voltage..................................................................................... 26 2.5.31 Detailed Site Survey (DSS) Procedures ............................................................................. 26
3

3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5

QUALITY REQUIREMENTS........................................................................................................................................................27 DESIGN STANDARDS .................................................................................................................... 27 SELECTION AND USE OF AUSTRALIAN AND INTERNATIONAL STANDARDS ............................... 27 RAILCORP STANDARDS .............................................................................................................. 27 STANDARD OF COMPLETED DESIGN........................................................................................... 28

Design Verification ................................................................................................................. 28 Technical Reviews................................................................................................................... 29 Reference Standards ............................................................................................................... 31 Access to RailCorp Standards................................................................................................. 32 Access to RailCorp drawings .................................................................................................. 32

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3.5 DESIGN DRAWINGS ..................................................................................................................... 32 3.5.1 Drawing Format ..................................................................................................................... 32 3.5.2 Cross Referencing ................................................................................................................... 32 3.5.3 Drawing Compatibility ........................................................................................................... 33 3.5.4 Drawing Revisions .................................................................................................................. 33 3.6 DESIGN APPROVAL ..................................................................................................................... 33 3.7 ENVIRONMENTAL MATTERS ...................................................................................................... 33 3.7.1 Review of Environmental Factors ........................................................................................... 33
4 FUNCTIONALITY REQUIREMENTS ........................................................................................................................................34

4.1 RAIL SAFETY AND SITE VISITS ................................................................................................... 34 4.2 CONSTRUCTION HAZARDS AND RISKS ....................................................................................... 34 4.3 HAZARD RISK AND HUMAN FACTORS ANALYSIS ...................................................................... 34 4.4 RELIABILITY ............................................................................................................................... 35 4.4.1 Functional Item Reliability ..................................................................................................... 35 4.4.2 Fixed Mechanical Items/Structures......................................................................................... 35 4.4.3 Maintainability........................................................................................................................ 36 4.4.4 Availability.............................................................................................................................. 36 4.5 INTERFACE MANAGEMENT ......................................................................................................... 36 4.5.1 With Existing Systems ............................................................................................................. 36 4.5.2 Interfaces with other Engineering service providers and other entities and or stakeholders who access the site. ............................................................................................................................... 37

Attachments ATTACHMENT 1 LAWSON CONCEPT DESIGN PACKAGE.............................38 ATTACHMENT 2 - DRAWING FORMAT ...........................................................40 ATTACHMENT 3: SCADA SYSTEM .............................................................41 ATTACHMENT 4 CONCEPT PROTECTION DETAILS .....................................44 ATTACHMENT 5: DEFINITION OF CABLE NUMBERING ...............................45 ATTACHMENT 6: EXAMPLE CABLE SCHEDULE ..........................................46 ATTACHMENT 7 VOLTAGE REGULATOR REQUIREMENTS ..........................47

RFT No. 08/08056 Design and Construction of Upgrading Works for Lawson Electrical Substation

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1 Executive Summary
RailCorp NSW is responsible for the operation and maintenance of train services and rail infrastructure in metropolitan and regional New South Wales. Fire damage recovery has made it necessary to upgrade the LV and HV facilities within the Lawson Traction Substation. This Technical Specification is for the detailed design and construction of facilities within a spare bay of the Lawson Traction Substation, including AC switchgear, transformer relocations and all associated works. The detailed design and construction will be carried out on the basis of a concept design provided by RailCorp and in accordance with RailCorp Engineering Standards. The designs will be required to incorporate major plant items nominated by RailCorp which will be supplied from supply agreements that RailCorp has in place. The substation must remain live and in operational service for the duration of the works. There are a number of items that have been identified that may impact on future expansions and/or works where it may be prudent to perform these works within this project. These have been requested as items to be included with tender; they are to be treated as separable components for the purpose of works scope.

2 Scope of Works 2.1 Design Scope of Works

The Contractor shall provide in relation to the scope of work: 1) Hazard, Risk and Human factors analysis 2) Reliability, Availability and Maintainability analysis 3) Design of the 66 kV outdoor switchyard, generally in accordance with Attachment 1 Lawson Concept Design Package. 4) Design of all associated cable routes within the substation boundary including 11kV cables. 5) Design of the 66 kV AC outdoor transformer and regulator arrangements, complete with bunding, drainage and retention as applicable to the scope. 6) Design of protection schemes in accordance with the concept protection scheme. 7) Design of control and indication cabling and cable routes. 8) Design of commissioning & test plan, including detailed commissioning & test procedures. The plan shall demonstrate that the designer has fully understood the management of the interfaces, both with existing systems and other engineering disciplines, which the commissioning and test plan will affect. 9) Design of 11kV switchboards, distribution boards and protection equipment in accordance with the Lawson Concept Design Package. See Attachment 1. The design of the below ground earthing installation does not form part of this RFT however the Contractor shall manage the interface between the above ground and below ground earthing installations.
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The detail design shall include, but not necessarily be limited to, the following elements: 2.1.1 General Design Requirements

2.1.1.1 Definitions For purposes of Design, Design Verification and Design Approval: Contractor shall be a person or organisation that has been accredited by RailCorp to carry out design works on the RailCorp electrical distribution infrastructure. Contractors Designer shall be a qualified engineer who has been duly accredited by RailCorp to carry out electrical design of the Design works. Contractors Verifier shall be a qualified engineer who has been duly accredited by RailCorp to carry out electrical design verification and validation of the Design works. Accredited shall be as defined by Division 1 of Part 2 of the Rail Safety Act 2002 No 96. The Designer and Verifier are required to be accredited for the separate sections of works: 1. Distribution Design: HV switchgear and regulators; LV switchgear and cables 2. Power Systems: Protection and Earthing Design 3. Main: 11kV cables and Aerials RailCorp Electrical Design refers to the RailCorps Electrical Engineering Standards and Services 2.1.1.2 Building Code of Australia The final design must comply with the relevant Parts of the BCA. Refer to Parts C, D and E in the BCA. 2.1.1.3 Existing Services The design documents shall indicate the existing services, using a RailCorp Services Search and other Dial before You Dig methods to locate the position of any existing services. As listed RailCorp will provide a services search, however it is to be treated as information only as it may not include all cabling and or services be they live or redundant within the works site. 2.1.1.4 Environmental Management Plan The Contractor shall prepare and submit an Environmental Management Plan. The Contractor shall demonstrate that the design complies with the Environmental Management Plan to address areas of potential environmental impact. 2.1.1.5 Compliance Comply with Acts, Ordinances, Regulations, By-laws and Proclamations of the Commonwealth, State of New South Wales and relevant Local Government and the accepted EMP.

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2.1.1.6 Bunding Considerations Refer to the Department of Environment & Climate Change (DECC) for guidelines for the design, construction and maintenance of bunds to minimise the risk of pollution from spills and leaks. Electrical transformers containing oil shall comply with requirements of the DECC. The Contractor must design the bund to comply with Australian Standard AS 1940: The Storage and Handling of Flammable and Combustible Liquids. Design documents are to include, an erosion control map and notification requirements to the DECC prior to commencement of work on site. 2.1.2 2.1.2.1 1) 2) 3) 4) 5) Architectural / Civil / Structural Design General Requirements

6) 7)

8)

Design shall comply with the BCA, Australian Standards, Local Authorities and RailCorp Standards; Design shall include relocation of existing services including structures (i.e. poles and buildings etc); The colours and materials shall be chosen with due consideration given to existing graffiti issues; All fill material specified for cable trenches shall be inorganic, non-perishable material of the types specified and free of sulphur content; All general filling material specified shall be: Granular material, maximum particle size 75mm Percentage passing .075 sieve 25% maximum Plasticity Index, not greater than 15% and not less than 2% All sub-grade fill specified shall be such that material in the top 150 mm shall have a maximum size of 75mm. The Contractor shall provide an Architectural / Civil / Structural Report to determine the as found bearing capacity of existing foundations that are to be reused. A Geotechnical Engineer must certify that the foundation design is suitable. A copy of the report and certificate must be included in the final design report. The Contractor shall ensure that all testing is carried out by a NATA approved laboratory in accordance with the requirements of AS 1289 series. Methods of Testing Soils for Engineering Purposes. Particular Requirements

2.1.2.2 1. 2. 3. 4. 5. 6.

The design shall include all incidental works and equipment, not specifically mentioned herein, necessary for the operation and performance of the systems. Provision of a geo-technical report enabling the suitable design of all foundations and civil works; Design shall include excavation for new pits and underground trenching; Design to include reinforced concrete cable trenches, pits, footings and slabs to the extent indicated on the drawings (non-slip finish to trafficable areas); Design all reinforced concrete plinths for the 66/11kV transformer and voltage regulator equipment as required where not existing and useable; Detail design of 66 kV Circuit Breaker support structure and foundations;

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7. 8. 9. 10. 11. 12. 13. 14.

Detail design 66 kV Air Break Switch support structure and foundations; Design to allow for galvanized metal gratings over service trenches. Design required for grating types, size and locations. Provide Operating and Maintenance Instruction manuals. Design to include the safely capping off by suitable means for the located unearthed service of all redundant services where found. Applications and fees to local councils and other authorities shall be included as a part of the designers deliverables. Provide an adequacy report for bunding oil retention and disposal system; Provide an adequacy report for drainage/storm water retention and disposal; Provide adequacy report for fire detection and control. Optional Additional Works

2.1.2.3

The following design and construction tasks are requested to be included with the tender: 15. All external and internal doors are solid-core timber doors. The Tender shall provide costing for replacement and or retro fitting the doors with louvers; 16. Design to allow for 150mm thick wool insulation (similar to CSR Glasswool and Rockwool) to whole of the roof space, all in accordance with the manufacturers instructions; 17. Provide detailed design for the relocated battery room to an agreed location. The designer shall ensure that the battery room is of sufficient size to adequately allow all equipment to function as intended. Design to include eyewash stands, which shall be located on the design drawings. 18. Design required for a system to ventilate the interior of the building (new control room and battery rooms only). The design may allow for a make-up air-intake, fixed-metal, Louvre panel systems to walls and nominated doors to supply air to the interior ventilation system. The ventilation and make up air shall provide a minimum of 15 air changes per hour, at a wind speed of 6km/hr, and ensure an inside/outside temperature difference of 8 degrees for an ambient temperature of 40 degrees. All to be in accordance with the requirements of AS1668.2:1991 - Mechanical Ventilation for Acceptable Indoor Quality, Clause F5.4, Health and Amenity Light and Ventilation Ventilation of Rooms. AS/NZS3666.1:2002 Clause F 4.5, Health and Amenity Light and Ventilation Ventilation of Rooms. Design of Class A rain resistant roof ventilation system employing turbine ventilators. The number of ventilators in the design shall be determined by substation internal air volume. 19. Design of replacement or augmentation of the existing proposed 66/11kV transformer foundation. 20. Demolition, dismantling and disposal off site of redundant structures and associated foundations where necessary. 21. Design associated with the relocation of the 66/11kV transformer from its present location to the proposed location. RailCorp might delete any or all of Items 15 to 21 from the Contract.

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2.1.3 2.1.3.1

Electrical Design General Requirements

The Contractor shall: 1. Provide safety clearances as detailed in AS 2067:1984, Switchgear Assemblies & Ancillary Equipment for Alternating Voltages above 1 kV, clause 10.2; 2. For any component of design where required and specific details are omitted, the Contractor shall provide design to the minimum standard as required by the relevant RailCorp and Australian Standards; 3. Provide a detailed Electrical Hazard and Risk assessment. See Section 4.3 Hazard Risk and Human Factors Analysis of this document; 4. Provide a detailed Reliability, Maintainability and Availability analysis. See Section 4.4, Section 4.4.3, and Section 4.4.4 respectively of this document; 5. Provide a detailed Designers Risk and Hazard Analysis in accordance with Occupational Health and Safety Regulation 2001, Regulations 86-97 and RailCorp Engineering Design Management Plan ED0008P Clauses 6.3.2, 6.3.3 and 7.2; 6. Provide all low voltage switchboards and miscellaneous marshalling or control cubicles with a minimum 20% spare capacity; 7. Provide design generally as detailed in RailCorps Standard EP 99 00 00 01 SP Substation Minimum Construction Standards; and 8. Cable numbering shall be as detailed in Attachment 5 Definition of Cable Numbering. 2.1.3.2 Particular Requirements The Contractor shall provide: 1. System Operating Diagrams concurrent with the project stage for the proposed arrangements to be submitted and approved prior to implementation; 2. Electrical design details for the 66 kV outdoor dual busbar arrangements, showing RLs for the new air break switches (isolators); 3. Electrical design details for the 66 kV outdoor isolator switchgear arrangements, showing RLs; 4. Electrical design details for the 66 kV ACCB arrangements, showing RLs; 5. Electrical design details for the 66/11 kV Transformer and 11kV regulator general arrangements, showing RLs; 6. Electrical design details for 66 kV ACCB Protection and Control Switchboard in accordance with the concept design. See EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network; 7. Electrical design details for 66 kV Feeder 865 ACCB Protection and Control including pilot wire and over-current protection schemes. Design shall be in accordance with concept design documents. See EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network. Pilot Wire transformer(s) to be located within the 66kV Protection Panel; 8. Electrical design details for 66 kV Feeder 871 ACCB Protection and Control including pilot wire and over-current protection schemes. Design shall be in accordance with concept design documents. See EP 19 00 00 02 SP Protection

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9.

10.

11.

12.

13.

14. 15. 16. 17.

18. 19.

20.

21.

22.

System Requirements for the High Voltage Network. Pilot Wire transformer(s) to be located within the 66kV Protection Panel Electrical design details for 66 kV Feeder 877 ACCB Protection and Control including pilot wire and over-current protection schemes. Design shall be in accordance with concept design documents. See EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network; Electrical design details for 66 kV Feeder 878 ACCB Protection and Control including pilot wire and over-current protection schemes. Design shall be in accordance with concept design documents. See EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network; Electrical design details for 66 kV Busbar (Blue and Yellow) ACCB Protection and Control including buszone protection scheme. Design shall be in accordance with concept design documents. See EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network; Electrical design details for 66/11 kV Transformer ACCB Protection and Control including transformer differential and overcurrent protection schemes. Design shall be in accordance with concept design documents. See EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network; Electrical design details for the eight (8) off 11kV ACCBs switchboard, plus the associated VTs and Protection and Control. EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network; Detailed design of cable routing arrangements within the Protection Panels and switch-room building, as required; Detailed electrical design of 220V AC, 240V AC, 415V AC, 120V and 50V DC auxiliary supply panels; Detailed design for the 11kV cable termination and route between the 11kV regulator and the 11kV switchboard. See attachment for suggest routes; Detailed design of control cable routes between external equipment and the switchroom building including cable penetrations and all cable support systems necessary within the building; Detailed design of cable routing arrangements within the building, this shall include all necessary rerouting and repair necessary to perform the task; Detailed design of cable routing for all high voltage cabling nominally (Feeders 659, 680, and H403 also the new No.1 transformer, and the 2 auxiliary transformers) arrangements within and external to the building, this shall include all necessary rerouting and repair necessary to perform the task. Note: 680 feeder cable was installed in 2007 and should be able to be rerouted rather than a new cable. Concept 11kV cable routes provided in Attachment 1 Lawson Concept Design Package; A cable schedule including details of conduit allocation for all works included in this scope. The schedule shall be in an approved MS Excel spreadsheet format and RailCorp Standards; detailed design for the marshalling of connections of control and indication wiring between equipment and the SCADA system. See attachment 3 SCADA System if necessary; A detailed site survey of all new equipment and cables installed or relocated in the vertical and horizontal planes for all services relating to the scope or within the defined scope boundaries;

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23.

24.

No provision for the augmentation or evaluation of the existing earthing system is required, however design shall incorporate earthing and bonding details for all new and or modified structures / equipment or foundations as is required in the applicable RailCorp Standard; and Electrical design details for Rectifier No.1 and 2, ACCBs protection and control. The design shall be in accordance with concept design documents. See EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network, for details.

2.1.3.3

Optional Additional Works

The following design tasks are requested to be included with the tender: 25. Design of Emergency Lighting for works under this scope, nominally control room, battery room and egress routes from such. 26. Detailed design of battery systems including sizing calculations, as defined by the concept design. Battery capacity shall be sufficient to maintain auxiliary supplies for seven days after loss of 415V AC. Design shall be as detailed in RailCorp Standard EP 06 00 00 01 SP System Substation Battery. It is expected that the 7 day requirement will realise a large system battery. For these reasons the tender will also be required to provide pricings for a 3 day capacity system. 27. Detailed design of optical fibre communications cable route between existing connections and newly installed equipment where necessary. 28. Detailed design of copper communications cable route between existing connections and newly installed equipment where necessary. Provide electrical design details for 66/11kV Transformer general arrangement. RailCorp might delete any or all of Items 25 to 28 from the Contract.

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2.2

Design Matters

2.2.1 Engineering Design Management Procedures The RailCorp design process is controlled by Engineering Design Management Procedures which are detailed individually in documents ED 0001 to ED0019. These documents are available on RailCorps extranet. 2.2.1.1 Design Reviews Appropriate RailCorp personnel will participate in the Technical Review process and, when approved accept the design on behalf of RailCorp. Design review presentations will be required. In accepting the Appointment under this Contract the Contractor is accepting responsibility and accountability as the designer and design verifier and will verify, validate, and sign off that the completed design complies with best engineering practice, standards, regulations, codes, guidelines and statutes applicable to the works. Design documents presented to RailCorp for review shall be packaged so that the applicable RailCorp Principal Engineer can complete design reviews independently, the following document groups shall be submitted: Principal Engineer Power Systems shallll review documents containing design for the RailCorp High Voltage Network and for Earthing, Bonding and Protection Systems. Principal Engineer Mains shall review documents containing design for High Voltage Aerial lines and Underground Cabling Systems. Principal Engineer Distribution shall review documents containing design for High Voltage and Low Voltage Distribution Substation and Power Supply upgrade.

Senior Design Officer, Electrical Systems shall review drawings for drafting and CAD acceptance. 2.2.1.2 Acceptance of Design Responsibility The Contractor shall accept full accountability for their design detailing the configuration change and verifying its compliance with applicable standards, statutory requirements, regulations, guidelines and engineering best practices. The Contractor shall supply a comprehensive set of engineering calculations, drawings, specifications, schedules and written documentation, in sufficient detail to enable verification of that compliance. The Final Design Documentation Package shall be endorsed as Approved by the Contractors approval authority. The verification and validation shall endorse that the design is complying and able to be accepted by the RailCorp Electrical Design for direct inclusion in the construction works.

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2.2.1.3 Design Approval Responsibility The Contractors accredited Designer and Design Verifier shall accept responsibility for design approval. RailCorp will review all design documents submitted for conformity with RailCorp requirements only. Following acceptance by RailCorp of all drawings the Contractor shall submit an A4 sheet, or sheets, in tabular form listing the document number and revision letter, description and date. The sheet shall identify the name of the Contractors organisation and carry a statement to the effect that the drawings referenced on the sheet are Approved for Construction by the Contractors Designer and Design Verifier signatories whose original signatures shall appear on the sheet. 2.2.1.4 Design Verifier The Contractor shall nominate their design verifier prior to acceptance of the design process and shall ensure that their nominated design verifier maintains compliance with the following requirements throughout the duration of the design: Holds the necessary qualifications to check design work for the discipline concerned; Has been duly accredited by RailCorp. For external contractors, design authority is delegated by the General Manager Engineering to the person(s) nominated by the Contractor; and Has not been directly responsible for producing the design.

Upon completion of the Final Detailed Design documentation the Contractors design verifier shall complete, sign and date a Design Verification and Approval Checklist. 2.2.1.5 Design Verification The Contractors design verifier shall carry out the verification of the design documentation according to the RailCorp Engineering Design Management Procedure ED 0011 P prior to submitting for review. Verification shall proceed progressively throughout the design process. Progress of the verification shall be reported at the Technical Review meetings by presentation of a Design Verification and Approval Checklist signed by the Contractors design verifier for the stage of the design covered by the meeting.

2.2.1.6 Design Validation The Contractors design verifier shall carry out the validation of the design documentation on behalf of the Contractor according to the RailCorp Engineering Design Management Procedure ED 0012 P, prior to submitting for review. 2.2.1.7 Design Programme A detailed design and interface management plan, including the design programme, shall be developed and submitted to indicate major project milestones. Milestones will form hold points for the design process, for which RailCorp acceptance and approval will be required before progress. Design progress beyond hold points (unapproved) which upon
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approval requires change shall not be reason or cause for claim of additional design consultancy fees based on unproductive use of engineering time. 2.2.1.8 Designers Responsibilities The Contractor shall provide a design which is fully fit for purpose and provide a comprehensive set of engineering drawings showing sufficient detail for the work to be completed as designed. The design shall make allowance for the methods of construction likely to be used during installation. The Contractor shall note that any or all responsibilities incumbent with the design shall remain with the Contractor.

2.3

Technical Review

The primary objective of Technical Reviews is risk reduction, to ensure that any departures from the intent of the design tasks are recognised and reviewed as early as possible in the design process and to enable corrective action to be implemented with minimal schedule and cost impacts. See 3.4.2 Technical Reviews for details of the review process. 2.3.1 Detail Design Review The review will comprise three types of meetings at a nominated RailCorp location. The Contractors representative shall attend these meetings as required during the design and review process. Meeting categories are as follows: 1. 2. 3. Project Initiation Review Detailed Design Review System Verification Review

2.4
2.4.1

Deliverables
Detailed Design

2.4.1.1 Technical Specification. Presented in an A4 size hard covered folder with sections separated by numbered dividers and one MSWord 97 compatible copy of the completed report on a CD. The following sections shall be included: 1. 2. 3. Document Control page Introduction detailing the project scope and contributors to the project. Technical specifications for the equipment proposed for the installation including sufficient information to allow construction to be completed without further reference to the designer. References specifically related to the installation phase. Drawing Index Cable Schedule Commissioning Documentation. The commissioning plan and associated documentation shall form part of the Technical Specification. The Commissioning

4. 5. 6. 7.

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8. 9.

Plan shall demonstrate that due attention has been paid to the local operating conditions which will prevail at the time of commissioning. Product information. Civil works specification.

2.4.1.2 Design Report. Presented in an A4 size hard covered folder with sections separated by numbered dividers and an MSWord copy of the completed report on a CD. The following sections shall be included: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Document control page. Introduction detailing the project scope, statement of responsibilities and a discussion of the observations noted. Equipment proposed. Design parameters, including sources. References specifically used in the design. Interface management plan. System Operating Diagrams concurrent with the project stage for the proposed arrangements. Hazard, Risk and Human factor analysis. Reliability, Maintainability & Availability analysis. List of RailCorp documents supplied for reference. Drawing index. Design Calculations. The report shall include copies of all design calculation completed (copies of hand written sheets are acceptable. All hand written sheets must be clearly legible, cursive text not to be used.). Product Information. Civil design verification documents. Detailed Project Construction Plan, including staging in accordance with hold points.

13. 14. 15.

2.4.1.3 Schedule of drawings. The schedule of drawings shall include drawing title, location, drawing description, drawing type, drawing size, in an approved format to which the designer can add the approved RailCorp drawing number. In some cases the requirement for particular drawings may be covered by the OEM drawings for the major electrical plant. In such cases it is acceptable that these drawings be incorporated into the drawing set by reference rather than being re-drawn, unless directed otherwise by RailCorp. The table below lists the minimum number of drawings anticipated for the project. Actual numbers may vary dependant upon the complexity of the design task.

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DRAWING NUMBER
TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA TBA

TITLE Site Plan showing a survey layout including all RLs., access gate, ramps, fencing etc. Substation outside arrangement, Floor Plan, section, elevation and details. Foundation layout Plan Foundation layout sections and details Major cable routes plan & sections. Conduit Layout Plan & Detail. Conduit Schedule Conduit Layout - Plan & Details. 66kV Feeders AC Schematic 66kV Bus Bar Interconnection AC Schematic 66kV Feeders Wiring diagram 66kv Switchboard protection, metering and control - single line diagram 11kV Circuits AC Schematic 11kV Circuits DC Schematic 11kV Feeders Wiring Diagram AC Board General Arrangement AC Board Schematic Light & Power Layout DC Board General Arrangement DC Board schematic SCADA Equipment general arrangement SCADA I/O list RTU marshalling panel termination diagram Miscellaneous Equipment Miscellaneous equipment panel Termination diagram

COMMENT

2.4.1.4 Full size paper copy of each drawing. 1. Three copies of each drawing shall be submitted for review, dated and marked PRELIMINARY. All preliminary drawings shall be marked for their relevant revision date and description. 2. Following acceptance by RailCorp, three full size copies of each drawing dated and marked FOR CONSTRUCTION, shall be submitted, accompanied by a separate copy dated and signed in red ink as approved by the person responsible for the design. 2.4.1.5 Electronic copy of each drawing. 1. The following electronic copies of drawings are required: A copy of each FOR CONSTRUCTION drawing in Microstation version 8 or AutoCAD version 2000. 2. A copy of each FOR CONSTRUCTION drawing dated and signed by the approving person, as detailed in 2.4.1.4 above, in TIFF MSB, Monolithic CCIT Group IV file format, non colour drawings - resolution 300dpi in both X & Y directions. Marked uncontrolled when printed.
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3. Note: A process incorporating digital signatures on documents is at present being formulated. The requirements of this section may be simplified should this process be incorporated by the time design drawings are submitted to RailCorp.

2.5

Scope of Construction Works

2.5.1 Extent of Work Works under this Contract comprise the supply of all labour, materials and equipment (except free issued items as detailed in Section 2.5.11) to complete the necessary upgrading of the Lawson Electrical Substation. The works include all specifically referenced and incidental works necessary to ensure a fully functioning installation in accordance with design documentation and RailCorps requirements. They include the following items that are to be carried out in accordance with this RFT Document: 2.5.1.1 Provision of Free Issue Equipment a) 66/11KV Transformer. (Onsite to be disconnected and relocated) b) 66kV Circuit Breaker (RailCorp to deliver to site) c) Air Break Switches (2) (RailCorp to deliver to site) d) 11kV voltage Regulator (RailCorp to deliver to site) All other equipment shall be supplied by the Contractor. 2.5.1.2 General Work Preparation, implementation and management of an integrated and comprehensive Project Plan with fully detailed hold points during the project including OHS&R Plan, Environmental Management Plan, Quality Plan, Traffic Management Plan, Demolition Plan and Daily Works Programme;

Establishment and maintenance of Hazard Log for duration of works; Site establishment and provision of amenities; Setting out of the works; Supervision of all activities on site, this shall include the successful management of works and staff movements within a live and operational substation; Supply of railway worksite protection, when required; Preparation and submission of as built drawings; Interface management for daily works as approval by RailCorp for the duration of the works. RailCorp shall be responsible where appropriate for the issue of all access permits as required; Site clean-up and de-establishment; 2.5.1.3 Civil Work

Earthworks including excavation and disposal off-site of all excavated material to an approved disposal site; Construction of bund;

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Construction of new busbar, strung bus support structures and equipment foundations; Demolition works including removal of redundant drainage, electrical structures, cable pits, retaining wall and foundations; and Building works including roofing, ventilation and insulation.

2.5.1.4 High Voltage Electrical Work Modifications to outdoor busbars at Lawson substation;

Construction of new 66kV dual busbar, strung bus and equipment support structures; Construction of new 66kV rigid and strung bus sections; Relocation and Installation of existing 66/11kV transformer, new 11kV regulator, 2 air breaks switches / isolators and ACCB. Installation of modified 11kV cable routes and new 11kV cable routes. Supply and installation of 11kV switchboard. Installation of all necessary earthing and bonding as applicable to this scope of work. Supply, installation and termination of 11kV cables.

2.5.1.5 Low Voltage Electrical Work Supply and installation of underground cabling;

Supply and installation of new miscellaneous switchboards / panels; Supply and installation of 66kV Protection switchboard. Supply and installation of all new or augmented 415V, 240V, 240V, 220V, 120VDC and 50VDC systems as required by design. Supply and installation of all new or augmented battery systems as required by design. Installation of all necessary earthing and bonding as applicable to this scope of work.

2.5.1.6 Testing and Commissioning Testing & commissioning all construction and equipment. A test and commissioning plan including records sheets with proposed pass/fail criteria shall be submitted for approval during design in the technical specification. Test and commissioning plans complete with minimum test requirements shall generally be in accordance with RailCorp Standards and submitted at least 6 weeks prior to the tests being required and accompanied with the relevant operational drawings that will be required. 2.5.1.7 Produce Records Submit test reports and QA documentation, including ITPs and check sheets;

Produce and submit records and surveys of all equipments cables and service locations for the new installation under this scope to the DSS standard; Produce and submit as-built drawings;

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2.5.2 Application of Standards The Contractor must verify that all Works comply with the requirements of all current Australian and industry accepted Standards to the extent that they are relevant and that they are not exceeded by other Contract requirements. 2.5.3 Project Plan Prior to commencing work on site, the Contractor shall prepare and submit to RailCorp for acceptance an integrated Project Plan, incorporating but not limited to the following details: 1. Names and contact details for key personnel (i.e. project manager, project engineer, site foremen, worksite protection officers, 24/7 contact person etc.). Information to be provided shall at minimum include qualifications relevant to the position, experience in the position, relevant tickets and licenses including RISI, electrical contractors license. Note the requirement for only RailCorp issued RISI tickets from July 08. This information will be used to assess competence and subsequent approval by RailCorp of key staff for that position; 2. Works Programme; 3. Quality Plan including quality procedures, hold points and witness points; 4. OHS&R Plan including Safe Work Method Statements (SWMS and SWIs) and emergency procedures; 5. Environmental Management Plan; 6. Worksite Protection Plan; 7. Demolition Plan; 8. Power outage requirements; 9. Site Plan showing areas required for construction, storage of materials and staff amenities. 10. Approved stage operating diagrams should be mentioned as hold points or milestones on the Project Plan. The Project Plan shall be submitted to the Principal for review and acceptance six (6) weeks prior to work commencing on site. No site work will be permitted to commence until the Principal has accepted the Plan. 2.5.4 Access to Site Access to the Substation is available from Northern side of the rail line via Loftus Street. Access to the worksite is via a gate at the eastern end of the substation at this location. Access to site is only permitted with the attendance of a RailCorp Substation Technician. A substation technician will be required to be in attendance for the duration of all daily works. The substation will remain LIVE and operational for the duration of the works. Note: The site is also a shared site with Integral Energy (IE) and as such total access to the whole site may not be able to be given. This should not impinge on this contract but the Contractor needs to be aware of this situation. 2.5.5 Site Compound The Contractor will be permitted to establish his site compound and amenities on land as may be available and mutually agreed between the Principal and the Contractor. The Contractor is to provide all site facilities and amenities as covered by the relevant industrial awards including site sheds, toilet and ablution facilities, power, water and communications. Responsibility for security, protection from theft and vandalism will remain with the Contactor for all their amenities, tools and equipment.
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2.5.6 Temporary Demarcation Fence The Contractor must ensure that the security of the substation, and public safety are not compromised. The Contractor shall prevent inadvertent encroachment of personnel into the substation. If necessary a demarcation barrier may be erected at the periphery of the work site. The Contractor must provide and maintain fences, to preclude public access and trespass into the substation where their arrangement or configuration is altered. The Contractor shall remove and dispose of all rubbish they generate on the site. The Contractor must keep all gates that might allow trespassers to access the substation locked at all times, unless they are attended by a responsible person and are in immediate use. The Contractor must lock the gates at the end of its daily activities. On completion of the work, the Contractor is to fully restore the area to its previous condition. 2.5.7 RailCorps Access to its facilities RailCorp may require access to its facilities at times. Accordingly, the Contractor must be able to clear the area to give access; The Contractor must keep clear access to the substation during non working times. 2.5.8 Working Hours Permissible working hours on site (with the exception of the full track closedowns) will be: Monday to Friday: 0700 to 1530 hours

Saturday: 0700 to 1300 hours, for works on Saturday if required, a minimum 2 weeks notice in writing must be given.

Any work outside these hours including the delivery of materials is subject to the approval of the Principal and availability of RailCorp substation technician. 2.5.9 Works Programme and Staging The Contractor is required to prepare, monitor and update as necessary a comprehensive works programme for the works. The programme may be in the form of a bar chart but must show any critical dependencies etc. Daily work sheets must be submitted to RailCorp 24hours prior to the proposed day of work for approval. Relevant risk assessments and safe work method statements must accompany works programme. This requirement is inflexible and must be strictly adhered to ensure safety in a live and operational substation. Access for modification and or connections to the 66kV bus will be restricted to outage periods only. Outage periods occur during possessions for the Blue Mountains region of which there are four per year. Outages outside possession times can some times be organised with sufficient notice given, especially individual feeders. The Contractor shall programme the works to take advantage of these outages. This shall be shown in the project plan. Also approved stage operating diagrams shall be shown as hold points or milestones on the project plan. Notification from RailCorp of occasional night outages will be provided as soon as possible. The Contractor shall ensure that a works programme is submitted for these outages a minimum of 12 weeks prior to the outage should they be required by the Contractor.

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2.5.10 Subsurface Conditions It is the Contractors responsibility to assess for himself from this and any other data that he may obtain the nature of the subsoil conditions across the site. Protection of Existing Infrastructure 2.5.11 Construction of the Work under this Contract shall proceed without any disturbance to the existing railway infrastructure (other than the nominated demolition works) and adjacent public and private property. The Contractor shall ensure that the stockpiling of materials and storage of plant on site shall not interfere with the rail infrastructure including track, signalling and electrical equipment. The Contractor and Principal shall agree on the locations for stockpiling before equipment and materials are delivered to site. 2.5.12 Coordination of Works with Others The Contractor will be required to co-ordinate his work with the Principal and any authorities whose services may require temporary or permanent relocation. If the Contractors work requires some prior work to be completed by the Principal or others, he shall advise his requirements to the Principal not less than thirty days before such completion is needed. 2.5.13 Railway Worksite Protection The Contractor shall provide Worksite Protection Services (WPS) for the works under the Contract as and when required. It should be noted that the works under this contract are not expected to require extensive access to the rail corridor. The WPS are to be obtained from any of the organisations approved to provide WPS by RailCorp. The requirement that the Contractor provide worksite protection personnel extends to any periods of full track possession and while working within the Danger Zone. 2.5.14 Setting out the Works The Contractor shall arrange all survey and setting out of the works in accordance with the Approved for Construction Drawings. The following stages of the setting out are to be certified by a registered surveyor engaged by the Contractor and constitute Hold Points under the Contract: 66 kV Structure and Equipment Foundations;

Transformer Foundation; Regulator Foundation; Cable pits and trenches; and Penetrations into the substation.

2.5.15 Services Search The Contractor shall confirm the location of all services within the work area, including contact and receipt of information from Dial Before You Dig and potholing as deemed necessary. Damage by the Contractor to known services that are located in the general vicinity as identified in the services search will be at the Contractors risk and cost. Completion of the services search shall constitute a Hold Point under the Contract Quality System.

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2.5.16 Occupational Health & Safety The Contractor shall implement OHS&R practices and procedures in accordance with relevant government legislation and the Special Conditions of Contract. The Contractor is to note that other contractors may be on site during the works. 2.5.17 Protection of the Environment The Contractor shall prepare and implement a comprehensive Environmental Management Plan (EMP) for the performance of the works. The EMP shall be prepared and submitted to the Principal for acceptance prior to the Contractor commencing work on site. All work shall be carried out in such a manner as to avoid nuisance and/or damage to the environment or disturbance to adjoining landowners. The Contractor shall comply with the requirements of the Environmental Planning and Assessment Act, 1979, associated legislation and all requirements of relevant statutory bodies. No extensions of time or variation to costs will be considered due to these requirements. The Contractor shall arrange for all necessary approvals required by the DECC and other bodies to enable the work to proceed. Further, the Contractor shall provide and maintain throughout the construction period, all necessary environmental protection measures required by the DECC. The Contractor shall mitigate the impact on the environment and the community at and near the work site that might arise from dust, contaminated soil, debris, noise, obstruction, vibration, attraction of vermin, and all other effects, irrespective of whether these effects are identified by RailCorp. In particular, the Contractor shall observe the following requirements: The whole of the works are to be planned and implemented to avoid erosion, contamination, and sedimentation of the site, surrounding country, watercourses and streams;

The Contractor shall not cause any unnecessary or excessive noise or smoke; The Contractor shall protect any watercourses from the ingress of sediments disturbed during construction work. Where necessary, sediment collection barriers and dams are to be provided; The washing down of concrete mouldings and agitators shall be carried out in an area that drains into a collection pond or in some other location where pollution of waters cannot occur; Fuel and oil stored on site shall be stored in an area designed to hold 120% of the volume of the largest tank within the bund. Such storage facility must not be located within a flood-prone area; Any vehicle maintenance, servicing or refuelling shall be carried out in an area where any spillage of fuel, oil and other lubricants cannot pollute waters; No material shall be burnt on site other than that considered necessary for safety purposes; The sites shall be cleaned regularly and left in a tidy condition on completion of the work;

The Contractor shall rectify any damage resulting from the Contractor not observing the above requirements.

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2.5.18 Signage The Contractor shall provide safety construction signs conforming to the OH&S Safety Regulation 2001, Part 8, and as otherwise required by the Contract. The general signage must include the Contractors and RailCorps logos, Danger Construction site sign; Notice sign, including RailCorps compulsory PPE requirements for construction site; Contractors Site Manager details; RailCorps contact details; and After hour emergency contact telephone number. The sign shall be made from corflute with minimum dimensions of 1200mm x 900mm. 2.5.19 Hot Work Authority The Contractor shall note that in the event of a Total Fire Ban, any work that has the potential to cause a fire will be prohibited. This restriction includes all welding with the exception that the work is being undertaken during a closedown or major track possession and the welding is essential for the continuance or restoration of rail services. In this event, it will be necessary for the Contractor to apply for a Hot Work Authority in accordance with the procedures detailed in RailCorp Engineering Manual TMC 501 Bushfire Hazard Management Manual. 2.5.20 Electrical Permits The Contractor shall provide an accredited electrical permit holder whenever necessary under RailCorps standards and safety procedures. 2.5.21 Documentation and As-Built Drawings The Contractor shall prepare and submit one hard copy set of the construction drawings, marked-up to indicate work-as-executed (WAE). Any variations to the detail as specified on the contract drawings are to be clearly shown on the WAE set. The Contractor shall mark-up the WAE drawings as the various items of the work progress and are completed. The Contractor shall submit WAE drawings for review at each of the progress review meetings. The Contractor must accurately document the location of all new services installed by the Contractor in accordance with RailCorps Detailed Site Survey (DSS) procedures. The Contractor must prepare and complete inspection test plans (ITPs) for new works and or equipment. 2.5.22 Quality Standards The Work under this Contract shall be undertaken in accordance with RailCorp Standard TMC 304. The Contractor shall allow RailCorp to perform regular audit of the work. The Contactor shall make available all documentation to RailCorp for work audit. 2.5.23 Concrete Works The scope of concrete works by the Contractor includes: Foundations for new busbar (strung and rigid) support structures. All necessary equipment (free issue or otherwise) whether specifically mentioned or which forms part of the detailed design; The above concrete works are to be treated as Witness Points under the Contract Quality System. The concrete works shall be constructed in accordance with relevant sections of RailCorps Standard TMC304 Structures Construction Manual.
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2.5.24 Drainage Works The scope of drainage work by the Contractor includes: Provide an adequacy report for the existing drainage lines where shown on the Drawings or identified in the services search with the works scope boundary. The Contractor shall maintain the existing drainage system to its best capacity during construction. 2.5.25 66kV Structures The scope of work on 66kV Bus Structures by the Contractor includes: Construction of footings for new 66kV equipment;

Fabrication and delivery to site of new steel structures, including all associated holding down bolts and fastenings; Installation and erection of new structures; If existing redundant footings interfere with construction of new structures, the footings may be trimmed to suit, by saw cutting. Such trimming shall not extend any deeper than the minimum required accommodating the new footing. This shall extend to demolition and removal if required. Fabrication and protective treatment of the new structures; All workmanship to be in accordance with A.S.4100 and A.S.1554.1 Unless otherwise noted, all steel to be grade 300 (hollow sections to be grade 350). All connection and stiffener plates to be minimum 10mm thick u.n.o. All welds to be continuous fillet special purpose welds u.n.o. All bolts to be M20 and no connection to have less than 2 bolts u.n.o. All bolts to be grade 8.8/tc u.n.o. All holding down bolts to be grade 4.6/s u.n.o. All structural steel items to be fully galvanised to A.S.4680 unless noted otherwise on the drawing. Shop drawings to be submitted in triplicate to the Contractor for approval. Fabrication not to commence until approval has been given. Unless otherwise specified all welds shall be 6mm cfw in accordance to AS1554 Part 1, Category SP. The extent of weld inspections shall be: a. 100% visual examination; and b. Minimum 10% non destructive testing.

The fabrication and erection of the structural steelwork shall be supervised by an engineer experienced in such supervision to ensure that all requirements of the design are met.

2.5.26 High Voltage Electrical Work The scope of high voltage electrical work by the Contractor includes:

Connection of existing 66kV Dual Busbar to the new wiring structures / equipment; Installation and connection of two new air break switches;

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Relocation, installation and connection of the existing 66/11kV transformer to the new location ; Installation and connection of the new 11kV voltage regulator; Installation and connections for the new 66kV ACCB; Supply and installation and necessary connection of new 11kV switchboard Relocation and augmentation of existing 11kV feeder cables as necessary to terminate at new switchboard. Supply and installation of all electrical components as shown on the Drawings including all cabling, cable trays, fastenings, isolating switches, surge arrestors, earth connections necessary to perform the works detailed by this scope of works design and construct contract. All high voltage electrical works shall be undertaken in accordance with the following RailCorp Engineering Standards, Specifications and manuals: EP 99 00 00 01 SP Substations Minimum Construction Standards EP 99 00 00 02 SP System Substation Commissioning Tests EP 99 00 00 04 SP Base Safety & Operating Standards EP 06 00 00 01 SP System Substation Battery EP 19 00 00 03 SP Commissioning of Translay Pilot Wire Protection Scheme EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network EP 16 00 00 02 SP Outdoor Ground Type Distribution Transformer EP 00 00 00 02 SP Electrical Technical Maintenance Coding EP 00 00 00 07 SP Requirements for Handling & Disposal of Material containing PCB EP 21 00 00 01 SP Insulation Co-ordination & Surge Arrester EP 20 00 00 03 SP Above Ground Cable Installation Systems Selection Guide EP 20 00 04 05 SP Cable Pits EP 20 00 04 01 SP Cable Route Selection Guide EP 20 00 04 04 SP Ground Entry Arrangements EP 20 10 00 02 SP High Voltage Cable Selection Guide EP 20 00 03 01 SP Requirements for Cable Polymeric Terminations and Joints EP 20 00 00 20 SP Testing of High Voltage Cables EP 12 10 00 20 SP Earth Mat requirements

The following stages of the high voltage electrical works are to be certified by a qualified electrical engineer engaged by the Contractor and constitute Hold Points under the Contract Quality System:

At each 66kV structure and equipment termination / commissioning stage for new wiring; and High voltage power supply switchgear commissioning.

2.5.27 Low Voltage Electrical Work The scope of low voltage electrical work by the Contractor includes:
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Supply and install new protection and miscellaneous power main switchboard; Supply and install all necessary and or incidental cabling to allow for completed installation and function in the intent of the design; Supply and install power cabling including trenching, conduits and backfilling; Supply and install access pits; and Supply all necessary luminaries, fittings and fixtures.

All low voltage electrical works are to be undertaken in accordance with the specifications included on the Drawings and the following standards:

Electrical Work AS/NZE 3000.2007 (Wiring Rules) Electrical Installations Selection of Cables AS3008 Quality Assurance AS 9000 Series New South Wales Local Government Act The Building Code of Australia EP 17000006SP Installation Inspection EP 12100010SP System Substation Earthing EP 95300002SL Isolation of Low Voltage Distribution EP 17000011SP Low Voltage Isolating Transformer

RailCorp Standards:

The following stages of the low voltage electrical works shall be certified by a qualified electrical engineer engaged by the Contractor and constitute hold points under the Contract Quality System: Low voltage power supply; and

Low voltage cable route to lighting.

The following item of low voltage work shall be treated as a Hold Point under the Contract Quality System: Commissioning and Test of Protection Switchboard.

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2.5.28 RailCorp Standards and Specifications The following RailCorp Standards, Specifications and Manuals are also referred to in this document and are available in soft copy on request to registered customers. Please contact Garry.Thong@railcorp.nsw.gov.au for a registration to receive these documents. Tenderers must allow sufficient time to effect their registration. 2.5.29 Civil No. TMC 501 TMC304/S01 TMC304/S03 TMC304/S04 TMC304/S10 TMC304/S22 TMC304/S25 TMC304/S41 2.5.30 TITLE Bushfire Hazard Management Manual Quality Assurance & Control Miscellaneous Earthworks Excavation & Foundations for Structures Concrete Works Miscellaneous Steelwork Protective Galvanised Coating of Steelwork Demolition of Existing Structures

Electrical : High and Low Voltage No. TITLE EP 99 00 00 01 SP Substations Minimum Construction Standards EP 99 00 00 02 SP System Substation Commissioning Tests EP 99 00 00 04 SP Base Safety & Operating Standards EP 00 00 00 02 SP Electrical Technical Maintenance Coding EP 00 00 00 07 SP Requirements for Handling & Disposal of Material containing PCB EP 06 00 00 01 SP System Substation Battery EP 12 00 00 01 SP High Voltage & 1500VDC System Earthing References & Definitions EP 12 10 00 10 SP System Substation Earthing EP 12 30 00 01 SP Electrolysis from Stray DC Current EP 16 00 00 02 SP Outdoor Ground Type Distribution Transformer EP 19 00 00 03 SP Commissioning of Translay Pilot Wire Protection Scheme EP 19 00 00 02 SP Protection System Requirements for the High Voltage Network EP 21 00 00 01 SP Insulation Co-ordination & Surge Arrester EP 20 00 00 03 SP Above Ground Cable Installation Systems Selection Guide EP 20 00 04 05 SP Cable Pits EP 20 00 04 01 SP Cable Route Selection Guide EP 20 00 04 04 SP Ground Entry Arrangements EP 20 10 00 02 SP High Voltage Cable Selection Guide EP 20 00 03 01 SP Requirements for Cable Polymeric Terminations and Joints EP 20 00 00 20 SP Testing of High Voltage Cables

2.5.31

Detailed Site Survey (DSS) Procedures No. TITLE EP 0491 to EP 0497 Detailed Site Survey Data Capture Procedure

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3 Quality Requirements 3.1 Design Standards


All design work performed by the Contractors Designer shall conform to standards stated. In the event of any ambiguity, inconsistency or discrepancy with the requirements of any reference documentation the designer must detail the ambiguity, inconsistency or discrepancy found, assess the impact and advise RailCorp.

3.2

Selection and Use of Australian and International Standards

The Contractors Designer shall be responsible for the selection and use of the appropriate Australian and/or International standards for individual design tasks, including:

The requirements of Lawson Concept Design Packages provided by RailCorp, and Requirements for compliance with NSW State and Federal Legislation and Regulations, including NSW Occupational Health and Safety Regulations 2001, Environmental Legislation and Regulations, Electricity Legislation and Regulations, and Additional requirements included in RailCorp Standards that limit or otherwise amplify the use of other standards for RailCorp applications.

3.3

RailCorp Standards

RailCorp has adopted a series of internal Standards for use within the design of rail infrastructure. These include Standards prepared by, or on behalf of, predecessor organisations (RSA, RAC, and SRA) that have had responsibility for design and maintenance of the NSW rail system infrastructure. The set of RailCorp Standards applicable to design tasks comprises two general types of documents, as follows: 1. Standard Specifications. These generally cover physical and functional performance requirements and limitations for items and materials used in infrastructure design and maintenance. Standard specifications also include details of items or products that have been type approved for use within the RailCorp system as well as limitations on the use of type approved products. Standard Designs. These generally cover type approved designs that have been developed for use in appropriate applications within the RailCorp Infrastructure.

2.

The RailCorp Standard Documents referenced above may be used by the Contractor however the responsibility for provision of a design which is fit for purpose remains with the Contractor.

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3.4

Standard of Completed Design

3.4.1 Design Verification Design verification ensures that the output from an individual design stage meets or is likely to meet the verified inputs to that stage. Design verification is part of the process whereby design outputs are progressively reviewed before the design is released for construction. The designer shall note that any review undertaken by RailCorp will not transfer design ownership to RailCorp. The design and any or all responsibilities incumbent with such design will remain with the designer. Verification of design output shall be achieved as specified below: 3.4.1.1 Design Verifier The Contractor shall nominate their design verifier prior to acceptance of the design process and shall ensure that their nominated design verifier maintains compliance with the following requirements throughout the duration of the design: Holds the necessary qualifications to check design work for the discipline concerned, and has been duly accredited by RailCorp. For external Contractors, design authority is delegated by the General Manager Engineering to the person(s) nominated by the Contractor. Has not been directly responsible for producing the design. Design checks shall be performed by the design engineer supervising the design tasks performed by members of that team but can be performed by any competent and properly authorised engineer meeting the foregoing criteria.

Upon completion of the Final Detailed Design documentation the Contractors design verifier shall complete, sign and date a Design Verification and Approval Checklist to sign off their verification of the final design. 3.4.1.2 Design Verification The Contractors design verifier shall carry out the verification of the design documentation according to the RailCorp Engineering Design Management Procedure ED 0011 P prior to submitting for review. Verification shall proceed progressively throughout the design process. Progress of the verification shall be reported at the Technical Review meetings by presentation of a Design Verification and Approval Checklist signed by the Contractors design verifier for the stage of the design covered by the meeting.

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3.4.1.3 Design Validation The Contractors design verifier shall carry out the validation of the design documentation on behalf of the Contractor according to the RailCorp Engineering Design Management Procedure ED 0012 P, prior to submitting for review. 3.4.2 Technical Reviews

3.4.2.1 Project Initiation Review A Project Initiation Review (PIR) will be carried out as early as possible after the award of the contract. The main purpose is to ensure that the design brief fully defines the requirements for the task and that any inconsistencies or omissions are identified and resolved. The PIR should take place after the design brief has been reviewed in detail by all applicable discipline groups and following initial requirements analysis and allocation. Submission of a Design Management Plan is required at the PDR including provisions for interface management. RailCorps Authorised Person will convene the PIR. Project Initiation Reviews shall be attended by representatives of the Contractors design staff, the RailCorp Delivery Manager, Stakeholders and representatives from RailCorp Design Section(s) appropriate to the scope of the task. The Delivery Manager will be responsible for chairing all such reviews, in conjunction with the Head of the applicable design section(s). 3.4.2.2 Preliminary Design Review Meeting The purpose of Preliminary Design Reviews (PDR) is to assess whether the proposed approach for the design is consistent with the functional and performance requirements of the design brief. PDRs will take place when the preliminary design has progressed to a level of detail that will allow the intended approach to be assessed for compliance with the design intent of the design brief. The PDR may be conducted in one session or in several sessions to consider individual parts of the design. PDRs conducted with the designer will be attended by the RailCorp Design Delivery Manager, Stakeholders and the Section Head or a Team Leader from each discipline involved. RailCorp staff nominated to attend PDRs will have reviewed information delivered by the designer prior to the meeting. Minimum levels of information necessary to conduct an effective review include: Preliminary design and layouts drawings, including interface definitions,

A summary of key assumptions made by the designer, Initial selection of major components and materials. The results of preliminary risk, hazard and human factors analysis, Preliminary reliability models and predictions available.

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Design reports and calculations may be required in support of the review process but are not normally delivered in advance of the review.

3.4.2.3 Detailed Design Review The Detailed Design Review (DDR) will take place at or close to the completion of the detailed design phase. The primary purpose is to ensure that the design appears to be suitable in all respects to proceed with construction and fabrication. In this Contract construction is involved, the DDR will form a major input for determining whether the requirements of the design contract has been met. In addition drawing reviews will be completed as detailed in Electrical Standard EP 00 00 00 15 SP Common Requirements for Electrical Power Equipment Paragraph B3.3 Drawings. Drawing review will be an iterative process until design is considered complete, following which all documentation as detailed in Section 2.4 above shall be submitted by the to RailCorp. The scope of the DDR is similar to the PDR, but addresses the proposed design in more detail. This includes detailed drawings and supporting design information (design report and technical specification), safety and hazard analysis and final reliability models and predictions for the design. The Design Delivery Manager is responsible for convening the DDR stage, by agreement with the Contractors Design Manager, as applicable. Wherever possible the DDR shall be attended by RailCorp Stakeholders as well as RailCorp Section Heads or Team Leaders from each discipline involved in the project. 3.4.2.4 System Verification Review A System Verification Review shall be carried out to ensure all verification and validation requirements of the contract have been met, including testing to the extent that it is appropriate to the contract task. 3.4.2.5 Design Checking Upon contract award design authority shall be deemed to be transferred to the Contractors designer, being the appointed design consultant. Design checking will also be the sole responsibility of the Contractors designer. Design checking shall include the systematic review of design assumptions, calculations, methodology, use of standards and compliance with mandatory requirements as part of the design process by an engineer who: a) Holds the necessary qualifications to check design work for the discipline concerned, b) Is properly authorised. For external service providers (Contractors designer) design authority is delegated by the General Manager Engineering to the person(s) nominated by the external service provider, as having responsibility for Design Approval; and c) Has not been directly responsible for producing the design. Design checks shall be performed by the design engineer supervising the design tasks performed by members of that team but can be performed by any competent and properly authorised engineer meeting the foregoing.

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3.4.3 Reference Standards The documents listed below are a representative list of applicable standards. The list is not comprehensive and it remains the responsibility of the designer to ensure compliance with all relevant standards. Number EP 99 00 00 01 SP EP 99 00 00 04 SP EP 99 00 00 02 SP EP 12 10 00 10 SP EP 12 00 00 01 SP EP 00 00 00 01 TI EP 90 10 00 01 SP EP 90 30 00 01 SI EP 21 00 00 01 SP EP 20 10 00 02 EP EP 90 10 00 02 SP EP 03 02 00 01 SP. EP 95 00 00 10 TI EP 95 00 00 00 TI EP 95 00 30 06 SP EP 20 00 04 01 SP EP 00 00 00 13 SP EP 00 00 00 12 SP EP00 00 00 15 SP EP 19 00 00 02 SP ED0001 ED0019 AS/NZS 3000 AS 2067 AS 4680 EP 95 00 00 10 TI EP 95 00 00 00 TI EP 95 00 30 06 SP EP 20 00 04 01 SP EP 00 00 00 13 SP Revision/Date of Issue Ver. 2 November 2001 Ver. 2 November 2001 Ver. 2 November 2001 Ver. 2.1 September 2002 Ver. 2 November 2001 Ver. 2 November 2001 Ver. 2 November 2001 Ver 1.0 June 1997 Ver. 2.0 November 2001 Ver. 1.0 October 2002 Ver 2.0 November 2001 Ver 1.0 July 2004 Ver 1.0 22 June 2001 Ver 1.0 22 June 2001 Ver 1.0 September 2003 Ver 1.0 October 2002 Ver 1.0 January 2004 Ver 1.1 November 2003 Ver 1.0 July 2004 Ver 3.0 July 2004 Ver 1.1 June 2004 2007 1984 1999 Ver 1.0 22 June 2001 Ver 1.0 22 June 2001 Ver 1.0 September 2003 Ver 1.0 October 2002 Ver 1.0 January 2004 Title Substations minimum construction standards Substations Base safety and operating standards System Substation Commissioning Tests System Substation Earthing High Voltage & 1500 System Earthing References & Definitions RailCorp Electrical system general description Electrical phase relationships Polarity of AC Signalling Supplies Insulation Coordination & Surge Arrestor Selection High voltage cable selection guide Standard Voltage Tolerances. Control and Protection for Rectifier Equipment Definitions Electric Power systems Safety Aspects Electrical Network Management Plan. Cable Route Selection Guide Electrical Power Equipment Design Ranges of Ambient Conditions Electrical Power Equipment- Integrated Support Requirements. Common requirements for Electrical Power Equipment Protection System Requirements for the High Voltage Network Engineering Design Management Procedures Electrical Installations (known as the Australian/New Zealand wiring rules) Switchgear assemblies and ancillary equipment for alternating voltages above 1 kV. Hot-dip galvanised (zinc) coatings on fabricated ferrous articles. Definitions Electric Power systems Safety Aspects Electrical Network Management Plan. Cable Route Selection Guide Electrical Power Equipment Design Ranges of

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Number

Revision/Date of Issue

Title Ambient Conditions Electrical Power Equipment- Integrated Support Requirements. Common requirements for Electrical Power Equipment Protection System Requirements for the High Voltage Network Engineering Design Management Procedures City Rail Sign Types Manual.

EP 00 00 00 12 SP EP00 00 00 15 SP EP 19 00 00 02 SP ED0001 ED0019 -

Ver 1.1 November 2003 Ver 1.0 July 2004 Ver 3.0 July 2004 Ver 1.1 June 2004 -

3.4.4 Access to RailCorp Standards Copies of all RailCorp Standards are located on the RailCorp Extranet. These can be made available to the Contractor if requested. Access to RailCorp drawings 3.4.5 Copies of all RailCorp and/or SRA original drawings can be obtained from the RailCorp plan room after RailCorp authorisation has been granted. RailCorp authorisation will be arranged by the Design Delivery Manager after written request by the Contractors designer. Drawings are being progressively scanned into the drawing database and where this has occurred the scanned copy may be made available electronically. It shall be the Contractor designers responsibility to ensure that the information contained on the drawing is complete. Information discrepancies may occur in particular during de-specking process for scanned drawings; this could result in some decimal points and characters being lost. Where the Contractors designer considers certain characters and numbers are not reproduced on the scanned drawing RailCorp shall be advised immediately in order that clarification can be provided.

3.5

Design Drawings

3.5.1 Drawing Format Drawings shall be completed in conformity with EP 00 00 00 15 SP Common Requirements for Electrical Power Equipment Section 6.1.3.1 CAD Drafting. RailCorp Drawing templates will be supplied to the Contractors Designer. Where an existing RailCorp or SRA drawing requires modification and is in a format other than RailCorp CAD it shall be redrawn by the design consultant in an approved RailCorp CAD format. Additional requirements regarding drawing format are detailed in Attachment 2 Drawing Format and in the RailCorp CAD manual, Electrical Design Standards For External Use. 3.5.2 Cross Referencing All cross-referenced drawings shall be listed in the section headed Reference Drawings on the RailCorp standard drawing sheet.

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3.5.3 Drawing Compatibility In addition to the paper/plastic copy, all drawings will be stored within the RailCorp drawing system in Microstation format, the preferred format for drawings being Microstation Version 8, however RailCorp will accept drawings produced in AutoCAD Version 2000; Attachment 2 Drawing Format is included to facilitate the translation from AutoCAD to Microstation. Drawing Compatibility Drawing Revisions 3.5.4 Drawings produced during the design process and submitted to RailCorp for review shall be dated and marked PRELIMINARY, a revision number optional. Where a Preliminary drawing is updated but still is a Preliminary drawing a revision number and dated will be required. Drawings accepted by RailCorp shall be marked FOR CONSTRUCTION and issued as Revision A. To facilitate the review process, all changes shall be identified by clouding the latest revision on each affected drawing. Once in construction any drawing changes must be issued with an updated issue id and dated and signed appropriately.

3.6

Design Approval

The Contractors accredited Designer and Design Verifier shall accept responsibility for design approval. RailCorp will review all design documents submitted for conformity with RailCorp requirements only. Following acceptance by RailCorp of all drawings the Contractor shall submit an A4 sheet, or sheets, in tabular form listing the document number and revision letter, description and date. The sheet shall identify the name of the Contractors organisation and carry a statement to the effect that the drawings referenced on the sheet are Approved for Construction by the Contractors Designer and Design Verifier signatories whose original signatures shall appear on the sheet. Design approval is the responsibility of the Contractors Designer, RailCorp will review all drawings submitted for conformity with RailCorp drawing requirements only. Following acceptance by RailCorp of all drawings (for format only) the Contractors Designer shall forward drawings as detailed in section 2.4.

3.7

Environmental Matters

3.7.1 Review of Environmental Factors A current Review of Environmental Factors (REF) will be made available on request but must be fully considered by the Contractor.

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4 Functionality Requirements 4.1 Rail Safety and Site Visits

RailCorp has developed a Safety Management System with 20 Elements to achieve its safety responsibilities as the owner and maintainer of the NSW Rail Network, in accordance with the requirements of: The Transport Administration Act 1988; The Transport Administration Amendment (Rev 1 Management) Act 2000; Rail Safety Act 2002 and Rail Safety Regulations 1999 A copy of the Safety Management System Elements will be made available to the Contractor. In fulfilling the safety responsibilities the Contractor shall consider the risks relevant to the Contract and manage the risks following RailCorp approved processes. In addition, the Contractor shall keep RailCorps Authorised Person informed of any safety or safety related issues. Note: Safety audits will take place through out the project without warning. Note: Access to the substation can only be with the attendance of a suitably Qualified Substation Technician and with the Sub Station Access Permit duly approved for the work to be preformed that day, so each day a Permit will be required to be filled out and approved by the relevant Substation Technician.

4.2

Construction Hazards and Risks

In addition to the maintenance of the Hazard log for the duration key personnel will be expected to attend an offsite Hazard Risk workshop before commencement of work on site. The Hazard risk workshop will identify hazards and risks associated with the job and job site.

4.3

Hazard Risk and Human Factors Analysis

Systematic analysis of hazards and risks shall be carried out by the Contractor. Prior to starting on site it is a requirement that key personnel listed will partake in a Hazard risk workshop at which a hazard log will be established for use as a living document throughout the life of the project. The Contractor shall maintain the hazard log and take the necessary corrective actions to eliminate the hazards.

Primary sources of hazards which should be considered can be from:


Normal operation. High Voltage Live equipment. Equipment failure. Improper use or maintenance. The environment. Dangerous goods. Hazardous substances.

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The impact on the following must be considered: Maintenance staff. The public. Construction staff. Operators. Other equipment. The environment.

A Preliminary Hazard, Risk Analysis shall be completed as soon as possible and submitted at the first review (SDR) A Hazard log will be done prior to any work on site and duly maintained throughout the project. The Hazard, Risk and Human factors Analysis is to evolve and be integrated with the design. The design report shall identify:

Any legal requirements; codes of practice; and standards and industry practice that is applicable. Record the closure of Safety-in-design issues and to identify residual risks and the mechanism to address these risks for the expected design life of the asset.

4.4

Reliability

Reliability and maintainability are treated as key performance requirements in all new design work carried out by RailCorp design staff or a third party designer. The levels of reliability and maintainability that are built in to the initial design not only govern the level of availability that can be achieved in service but also have a major influence on the cost of maintenance over the life of the asset. For this reason it is essential that all infrastructure equipment that is designed by RailCorp, or is specified either for procurement as a standard item or for design by a third party, should incorporate the best possible levels of reliability and maintainability, commensurate with the acceptable cost, for the item. 4.4.1 Functional Item Reliability Specific reliability requirements for functional items should normally be included in the specification. For this installation RailCorp expects an operational life of 40 years. 4.4.2 Fixed Mechanical Items/Structures Reliability criteria for fixed installations are normally specified in terms of a minimum replacement life, coupled with appropriate maintainability features designed to prolong the service life of the equipment. For this installation RailCorp expects an operational life of 40 years.

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4.4.3 Maintainability Maintainability characteristics should be included in the technical specification, as either essential or desirable features, as appropriate. This will usually involve specific considerations such as: 1. 2. 3. 4. 5. 6. 7. 8. 9. Accessibility. Interchangeability. Self Diagnostic Features (Built-in-Test) / Condition Monitoring. Construction Features. Types of material to be used. Protective finishes and corrosion protection. Compatibility. Handling provisions. Adjustment and Alignment.

Availability 4.4.4 The definition of availability should include functions which are essential for the equipment to be classed as available and also conditions under which the equipment may be assessed as capable of performing the primary function (and thus available), even though a failure has taken place. This may include operation in a manually controlled mode when the normal mode is automatic control, or operation at a reduced level of performance i.e. reduced speed limit. A maximum period can be specified for operation in this condition, if required. The detailed design to be completed by the Contractor against this Specification shall not significantly reduce the availability of the system otherwise obtained from the Concept Design developed by RailCorp and also the major plant nominated by RailCorp.

4.5

Interface Management

With Existing Systems 4.5.1 Many projects undertaken by the RailCorp may either affect, or be affected by, interfaces between the item/system being modified and other systems. These interfaces may involve other hardware and/or software items or systems but may also involve operating systems and procedures, information systems or conditions of use of the infrastructure that are outside of the direct control of RailCorp. Management of these interfaces is critical for effective configuration management and for maintenance of the safety and integrity of RailCorp infrastructure. The Contractors Designer shall demonstrate that such interfaces have been considered. Particular interfaces of concern are: Power System Protection equipment interconnection, both to existing RailCorp infrastructure and Third party distributor infrastructure where relevant.

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4.5.2

Interfaces with other Engineering service providers and other entities and or stakeholders who access the site. The design task will either effect or be affected by interfaces between other engineering service providers. Particular services providers are RailCorp Construction Control and Communications Systems Integral Energy (a through access is maintained at present and may present challenges as the project proceeds as IE are also upgrading their facilities as well so close communications and planning will be needed.)

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Attachment 1 Lawson Concept Design Package PROJECT: Lawson Sub Station

DOCUMENTS: 1. 2. 3. 4. Lawson Substation General Arrangement Information Drawing B Lawson Substation New Switchboard Arrangement Information Drawing A 12kV SM6 Switchgear General Arrangement Sheet 1 of 1 TENDER 1 Rev 0 12kV SM6 Switchgear General Arrangement Sheet 1 of 1 TENDER 2 Rev 0

ASSOCIATED DOCUMENTS:

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Attachment 1 Lawson Concept Design Package

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Attachment 2 - Drawing Format

DRAWING FORMAT To minimise the complications arising from conversion from AutoCAD to micro station & vice versa the following should be observed: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Copy and rename (e.g. EL 0037125.dwg etc.) this border sheet for drawings of 1:100 scale; Use the renamed file to draw and annotate; For linework draw in modelspace at 1:1 scale, units are in mm; For annotation draw in modelspace at 100 times (e.g. to get printed text size of 2.5mm, draw text at size 250mm); Do not attach xrefs. If you do, merge them & detach xrefs; Do not use paperspace; Do not use viewports; Use one scale only in one drawing. Xrefs and viewports should not be used; Use isocp3.shx as font file with width factor of 1.05; Do not use shared cells.

The border sheet has elements on level 60. Do not draw anything on this level; do not delete anything form this level (if needed please consult RailCorp). Do not move the border area. The final printed size is ISO A1 (841mm x 594mm).

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Attachment 3: SCADA System

SCADA System

The electrical SCADA system monitors and controls all HV and DC systems, providing information on the status of electrical equipment to two master stations located at Prince Alfred sidings in Sydney (PA) and Broadmeadow. The remote sites compromise a SCADA Remote Terminal Unit (RTU), I/O signals and associated cabling as well as power supply cabling. Equipment to be controlled and monitored by electrical SCADA shall include: All 66kV switchgear, status monitoring of essential substation equipment and indication of voltage and current signals. I/O field terminals should generally be Weidmuller SAK type terminals of suitable make to allow terminations to be made using a standard 4mm blade screwdriver for termination inside the SCADA cabinet. I/O Functions Each I/O port has a particular function, these functions are listed below: Alarm: If the I/O point is defined as an alarm function, then when an active alarm function is generated operator action is generally required. An alarm function can also be a precursor to a trip occurring. If the I/O point is defined as a status function, then this is used to show the status of a device and is for information only. No operator action is required for a status point, i.e. the information gathered is for information only in the control of the process. If the I/O point is defined as a signal function, then this is used for measurement or monitoring of measured values. The signal is to be displayed in engineering values. The signal point can also be used to generate trip points. Basically this is an analogue I/O point. If the I/O point is defined as a trip function, then the device will immediately change state to the safe operating position, i.e. opening a CB. Generally this is an input I/O point. If the I/O point is defined as a control function, then a device is controlled by this I/O point, i.e. Opens or Closes a CB or turns on a valve or starts a motor. Generally this is an output I/O point either digital or analogue.

Status:

Signal:

Trips:

Control:

I/O signals to be provided shall include, but not necessarily be limited to those listed in the following table.

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Description Fire Panel Healthy Fire System Failed Fire Detected Substation Room Staff Detected Substation Room Door Switch Opened Substation Room Staff Audible Alarm Substation Room Staff Emergency Alarm Substation Room Temperature Substation Room Filter Blocked Substation Room Ventilation Fan Running Typical 11kV Circuit Breaker Current Typical 11kV Circuit Breaker Opened Typical 11kV Circuit Breaker Closed Typical 11kV Circuit Breaker Overcurrent Trip Typical 11kV Circuit Breaker Earth Fault Trip Typical 11kV Circuit Breaker Remote Control Selected Typical 11kV Circuit Breaker Open (trip) Typical 11kV Circuit Breaker Close 66kV Circuit Breaker Current 66kV Circuit Breaker Opened 66kV Circuit Breaker Closed 66kV Circuit Breaker Overcurrent Trip 66kV Circuit Breaker Earth Fault Trip 66kV Circuit Breaker Remote Control Selected 66kV Circuit Breaker Open (trip) 66kV Circuit Breaker Close 66kV Circuit Breaker Directional Earth Fault Trip 66kV Circuit Breaker Bus Zone 2 Overcurent Trip 66kV Circuit Breaker Directional Overcurrent Trip 66kV Circuit Breaker Earth Switch Opened 66kV Circuit Breaker Earth Switch Closed 66kV Switchboard Station Battery Charger Battery DC Voltage 66kV Switchboard Station Battery Charger Battery Float Healthy 66kV Switchboard Station Battery Charger Battery Boost Healthy 66kV Switchboard Station Battery Charger AC Voltage Available 66kV Switchboard Station Battery Charger DC Voltage Available 66kV Switchboard Station Battery Charger Control Healthy
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Device Fire Panel Fire System Fire Room Room Room Room Room Room Room 11kV Circuit Breaker 11kV Circuit Breaker 11kV Circuit Breaker 11kV Circuit Breaker 11kV Circuit Breaker 11kV Circuit Breaker 11kV Circuit Breaker 11kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker 66kV Circuit Breaker Station Battery Charger Station Battery Charger Station Battery Charger Station Battery Charger Station Battery Charger Station Battery Charger

Function Status Alarm Alarm Status Status Alarm Alarm Signal Alarm Status Signal Status Status Trips Trips Status Control Control Signal Status Status Trips Trips Status Control Control Trips Trips Trips Status Status Signal Status Status Status Status Status

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LV Main Switchboard Switchboard Voltage LV Main Switchboard Switchboard Power LV Main Switchboard Switchboard Current Red LV Main Switchboard Switchboard Current White LV Main Switchboard Switchboard Current Blue LV Main Switchboard Switchboard Power Factor LV Main Switchboard Incoming Supply Phase Failure Trip LV Main Switchboard Incoming Supply Healthy LV Main Switchboard Bus Bar Phase Failure Trip LV Main Switchboard Switchboard Energized LV Main Switchboard Control Supply Energized LV Main Switchboard Control Supply Available LV Main Switchboard Control Supply Output Voltage Healthy LV Main Switchboard Main Circuit Breaker Opened LV Main Switchboard Main Circuit Breaker Closed LV Main Switchboard Main Circuit Breaker Overcurrent Trip LV Main Switchboard Main Circuit Breaker Earth Fault Trip LV Main Switchboard Main Circuit Breaker Remote Control Selected LV Main Switchboard Main Circuit Breaker Open (trip) LV Main Switchboard Main Circuit Breaker Close LV Main Switchboard Main Circuit Breaker Transformer Differential Trip LV Main Switchboard Main Circuit Breaker Locked Out (racked Out)

Switchboard Switchboard Switchboard Switchboard Switchboard Switchboard Incoming Supply Incoming Supply Bus Bar Switchboard Control Supply Control Supply Control Supply Main Circuit Breaker Main Circuit Breaker Main Circuit Breaker Main Circuit Breaker Main Circuit Breaker Main Circuit Breaker Main Circuit Breaker Main Circuit Breaker Main Circuit Breaker

Signal Signal Signal Signal Signal Signal Alarm Status Alarm Status Status Status Status Status Status Trips Trips Status Control Control Trips Status

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Attachment 4 Concept Protection Details

PROJECT:

Lawson Extension

DOCUMENTS: 1. Concept Protection Design for the 66kV Modifications ER0168 dated 15th October 2007 (17 pages) 2. Lawson Substation 11kV Switchboard & 66kV Modifications Protection System Schematic TSU Drg Number LAW001-66kV dated 16/10/2007 Version 2.0 3. Concept Protection Design for the 11kV Switchboard ER0166 dated 12th October 2007 (19 pages) 4. Lawson Substation 11kV Switchboard Protection System Schematic TSU Drg Number LAW001-11kV dated 12/10/2007 Version 1.0

ASSOCIATED DOCUMENTS:

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Attachment 5:

Definition of Cable Numbering

Rules for cable numbering 1. 2. 3. 4. Cable numbers are to be continuous. Each cable is to have a unique number irrespective of the prefix number. Cable numbers are made up of a cable number prefix then a cable number. For single core phase cables a character shall be added after the cable number as follows; A, B, C: For Red, White and Blue Phases.

Cable Prefixes S R R AC AC DC M C P T E SCADA Cables 1500V DC Cables Negative and Negative rails 1500V DC Positive For all AC cables. Generally Feeders and Submains. is also used for 120V AC cables. Generally and Submains. For 120V DC Cables mostly for HV Switchgear control For Miscellaneous Cables For Control Cables For Power Cables. Generally Lighting Cables or Small Power to motors. For Telephone Cables For all Earthing Cables

Cable Numbers 0001 to 799 0801 to 999 1001 to 1999 2001 to 2999 3001 to 3999 4001 to 4999 5001 to 5499 5501 to 5999 6001 to 6499 6501 to 6999 For AC Type Cables For AC 120V AC Cables for signalling For DC Type Cables For R Type Cables For C Type Cables For S Type Cables For M Type cables For T Type Cables For P Type Cables For E Type Cables

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Attachment 6: Cable From Number Device

Example Cable Schedule Estim Actu Via No. No. Cabl Cabl Volt Approx Spare ate. al Cable of of e e Gra . O/A Cores Lengt Leng Route Cable Cor Size Typ de Dia h (m) th s es mm e (mm) Related Drawings Remarks Revisi on

To Device Functi Cable on Screen Earthing Location

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Attachment 7 Voltage Regulator requirements PROJECT: Lawson Sub Station

DOCUMENTS: 1. RailCorp Lawson Substation 11kV, 50A, Single Phase Voltage Regulator Mounting Sketch 27 May 08 1:20 @ A3 ASSOCIATED DOCUMENTS: Voltage Regulator Three off Single Phase, 50Amp, Star connected, Voltage Regulators equivalent to Cooper VR32 will be free issued to the Contractor. The Contractor is to include for design, supply and Installation of the Civil Footing, Hot Dip Galvanised Steel mounting structure, cable supports, cabling, surge diverters, supports and completion of assembly and termination for the 3 voltage regulators, in a single configuration. Mounting The voltage regulators shall be arranged on three sides of the square HDG Steel mounting framework, with suspension mounting using the pole mounting brackets by a single pivot upper mounting and a lower fixing point for each regulator. The HDG Steel framework shall be designed to support the three voltage regulators and act as cable support for the 11kV cabling between the 66/11kV transformer and the regulators and between the regulators and the 11kV switchboard. The framework shall provide for mounting of the regulators so that the top tank flange of the tank is not lower than 2440 above the substation finished ground or gravel level, whichever is the higher. The framework shall incorporate mountings for 3 x termination surge diverters and for support of incoming and outgoing cable terminations and fixings. Cable Support A second HDG Steel framework shall be designed, supplied and installed to support the 11kV cables to the terminations at the 66/11kV transformer. The framework shall be designed to provide for mounting of 3 x termination surge diverters, cable terminations and fixings. Cabling The Contractor is to design for cable size, type and routing from the 66/11kV transformer, via the cable support structure at the transformer 11kV terminations, underground to the Voltage Regulator, within the Voltage Regulator Support structure, including arrangement of terminations and surge diverters and from the Voltage Regulators to the 11kV Switchboard.
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Foundations The Contractor is to design, supply and construct the civil footing for the Voltage Regulators, including cable penetrations, framework fixings and earthing provision. Drawings All drawings for the Voltage Regulator framework, cable support framework, surge diverter mountings, cable termination and supports, footing and Voltage Regulator general arrangement are required to be submitted to RailCorp ES&S, Electrical Distribution Design for Acceptance. References: Further Information regarding the Cooper VR-32 Voltage Regulator can be found at the following site: http://www.cooperpowersystems.biz/Library/Literature/ Menu Item Voltage Regulating Apparatus

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Attachment 8: Proposed Lawson H.V. Operating Diagram PROJECT: Lawson Sub Station

DOCUMENTS: 1. Rail Corporation New South Wales Proposed Lawson S.S. H.V. Operation Diagram A3 No. EL0480046 D

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