E. Gen. Requirement - 133-165

No. IRCON/9030/MAL.SGDT/S&T/Commn./Pkg.III Date:04.01.
2010
GENERAL REQUIREMENTS
133
Stamp & Signature of Tenderer/s

No. IRCON/9030/MAL.SGDT/S&T/Commn./Pkg.III Date:04.01.2010
1.0 GENERAL
1.1 This document sets out the general technical and related requirements for the
Systems Works and covers the Signalling, Communications, Electrification and
other related portions of the Works. It should be read together with all other
relevant documents which apply to the respective portions of the Works.
2.0 PRACTICES AND STANDARDS
2.1 The works shall be implemented in accordance with recognised national and
international railway practice.
2.2 Except where otherwise stated, the Works shall comply with the relevant
standards, regulations, codes of practice, recommendations etc. of recognised
organisations and authorities as stated below: -
a) Keretapi Tanah Melayu Berhad (KTMB) (Technical Standards and

Procedures)
b) Malaysian Standards Specification (MSS)
c) The International Organisation for Standardisation (ISO)
d) The International Electrotechnical Commission (IEC)
e) The International Radio Consultative Committee (CCIR)
f) The International Telephone and Telegraph Consultative Committee
(CCITT).
g) The European Committee for Electrotechnical Standardisation
(CENELEC).
h) Union International des Chemis De Fer (UIC) (The International Union
of Railways.
i) British Standards Institution (BSI).
j) Institution of Electrical Engineers (IEE).
k) Suruhanjaya Bekalan Elektrik (SBE)
l) Jabatan Keretapi
m) Suruhanjaya Multimedia
n) Tenaga Nasional Berhad (TNB)
o) All current laws in Malaysia.
2.3 The National or International Standards referred to above represent the minimum
requirements that shall be met. The Contractor is free to adopt other standards,
provided always that those such other standards are equivalent to, or superior to,
those stated above. The use of alternative standards shall be subject to the
specific approval of the S.O.
2.4 The Contractor shall maintain consistency in the adoption of, and conformance
to, any of the standards chosen.
2.5 In cases where the Contractor is required to change from one standard to another
or where any conflict exists between provisions of two (or more) applicable
standards, the matter shall be referred to the S.O for determination.
134
Stamp & Signature of Tenderer/s

2.6 The works shall conform to standard Minimum Structure Diagram for Single and
Double Track Drawing and to Typical Cross Section drawing.
2.7 The work shall conform to manufacturers instructions, safety requirements,

procedures, etc. including use of personnel safety-ware and protection
requirements.
2.8 Metric standards and SI units shall be utilised unless otherwise approved.
2.9 Where KTMB’s Standards or British Standards or other standards are

mentioned in these documents, the editions and amendments thereto current
at the date of this document shall apply, unless otherwise specified herein or
agreed by the S.O.
2.10 Where KTMB’s Standards or British Standards or other standards are

mentioned in these documents, the equivalent ISO or IEC Specifications or
Recommendations may be substituted, subject to the S.O.'s approval in each
case.
2.11 In the event of any conflict between such approved equivalent specification
and any Malaysian or British Standard or similar document, the specification
or standard stipulated in these documents shall prevail.
3.0 COMPATIBILITY
3.1 It is the Contractor’s responsibility to provide systems, plant and equipment, so

as to ensure that the Works are fully compatible within themselves and also that
the Works are fully compatible with associated Works and adjacent KTMB and
3rd party systems, plant and equipment.
3.2 Accordingly it is the Contractor’s responsibility to ensure that all matters of

interfacing, immunity and interference are satisfactorily addressed and resolved
in respect of the Works and such associated Works and adjacent KTMB and 3rd
party systems, plant and equipment taking into account normal and abnormal
operation and fault conditions.
3.3 In respect of the Works, associated Works and 3rd Parties, it is the Contractor’s
responsibility to conduct such negotiations, dialogue, discussions etc. as are
necessary and to exchange such information as is necessary to ensure the
successful implementation of the Works.
3.4 The Contractor’s attention is drawn particularly to the following: -
(a) Interference effects of the electrification systems.

(b) Interference effects of traction drive systems in EMUs, train sets and
locomotives.
(c) Operation of track circuits.
(d) Effects of 415V 50Hz 3-Phase diesel generator power cars
(e) Effects of hanging tail magnets that form part of KTMB’s Relay Automatic
Block Tokenless Block System
(f) Adjacent Telecommunications systems
(g) Adjacent Rapid Transit electric traction systems.
Signature & Stamp of Tenderer/s 135

(h) Relationship between signals and electrification masts and overhead wire
pull-offs.
(i) Relationship between the location of trap points, buffer stops etc. and the
position of electrification masts.
(j) Relationship between track position and overhead line registration.
(k) Interfacing of track circuit and electrification bonding.
(l) Earthing and bonding arrangements for systems, services and utilities.
(m) Connection of dissimilar metals e.g. aluminium and copper cables.
4.0 PROVEN SYSTEMS
4.1 All systems, plant and equipment provided under the contract shall be proven
and tested in the service of an internationally recognised railway system as well
as with substantial satisfactory service history. Full and complete technical and
operational information and details shall be included in the proposal for all major
components together with full service history and performance details, number of
units in use etc. and identities of users with addresses, telephone and fax
numbers etc. for reference purposes.
5.0 SYSTEM ARCHITECTURE AND PERFORMANCE
5.1 Reliability
5.1.1 The Works shall be designed and constructed so as to achieve a high level of
availability and fault tolerance. Reliability data including Mean Time Between
Failure (MTBF) figures for performance of main components and systems shall
be given in the proposal.
5.1.2 Condition monitoring techniques shall be employed, where possible, such that
degradation of system performance is automatically detected and alarmed well
before system failure occurs.
5.1.3 Integrated system diagnostics shall be incorporated to continuously check the

condition of hardware, data links etc. Failure of diagnostics shall not affect
system operation.
5.1.4 Multiplicated system architecture shall be employed for microprocessor based

and solid state systems etc utilising fully updated standby systems configured in
a truly hot-standby mode, redundant data links, etc. and automatic changeover
facilities. Changeover between such systems shall be fully automatic requiring no
manual actions whatsoever.
Changeover between systems shall have no effect whatsoever on system

operation or the status of controls or indications etc. and shall be imperceptible to
operators. Such facilities shall be provided in respect of, but not limited to, the
following systems:-
(a) CTC Control and Indication Systems

(b) Signalling telemetry systems
(c) Microprocessor Interlocking
(d) Train Describer Systems
(e) Train Timetable System

(f) Automatic Train Reporting System

(g) Automatic Route Setting System
(h) Transmission Multiplexing Systems
(I) PABX systems
(j) PAX type Signal Post Telephone Systems
(k) Passenger Information Systems
(l) CCTV and Station Automation Systems
(m) Power Supply Systems
(n) Train Radio System
(o) Automatic fare collection System
(p) Electrification SCADA system
5.1.5 Standby systems, data links etc. shall be continuously monitored and semi urgent
alarms given immediately on loss of such systems.
5.2 Alterability
5.2.1 Hardware and software shall be inherently alterable such that KTMB, within its
own resources, shall be able to implement engineering modifications to
accommodate track layout and associated system changes etc.
5.2.2 Software shall be modular and structured such that system software and
application data are entirely independent. Application data shall be entirely user
configurable.
5.3 Operational Performance
5.3.1 Systems shall perform at high speed such that there is no perceptible delay in
system response to operators. System reaction to operator interfaces shall
appear as virtually instantaneous to operators. Transmission of controls to the
field without status change shall be effected not exceeding two (2) sec. unless
specified otherwise. Events occurring in the field shall be reported back to
operators in absolutely minimum time, which shall not exceed four (4) seconds,
unless specified otherwise.
5.3.2 The maximum time taken to completely re-write a VDU screen with all new
information, data, maps etc. shall not exceed five (5) seconds.
6.0 SPARE CAPACITY AND MAINTENANCE TOOL
6.1 Spare capacity and maintenance tool shall be included in systems and
equipment to facilitate future changes to the railway network. The precise nature
of such spare capacity and maintenance tool will be dependant on the types of
systems and equipment supplied.
6.2 Unless otherwise specified, a minimum of 10% increase in track work, systems
works and associated facilities shall be allowed for.
6.3 Cables shall have a minimum of 25% spare cores or pairs subject to a minimum
of 2 cores/pairs.

6.4 Power supplies, UPS and Transmission Multiplexing Systems shall have
minimum spare capacity of 25% unless otherwise specified.
6.5 It is anticipated that spare capacity shall be included in, but not limited to the
following:-
a) Cabling
b) Transmission Multiplexing Systems
c) Power supply systems
d) Microprocessor interlocking systems
e) Equipment housings and racks
f) Trunk Radio System
g) Automatic Fare Collection System
h) Electrification SCADA system
7.0 DOCUMENTATION AND DRAWINGS
7.1 Documentation and drawings shall consist of a series of diagrams, schematics,

drawings, layouts, plans, tables, method statements, handbooks, manuals etc.
which together shall comprehensively describe and detail the whole of the Works
in every respect.
7.2 Copies of all such designs, documentation and drawings shall be submitted to the
S.O in accordance with the approved programme. Such submissions shall be for
the sole benefit and information of the S.O. Notwithstanding such submissions,
or any comments that may subsequently arise therefrom, the Contractor shall be,
and shall remain, wholly and solely responsible and liable for any non-
conformances, discrepancies, errors or omissions etc. contained in any designs,
documentation and drawings.
7.3 Such documentation and drawings shall contain sufficient information and details
so as to facilitate provision of the Works and to permit KTMB to eventually
maintain, operate and carry out engineering modifications to the Works.
7.4 Maintenance documentation shall be structured and presented in such a manner

as to facilitate a 1st, 2nd and 3rd Level Maintenance hierarchy.
7.5 With the exception of established proprietary documentation, all documents and
drawings shall be produced by the following processes: -
Documents : WinWord (Latest release)

Drawings : AutoCAD (Latest release)
and shall be issued in hard copies and on CD ROM’s.
7.6 The Contractor shall handover to KTMB two (2) copies of licensed full version
software for the latest release of AutoCAD (as used for the drawings) at least
thirty (30) days before the submission of the drawings.
7.7 Hard copies of documentation shall be presented and bound in a fashion which
will allow easy use, maintenance and updating and will be hard wearing such that
it shall last for the lifetime of the system. Books of design details shall be of

maximum A3 size unless otherwise approved by the S.O. Prints of drawings

shall be substantially mounted in hard covers in such a manner as to readily
permit insertion and removal of individual drawings.
7.7 All documentation shall be clearly legible, comprehensively indexed, fully cross-
referenced, set out logically and consistent in the use of symbols, texts, layouts,
title boxes etc.
7.8 Each and every sheet of documentation shall contain the following:-
(a) Main Title

(b) Sheet Number
(c) Sheet Title
(d) Issue Type e.g. Preliminary, Inspection, Approval, Construction, Testing,
As-Built etc.
(e) Modification Status.
(f) Revision No. & Date
(g) Signatures in respect of preparation, checking and approval.
7.9 Each and every sheet of documentation, which is in circulation, shall be endorsed
with its current status.
7.10 Unless otherwise specified numbers of copies of documentation and drawings to

be submitted to the S.O. shall be as follows:-
Issue Nos. of Copies

Inspection/Approval 2
Testing Records 1
Commissioning Maintenance Copies 2
Final As-Built Records 4 (plus 1 CD ROM)
Final Manuals, Handbooks etc 10 (plus 1CD ROM)
(including operational manuals)
7.11 Unless otherwise specified numbers of copies of documentation and drawings to

be submitted to the S.O. shall be as follows:-
Issue Nos. of Copies

Inspection/Approval 6
Testing Records 3
Test Certificates 3
Commissioning Maintenance Copies 4
Final As-Built Records 5 (plus 3 CD ROM)
Final Manuals, Handbooks etc 10 (plus 3 CD ROM)
(including operational manuals)
7.12 The bidder’s financial offer should be inclusive of the cost of all such drawings &
documentations including software etc. mentioned above. No separate cost
towards this shall be payable.
8.0 STANDARDISATION
8.1 The numbers of different types of systems and equipment provided under the
contract shall be kept to an absolute minimum.

8.2 To minimise KTMB’s spare holding, staff retraining etc., all equipment to be
supplied shall be types which are of current design and already approved for in
use within KTMB’s railway network. Any proposal for new equipment or system
shall be subjected to specific approval by the S.O.
8.3 In respect of the following, only KTMB standardised systems and equipment are
permitted, such systems and equipment to be provided must be compatible and
fully interchangeable with existing system equipment:-
(a) Automatic Train Protection (ATP) system.
9.0 ENVIRONMENTAL CONDITIONS AND ASSOCIATED REQUIREMENTS
9.1 General
The works shall operate satisfactorily and fully in accordance with the
specification under all environmental conditions experienced in Malaysia. For
each of the environmental conditions specified the Contractor shall state the
range, intensity, levels etc over, or at, which systems and equipment will:-
(a) Function normally in accordance with the specification.

(b) Not suffer any permanent degradation or damage.
9.2 Tropicalisation
9.2.1 All equipment supplied under the Contract shall be fully tropicalised
particularly having regard to the following features:-
(a) Able to withstand ambient temperature encountered in Malaysia.
(b) Proof against condensation and deterioration arising there from.
(c) Protection against corrosion.
(d) Proof against development of fungi.
(e) Precautions against electrolytic or bimetallic corrosion.
9.2.2 The following equipment shall be fully tried and tested for trackside
installation in tropical countries without provision of environmental
conditioning: -
(a) Processor based interlocking equipment.
9.3 Temperature and Humidity
9.3.1 Systems and equipment shall operate correctly under all temperature and
humidity conditions.
9.3.2 Account shall be taken of condensation, which may occur under a combination of
temperature and humidity conditions.

9.3.3 When considering heating effects, account shall be taken into consideration of
outside ambient temperatures together with the accumulated effects of solar
radiation and heat generated within enclosures.
9.3.4 Lineside equipment cases shall be designed specifically to limit internal

temperature rise and shall include the necessary features to maintain adequate
ventilation. They may require extra panels to act as sunshades and or heat
dissipaters.
9.4 Pollution
9.4.1 Systems and equipment will be in contact with the atmosphere which will
generally be polluted. Pollutants may be either chemically active or inert such as
dust.
9.4.2 All systems and equipment shall operate correctly in a polluted and dust laden
atmosphere. Means shall be provided to prevent, either ingress of pollutants or
the direct, or indirect, effects of pollutants, causing incorrect operation or
permanent damage during operation, transport or storage.
9.4.3 Chemically active pollutants may occur in the atmosphere near sea water or in
industrial areas. In the latter case gases may dissolve in condensation or
condense in or on equipment. Equipment shall be protected against the effects
of such corrosive substances.
9.4.4 Equipment exposed to the weather shall be resistant to attack by detergents,

sewage, toxic substances such as weed killer and lubricating and fuel oils.
9.5 Solar Radiation
9.5.1 Systems and equipment shall be impervious to and shall not deteriorate or
discolour under the effects of direct solar radiation.
9.5.2 Dot matrix displays for Passenger Information System installed on platforms shall
be shielded from direct solar radiation.
9.6 Electromagnetic Effects
9.6.1 All equipment and systems which are susceptible to electromagnetic affects
shall be suitably protected with electromagnetic noise free screened
enclosures to ensure correct operation and avoid permanent degradation.
9.6.2 Vital control equipment shall be accredited by internationally acclaimed

organisations for compliance with Electromagnetic Compatibility which shall
include, but not limited, to the following: -
(a) Processor based interlocking equipment

(b) Digital Transmission Equipment
(c) Centralised Train Control Equipment
(d) Communication equipment
9.7 Lightning

9.7.1 As the project area is in a region with a high incidence of thunderstorms with very
severe lightning, adequate protection against damage or malfunctioning of
systems, plant and equipment, cable etc. due to high transient voltages and
currents shall be incorporated. Equipment to be connected to the power supply
mains and items to be connected to or mounted close to the railway track should
receive special attention.
The importance of providing adequate safeguards for prevention of damage by

lightning cannot be too strongly stressed; details of high voltage surge arrestors,
fuses, chokes, etc. being provided for this purpose must be included in the
proposal.
9.7.2 The specific protection requirements mentioned in this section shall be regarded
as only the minimum requirements, which may not necessarily be adequate in
particular situations.
9.7.3 For protection against transient high voltages and currents introduced via the
mains power supply, the minimum protection shall be a Surge Reduction Filter
(S.R.F.) of appropriate size fitted to the incoming supply lines and having the
following features:-
(a) Either three-phase or single phase type according to the type of supply at
the particular place, and rated for operation at 415 V 50 Hz (3-phase) or
240V 50Hz (single phase).
(b) Provide protection against both differential and common mode transients
from the supply lines.
(c) Incorporate high energy clamping devices and filtering components with
low frequency (low-pass) characteristics. Inductors shall be air-cored
(non-saturable) and capacitors shall be of 'self-healing' type.
(d) The neutral conductor shall not be bonded to earth (ground), but it shall
be so protected that any surge arriving via the neutral conductor will also
be diverted to earth.
First (1st) level protection for the power supply mains in buildings will be
normally be provided at the main power supply switch-board by the party
responsible for the building’s electrical system.
9.7.4 For protection against transient high voltage and high current surges introduced
via the communications lines, data lines, and other lines connected to equipment
having electronic components, the minimum protection shall be by Transient
Protection Units (T.P.U.) of appropriate size fitted to the external lines and having
the following features:-
(a) For balanced lines (for example, 600 Ohm balanced telephone or data
lines) the T.P.U. shall be of the balanced type and provide protection
against both differential and common mode transients.
(b) For unbalanced lines, the T.P.U. shall be of the corresponding type, and
provide protection against transient voltages between the line and the
return connection and also between the lines, return connection and earth
(ground).

(c) Two stages of protection shall be incorporated in each T.P.U., with

separate modules being used for the primary and secondary protection
so as to facilitate testing and replacement, and the two modules securely
connected together with high grade connectors.
(d) Connection pins or terminals shall have adequate current carrying

capacity to withstand the high transient currents in addition to the normal
current.
(e) The secondary protection module shall include a matching attenuator or

filter and high energy clamping devices (with a response time less than
100 Pico seconds). For protection of balanced lines, such clamping
devices shall be equally effective against surge voltages of either polarity
appearing between lines or between either line and earth (ground).
(f) For telephone and data circuit use, the insertion loss of a complete T.P.U.
shall not exceed 1 dB over a frequency range from D.C. to 50 kHz. The
clamping voltage shall be selected to prevent decadic dial impulse
distortion and 'ring trip'.
(g) The T.P.U. shall be designed to allow easy installation and connection of
the incoming and outgoing lines to the primary protection module.
Removal and insertion of the secondary protection module should be
possible without having to disconnect the lines.
9.7.5 For protection against transient high voltage and high voltage and high current
surges introduced from the railway track via the track circuit connections, the
minimum protection shall be by appropriate Transient Protection Units (T.P.U.)
fitted to the external lines and having the following features:-
(a) Provide protection against transient voltages between the lines and
between each line and earth (ground).
(b) One or more stages of protection incorporated in each T.P.U. according

to the requirements of the particular track circuit equipment.
(c) Connection pins or terminals shall have adequate current carrying

capacity to withstand the high transient currents in addition to the normal
current.
(d) The T.P.U. shall be designed to allow easy installation and connection.
Removal and insertion of the protection modules should be possible
without having to disconnect the lines.
9.8 Vibration
All systems and equipment shall be capable of satisfactory operation and

permanent storage without deterioration or damage in vibration conditions which
are consistent with the passage of trains.
9.9 Waterproofing
9.9.1 The project area is in a region which experiences severe tropical rainstorms.

9.9.2 All equipment installed external to permanent buildings must be proofed against
ingress of water caused by such rainstorms or other liquids not only in the vertical
plane but also in any other direction.
9.10 Wind
Systems and equipment shall be able to withstand, and shall operate correctly
under, the most onerous wind conditions. Wind effects shall be suitably
factorised to take account of ground topography and exposed areas.
9.11 Vandalism
The works shall include protective measures to counter either accidental or

malicious damage by vandalism particular attention shall be paid to:-
(a) Lineside installation including signal heads, point machines, ATP

transponders, bonding etc.
(b) Cables
(c) Glassware
(d) Lineside equipment housings
(e) Outdoor telephone sets
(f) TVM, flap gates
(g) Closed circuit TV cameras
(h) Dot matrix display boards for PIS
(i) Overhead line catenary equipment
(j) Power Supply equipment
(k) Graffiti Resistant finishes
9.12 Reptiles, Insect and Rodent Protection
9.12.1 Materials, cables, installations and equipment shall be designed and constructed
to be unattractive to and to be resistant to reptiles, insects and rodents etc.
9.12.2 In respect of equipment and operational rooms, line side equipment cases,
termination boxes, etc., cable entries, ducting, etc., shall be sealed, and cables
shall enter through close fitting cable glands to prevent ingress of reptiles, insects
and rodents.
9.13 Environmental Conditioning
9.13.1 It is preferred that all systems and equipment shall operate and perform
satisfactorily in accordance with performance specification without any reliance
on environmental conditioning.
9.13.2 Any cases where environmental conditioning is necessary or recommended in

respect of systems and equipment performance, shall be fully detailed by the
Contractor for the Systems. Provision of such environmental conditioning within
buildings shall be the responsibility of the Contractor who is responsible for the
building works. The Systems Contractor shall satisfy himself and furnish
confirmation as to the adequacy in provision of environmental conditioning.

9.13.3 The Contractor shall identify any spares which are required to be stored in a
conditioned environment, together with details of the conditioning required.
9.14 Painting, Protection and Finishes
9.14.1 Painting, protection and finishes shall be suitable for the environmental
conditions and shall also take due regard of the following:-
(a) Whole life durability

(b) Protection against fungi, corrosion, electrolytic corrosion etc.
(c) Resistance to accidental damage and vandalism
(d) Colour schemes
(e) Maintenance and cleaning
(f) Resistance to deterioration due to touch
(g) Staff safety
9.14.2 All outdoor equipment cases, distribution boxes, cable disconnected cases etc
shall be fabricated with high quality stainless steel plate with powder coating in
accordance with KTMB’s standard colour code.
9.14.3 All nuts, bolts, fittings, washers etc. utilised in outdoor locations shall be of a non-
corroding material or shall have suitable means of protection such as nickel
plating, galvanising etc.
9.14.4 Where paint or other finishes are damaged during delivery or installation etc. they
shall not be patched finished. They shall be properly prepared such that the
original protection shall be restored in full including preparation, undercoating and
top finishes as required.
10.0 MAINTENANCE REQUIREMENTS
10.1 The Works shall be designed and constructed so as to be wholly maintainable.

Attention shall be given to adequate equipment spacing, working environment,
accessibility of components, plugs, sockets, terminations etc. adequacy of
lighting etc.
10.2 Systems, plant and equipment together with documentation, drawings, manuals
etc shall be structured so as to be maintainable by the following general
maintenance hierarchy:-
(a) First Level Maintenance
Technician Level maintenance comprising routine periodic activities and

rectification of failures or potential failures which can be remedied by use of
diagnostics and module replacement.
(b) Second Level Maintenance
Investigation and rectification, with the use of special test equipment as

necessary, of such failures or potential failures, with respect to on-line or
standby systems etc, that the 1st Level Maintenance procedures have
been unable to cope with.

(c) Third Level Maintenance
Off-site diagnosis and repair of modules which have been removed and
replaced under 1st level or 2nd level maintenance.
10.3 Equipment shall be laid out in equipment rooms, compounds and other housings
in a logical and consistent manner. The spacing between equipments,
equipment modules, cable terminations, plugs/sockets etc shall be such as to
allow easy access for maintenance purposes and shall be subject to an absolute
minimum of:-
a) 800 mm working clearance between equipments, mounted on the floor,

wall, adjacent racks etc. where maintenance work is carried out.
(b) 600 mm passing clearance at ends of racks etc. where walkways only are
involved.
10.4 Comprehensive maintenance, diagnostic and faultfinding facilities shall be

provided with clear and concise status and failure indications etc. System
performance/fault logging storage, display and hard copy printing facilities shall
be provided for microprocessor and solid-state systems.
10.5 To minimise Mean Time to Rectification and simplify procedures for maintenance
staff, all systems and equipment shall be installed on a modular basis.
Preference will be given to systems utilising a “plug-in” method of connecting
modules.
10.6 The number of different types of module in the system shall be kept to a
minimum. Maximum use shall be made of interchangeablity of modules.
10.7 There shall be a mechanism which physically prevents insertion of an incorrect

module or plug into a location.
10.8 Where adjacent cable plug/socket terminations are utilised, physical means shall
be provided to prevent cables from being erroneously interchanged.
10.9 Where a module requires replacement, an indication system must make it easily
and immediately apparent to the maintainer to identify which module should be
replaced.
10.10 All modules shall be capable of being fitted and removed by one person.
Preferably, the maximum weight of each item shall not exceed 15kg and the
weight shall be evenly distributed.
10.11 Where appropriate equipment modules shall be fitted with handles by which they
can be removed from the equipment rack and carried.
10.12 All modules shall be indelibly marked with both a unique serial number and a
version number/modification status code. The marking shall be so located that it
can be easily seen and read.

10.13 Full, complete and up-to-date sets of Commissioning Maintenance

Documentation and Drawings shall be available at each stage commissioning of
the Works.
10.14 All cable plugs/sockets used shall be of good quality and not susceptible to any
degradation resulting in loose or poor electrical contact. The cable plug/socket
types to be supplied shall be subject to prior approval by the S.O.
11.0 POWER SUPPLIES
11.1 General
11.1.1 Mains power supply points at 415V (+8%, - 15%) 50Hz, (+ 0.5Hz, - 0.5Hz) three
phase will be made available at various locations as stated in the Statement of
Needs.
11.1.2 For each of the mains power supply points, the Contractor shall give the following
details to the relevant Contractor or party responsible for the electrical system, if
this is not a part of the Systems Contract, for incorporation in the electrical
system works, in respect of signalling, communications and medium voltage
electrification systems: -
(a) The estimated maximum continuous load; and

(b) The estimated maximum peak load, and its duration.
These values shall be ratified by the Contractor at the systems design stage.
11.1.3 The Contractor shall be responsible for distribution of power throughout the
Works from the AMF board or other designated mains supply point.
11.1.4 The necessary equipment, wiring and cable distribution network shall be
provided by the Contractor for distribution of power to all interlocking area,
lineside equipment and medium voltage electrification installations. This shall
include, but not be limited to, the following:-
(a) Main equipment rooms

(b) Operational rooms
(c) Line side equipment rooms and cases
(d) Level crossing installations
(e) Line side equipment
(f) Centralised Traffic Control (CTC) rooms
(g) AVM, closed circuit cameras, speakers, dot matrix display boards etc.
(h) Feeder stations and TSL
(i) Radio base stations
11.1.5 Power supply equipment to be provided shall include any special power
conditioning units, filters, regulators, etc. as are necessary for reliable operation
of the Works taking into consideration voltage fluctuations, interruptions, and
other disturbances which may occur.
11.1.6 All circuits shall be protected against damage from excessive currents by means
of adequate safety fuses (cartridge type) and/or circuit breakers, which shall be

distributed so as to limit and localise failure of equipment resulting from the

operation of such protection devices.
11.1.7 All work and equipment installation associated with main power supply points,
and all work on power cables and circuits, shall only be carried out by personnel
who are properly licensed and registered with JBE to carry out such work. All
such work shall be carried out in compliance with the Electricity Supply Act and
Regulations.
11.1.8 Power cables shall be rated such that the maximum volt drop from the supply
point to the furthest point on any power supply feeder shall not exceed 10% of
the supply voltage under maximum loading conditions.
11.1.9 Fuses or single pole switches shall not be connected in series with the neutral
connection of the mains power supply.
11.1.10 Power supplies feeding vital signalling interlocking and control circuits shall be
self contained, shall not feed other equipment or systems and shall be isolated
from other power supplies by double wound isolation transformers.
11.1.11 Independent isolated supplies (e.g. North, South etc.) shall be provided for each
direction to feed vital line side signalling control circuits where such circuits
emanate from equipment rooms or lineside apparatus cases.
11.1.12 Suitable stationery standby power supply equipment in the form of storage
battery/inverter sets (UPS Systems) shall be provided by the Contractor at each
mains power supply point to supply power to systems so that systems shall
function normally, during interruption of mains power.
11.1.13 Interface circuitry shall be provided by the Contractor to extend the

mains/standby generator indications and manual controls, the status of the mains
power supply, UPS, etc. at each station to the local control and indication (VDU)
facility the station, and also to the Centralised Traffic Control (CTC). Similarly, the
Contractor shall also provide for the mains/standby generator indications and
manual controls, the status of the mains power supply, UPS, etc at Halts to be
extended the local control and indication VDU facility at the nearest station and to
the CTC.
11.1.14 Tests shall be carried out to demonstrate that power supply wiring shall be able
to withstand a 2 kV ac test voltage between line and earthed or insulated parts.
11.2 Uninterruptible Power Supplies (UPS)
11.2.1 UPS systems shall be designed to supply power when the power supply (either
mains supply or standby generator supply) is interrupted, or if the voltage varies
beyond acceptable limits, such that equipment and systems will continue to
operate normally and without any disturbance. The UPS system shall include
storage batteries, provision for battery charging, invertors (conversion from D.C.
to A.C.), automatic control and switching facilities etc.
11.2.2 The UPS system shall be modular in design based on n+1 configuration such
that a single component failure will not cause any interruption of the power
supply. The UPS shall have built-in automatic and maintenance bypass facilities.

11.2.3 The storage battery used for the UPS system shall be an industrial grade
maintenance free type stationery battery, and shall, as far as possible, be
installed indoor in a ventilated room (battery room). The battery charging system
shall operate from the mains supply and from the standby generator set, so that
under normal conditions the battery shall be maintained in a fully charged state.
11.2.4 The switch board or panel for the UPS system shall include indication lamps for
the status of the mains supply and UPS output (separate indication for each
phase), a voltmeter and ammeter (with phase selection switch if three-phase)
and a supply by-pass switch to isolate the UPS system during a fault or for
maintenance. The status of UPS output shall be indicated on station VDU control
and indication.
11.2.5 UPS systems shall be rated to supply power for all equipment and systems
forming part of the Contract which require to run from the UPS system during an
interruption of the power supply, plus an allowance of at least 25% for additional
loads in the future. Unless otherwise specified no allowance has to be made for
station lightning, or other loads which are not part of the Contract.
11.2.6 The UPS system shall have sufficient capacity to supply power for all equipment
and systems, as required, for a duration of not less than one (1) hour.
12.0 EARTHING AND BONDING SYSTEMS
12.1 General
12.1.1 Unless otherwise specified all non-current carrying metalwork shall be so

constructed or bonded so that all parts are maintained at the same potential and
shall be connected to an earthing system.
12.1.2 Within any one equipment room, building, equipment case, enclosure etc. a
single earthing system shall be employed so as to eliminate personnel hazards,
which would otherwise arise, as a result of differing earth potentials appearing on
exposed metal work, equipment etc.
12.1.3 Where more than one earthing system is required, any exposed metalwork,
equipment, etc., connected to different earthing systems shall have a permanent
separation of at least 2.5 m, or shall be separated by a wall or other physical
barrier to prevent simultaneous contact. Where this cannot be achieved such
circuits, links, terminals, equipment, etc., shall be insulated, shrouded and fitted
with warning labels.
12.1.4 Earthing distribution systems shall be star configured equi-potential bonding

systems and shall utilise a prime earth bus bar from which individual earth
conductors shall be radially distributed to the various points to be earthed to
prevent the occurrence of circulating currents.
12.1.5 In respect of equipment rooms, operational rooms, equipment cases, enclosures,

etc., which employ independent earthing systems, all metallic pipes, ducts or
conduits associated with building services, including power supplies, lighting, air
conditioning, ventilation, water, gas, fire alarms, etc., and any other services
which extend into or pass through such equipment or operational rooms, cases,

enclosures, etc., shall be gapped at the entry and exit. Such gapping shall be
provided at the exit/entry wall. However, should this not be possible, then
gapping shall be such that a minimum of 2.5m separation is provided between
the earthed and unbonded metalwork, or between metalwork bonded to different
earthing systems. Earth segregation of incoming power supplies shall be
achieved by the use of isolating transformers.
12.1.6 In cases where separate test earths are required within a single room, case or
enclosure, etc., for earth leakage detection purposes, such earths shall be
insulated, shrouded and labelled as follows:-
"WARNING - INDEPENDENT TEST EARTH".
12.1.7 Earth resistance values shall be sufficiently low to ensure adequate protection to
personnel and proper operation of equipment and systems including
surge/lightning arrestor devices. In any case, unless otherwise specified, earth
resistance values shall not exceed 10 ohms. In exceptionally difficult areas
dispensation may be allowed in respect of earthing values but only with the
specific approval of the S.O.
12.1.8 Lightning protection earths shall be fast transient earths, connected with cabling
which is as short as possible, having the minimum number of bends and free of
coiling.
12.1.9 Cables utilised for earth connections shall be rated to accommodate the highest
value of earth fault current to be expected, due regard being given to the
operation of surge/lightning protection devices.
12.1.10 The preferred method for making an earth connection is to use "Copperweld"
earth rods approximately 13mm in diameter coupled together as required and
driven vertically into the ground, selecting a damp area for this purpose where
possible. Longer rods or additional rods, earth farm arrangements etc shall be
used to obtain the necessary low earth resistance value. If a different method is
to be used prior approval shall be obtained from the S.O.
12.1.11 Earth-rods shall be driven into the ground such that the top end of the rod is
approximately 15 cm below ground level and enclosed by a suitable concrete
enclosure provided with an inspection cover (at ground level) to mark the
location. The enclosure cover shall be easily removed for inspection and earth
testing purposes.
12.1.12 Earthing cables shall be connected to the earth rods using thermic welded bonds.
12.1.13 In respect of independent earth systems the electrodes shall be located such that
ground coupling between independent earth systems and traction earth systems
shall be minimised.
12.2 Traction Return/Earth System
12.2.1 For safety purposes it is necessary to ensure that adequate provision is made for
the return of traction current to the supply system neutral and that non-current
carrying metalwork is bonded in such a manner that no dangerous potentials
exist either under normal operating or fault conditions.

12.2.2 Earthing means effectual connection to the general mass of the earth by means
of a suitable earth electrode. The foundations of the overhead line structures,
connected in parallel by means of the earth wire or traction return rail, constitute
such an electrode. Except where otherwise stated, these are the electrodes to be
used, connection being made to the impedance bonds, traction return rail, earth
wire or overhead line structure as appropriate and convenient.
12.2.3 The traction return system shall be through connected and bonded so as to
ensure its continuity.
12.2.4 Electrification continuity cross bonding between tracks in track circuited areas
shall be applied in such a manner as to ensure that there are no detrimental
effects on track circuit operation, or safe detection of trains, under conditions of
broken rails or disconnected bonds.
12.2.5 Except where specified otherwise, any exposed metalwork that may be subject to
25KV flashover, inadvertent contact with 25KV line equipment, induction, or
capacitive charging effects, shall be bonded to the traction return/earth system.
12.2.6 The traction return system shall be installed so as to ensure its connection to the
general mass of earth through the rails, overhead line structure foundations and
other means which maybe considered necessary.
12.2.7 The rise in potential, with respect to the general mass of earth, of the traction
return system and all exposed metalwork bonded thereto, together with all
associated step and touch potentials, shall not exceed the following limits:-
(a) 60V under normal load conditions.

(b) 430V under fault conditions.
12.2.8 Where an earthing electrode other than the running rails is specified herein and
the maximum value of earthing resistance is not stated, the principles to be
followed in determining the value of earthing resistance to provided are:-
(a) To hold the potential of exposed metal to a value not exceeding 60V
under normal operating conditions or 430V under traction system fault
conditions, measured to the general mass of the earth, and
(b) To ensure the correct operation of all the protective devices concerned,
which may, or may not, all be in the same circuit.
12.2.9 As part of the design process an Earthing and Bonding Study shall be
undertaken which shall determine the spacing to be applied to traction
intermediate earth connections in double rail track circuit areas. Such a study
shall clearly demonstrate that, with the spacing chosen, the specified maximum
limits in respect of step and touch potential and induced voltage shall not be
exceeded. The study shall also analyse the sensitivity of the earthing system to
variations in ground resistance and in intermediate earth connection spacing.
The study and report shall be submitted to the S.O. for inspection. On
completion of installation the study results shall be verified as part of the system
testing procedures.
12.2.10 All traction return and earthing bonding shall be a minimum of 150mm sq.
aluminium stranded cable PVC sheathed to BS 6405.

12.2.11 Bonds which form part of the traction return path shall be clearly identified as
disconnection of such bonds can result in exposure to high potentials. Such
bonds shall be provided utilising distinctive red-sheathed cable. Red-sheathed
cable bonds shall include the following:-
(a) Bonds between the return current bus bar and the impedance bonds or
running rails at substations.
(b) Connections from a return conductor to the impedance bond or running

rails.
Note: Red sheathed cable shall be applicable to impedance bond side leads at
locations (a) and (b) above.
(c) Side leads and transition leads connected to impedance bonds/rails at

double rail/single rail track circuit interfaces.
(d) In any other case, where disconnection of a bond could leave equipment
in a dangerous condition by the appearance of a high voltage across the
disconnection or where the disconnection of the bond would separate two
earthing systems, e.g. bonding of external power supply earths to the
traction return/earth system.
12.2.12 Where non-metallic or reinforced concrete structures are so close to live

equipment that they are at risk from flashover, arrangements shall be made to
ensure that such flashovers are discharged to the traction return current path,
e.g. earth strips shall be required to be fitted to the underside of bridges where
flashover is likely as a result of interference by birds.
12.2.13 Arrangements shall be made to ensure that surface or buried metal pipes, earth
electrodes and other metallic objects do not develop hazardous potentials
through induction from the traction current or voltage, and are not damaged by
any traction return current which may flow in them. Special arrangements shall
be required in respect of metalwork which is fitted with cathodic protection
systems.
12.2.14 At locations where external power supplies enter railway premises, such as at
Stations, Depots, Halts etc, and such power supplies encroach close to the 25KV
traction system so that there are risks of interference between the two systems
including:-
(a) Flashover
(b) Induction
(c) Possibility of simultaneously touching of both earth systems.
then, the external supply earth shall be bonded to the traction return/earth
system. In such cases the contractor shall obtain the necessary approval of the
local supply authority. Where such approval is not forthcoming suitable
insulation, screening and other measures shall be provided as necessary.
12.2.15 At the boundary of the electrification system all tracks shall be electrically isolated
from the non-electrified portions of the railway system. This shall be achieved by
the provision of insulated rail joints (IRJ's) in each rail. Two (2) sets of such IRJ's

shall be provided, and separated so that they cannot be simultaneously bridged

out by the longest train. Any track circuiting arrangements in the area shall take
such requirements into account.
12.3 Bonding / Isolation of Sidings
12.3.1 KTMB sidings which are not track circuited shall be continuity bonded to the
nearest traction return rail and shall include all necessary track to track and rail to
rail cross bonding to maintain specified limits of rail potential under normal,
broken rail, disconnected bond etc. conditions. Buffer stops shall not constitute
rail-to-rail connections.
12.3.2 Non-wired Private Sidings shall be electrically isolated from the 25KV
traction/earth system by the provision of IRJ's in each rail. Two (2) sets of such
IRJ's shall be provided located the maximum distance apart allowable by site
conditions.
12.3.3 In situations where adequate separation of the private sidings from the traction
return/earthing system cannot be achieved the circumstances shall be referred to
the S.O. for resolution.
12.4 Low Flash Point Product and Oxygen Installations
Where low flash point product and oxygen installations are connected by sidings
to a 25KV electrified railway system or where such installations are situated
adjacent to such a railway system they shall be subject to special isolation,
earthing and bonding arrangements to be determined by the S.O for each
particular case.
12.5 Main Signalling and Communications Equipment Rooms, and Operational

Rooms and Buildings
12.5.1 Main signalling and communications equipment rooms and operational rooms
and buildings containing active solid state signalling or communications systems
shall employ an independent earthing system which shall be entirely separate
from the traction return and other earthing systems or latest international practise
employed by Railway operators in the world. The main earthing system for the
building at stations and halts will be provided by the contractor responsible for the
building works, taking into account the signalling, communications and other
systems requirements as stipulated by the contractor for the systems works.
12.5.2 Such independent earthing systems shall employ dual earth farms, each of which
shall not exceed one (1) ohm. The earth farms shall be independently connected
via maintenance disconnection links to the Prime earth bus bar.
12.5.3 All exposed metalwork etc within such rooms or buildings which requires an earth
shall be connected to the independent earthing system.
12.5.4 Circuits which are directly connected to the traction return/earth system, e.g.
track circuit feed and relay circuits, shall not be installed in such rooms and
buildings.
12.6 Signalling and Communications Line side Equipment Cases, Walk-in

Equipment Cases, Enclosures etc.

12.6.1 Lineside signalling and communications equipment cases, enclosures etc. shall
not be located within 2.5m of any traction return or earthed equipment. Such
cases shall not be bonded to the traction return/earth system.
12.6.2 Equipment cases, enclosures etc. containing active solid state equipment,
together with any adjacent cases or associated metalwork, shall employ an
independent fast transient earth. This fast transient earth shall be installed
immediately adjacent to the equipment case and shall be bonded with leads
which shall be as short as possible, contain the minimum number of bends and
shall be free of coiling. Such fast transient earths shall have a maximum value
of four (4) ohms and should be located such that ground coupling with the
traction earthing system is minimised.
12.6.3 Where track circuit feed and relay circuits, which are directly connected to the
traction return system, are installed in equipment cases then the wiring shall be
installed such that separation of at least 75mm is maintained, as far as possible,
from other wiring and all associated links etc. shall be insulated, shrouded and
labelled as follows:-
“WARNING - TRACTION EARTH POTENTIAL EXISTS ON TC

CONNECTIONS".
12.7 Lineside Cabling Systems
12.7.1 Lineside communications screening cables shall be earthed at nominal 1 km

intervals utilising earth electrode systems of 4 ohms of less. Such earth
electrode systems shall generally be installed at locations coincident with cable
joint positions, they shall not however, be installed within 50m of any equipment
rooms, line side equipment cases, track section locations, return conductor/rail
connections nor within 100m of any traction feeder stations.
12.7.2 Screening cable earth electrode systems shall be independent and shall not be
bonded to the traction return/earth or any other earth systems and shall not be
taken into any line side equipment rooms, buildings or cases etc.
12.7.3 Metallic sheaths, armouring etc of cables shall, prior to entering equipment
rooms, operational rooms, buildings, line side equipment cases, equipment
enclosures etc, be gapped such that electrical continuity does not exist between
the external metallic sheaths, armouring etc. and that within the room, building or
case etc.
12.7.4 Metallic sheaths, armouring, etc shall also be gapped at each joint position.
12.7.5 Sheaths gaps shall be of 40mm width, shall be positioned between 3m and 30m
from the associated room, building or case etc and shall be enclosed in a non-
conductive joint closure. Alternatively metallic sheaths/armouring shall be
stripped back from the internal cable termination to a point outside the room or
case and suitably sleeved and insulated.
12.7.6 Aluminium moisture barriers, brass tapes etc, where provided in cables, shall be
maintained earth free. They shall be brought into equipment rooms, buildings,

cases etc, terminated on an insulated terminal, suitably labelled and treated as a

spare cable conductor.
12.7.7 All metallic cable sheaths, moisture, barriers, brass tapes etc shall be suitably
isolated and sectionalised to ensure that maximum specified induced voltage
levels are not exceeded.
12.8 Lineside Structures and Apparatus
12.8.1 All lineside structures and apparatus including:-
(a) Straight post

(b) Gantries
(c) Ground signals
shall be bonded to the traction return/earth system. Such bonding shall,

preferably, be applied to the traction return rail in single rail track circuited areas
and to the centre point of impedance bonds in double track-circuited areas.
12.8.2 Point operating mechanisms shall be insulated from the rail system and shall not
be earthed or bonded to the traction return/earth system.
12.8.3 Where there is any possibility of any part of a level crossing barrier arm, whether
standing or knocked over, coming within 150mm of live traction equipment or
return conductor, then a continuous metal strip of adequate section shall be
installed along the length of the arm and shall be bonded, together with the
supporting post, to the traction return earth system.
12.8.4 Aerial towers shall be bonded to the traction return/earth system unless such
towers are located remote from the traction system and there is no possibility of
the tower coming into contact with the traction system during mishap.
12.8.5 Irrespective of whether aerial towers are bonded to the traction return/earth
system or not, they shall be bonded to a separate lightning protection earth.
12.8.6 Radio aerial structures fixed to line side structures, including signals, tunnel walls
or mouths etc, shall be bonded to the traction return/earth system.
12.8.7 Where radio aerial structures are bonded to the traction return/earth system, then
associated fixed radio equipment shall be located such that simultaneous contact
with both radio equipment and structure is not possible. In such cases aerial
feeder cables shall be isolated from the fixed radio equipment by 2KV isolating
devices. Isolating devices shall provide isolation of both inner and outer
conductors and shall be insulated and installed in such a manner that
simultaneous contact of both sides of the device is not possible.
12.9 Vital Signalling Systems
12.9.1 Vital signalling relay interlocking and control circuits and associated circuits shall
be earth free.
12.9.2 Such circuits in Main equipment rooms shall employ earth leakage detection
together with associated alarm facilities in respect of:-

(a) Bus bars supplying vital circuits.

(b) Bus bars supplying point operating mechanisms.
13.0 OUTDOOR EQUIPMENT CASES AND DISCONNECTION BOXES
13.1 All lineside electrical components such as relays, resistors, fuses, power supplies
etc. shall be mounted within weatherproof equipment cases. Such cases shall be
supplied pre-wired as far as possible.
13.2 Out-door equipment cases and disconnection boxes shall be fabricated from high
quality stainless steel.
13.3 Boxes shall be designed to have good accessibility for maintenance. Equipment
cases shall normally be provided with large front and rear doors for this purpose,
but for cable disconnection boxes a single cover or door may be adequate.
Equipment cases shall be equipped with internal lighting.
13.4 Every box shall be mounted on a heavy concrete base such that the lowest part
of the box will not be less than 20 cm above ground level. A layer of soft but
durable plastic material shall provided between the bottom of the box and the
upper surface of the concrete base. The upper surface of the concrete base
shall slope away from the base of the box so that any rainwater flowing down the
sides of the box will flow off away from the box.
13.5 An earth terminal shall be fitted on the inside of every box, at a place with good
access and preferably near the cable entry areas, to enable a good electrical
connection to be made to the box.
13.6 Every box shall be given its own distinctive identification number or code which
shall be clearly visible. The same number or code shall be used in the drawings
to refer to the box.
14.0 CABLE ROUTES AND CABLING
14.1 Prior to starting any cable laying work, the Contractor shall ensure that sufficient
labourers, machines, and tools, as well as all specialised materials and
equipment required are available at site, so that the cables can be laid
immediately after the cable route has been prepared.
14.2 During the installation of cables, cable routes shall be left open for an absolute
minimum period of time in order to prevent accidents and contamination of the
route and to afford maximum protection of cables. Unless otherwise approved
the absolute maximum period any portion of a route may be left open shall be
one (1) week.
14.3 Cable laying in concrete trough routes, trenches and drawing the cable into
pipes, conduits, tubes etc. may be done from rail borne vehicles. If the areas
permit, the cable can also be rolled out alongside the route and then laid. Cable
protection measures, cable jacks, rollers and other suitable equipment shall be
used as necessary.

14.4 All cables run in respect of the following shall be laid in G.I. pipe and buried under
the ballast to a depth of at least 300 mm below the sleeper base.
(a) On Track Equipment

(b) Equipment, Signals etc. between tracks
(c) Rail connections
(d) Across track Electrification Bonds
14.5 In general tracks shall be crossed by cables at right angles. Crossing of the track
within turnout areas shall be avoided.
14.6 Where cables are required to be buried, cable trenches shall be such that the
buried cables shall be not less than 0.80m deep below ground level. The
trenches shall not be more than 0.20m wide. In rocky ground the cables may be
buried at 0.60m depth, but over a short distance only. The trench bottom shall be
of soft soil or sand with a maximum grain size of 5 mm. If the bottom is rocky, a
layer of sieved soil or sand shall be put in, before the cable is laid. If the required
minimum depth below ground level cannot be attained without incurring unduly
high costs due to hard rock or other obstructions the cable may be installed in
galvanised mild steel pipes of suitable size, either buried, or otherwise fixed in
place by suitable means. Such work shall require prior approval by the S.O.
14.7 Where buried cables are provided soil filled in above laid cables shall be
compacted by layers of 0.20 to 0.30 m. A durable plastic tape (yellow colour) at
least 40 mm wide and 0.1 mm thick shall be laid at a depth of 0.30 m to 0.40 m
above the laid cable. The warning tape shall bear the inscription "Kabel K.T.M."
in black colour continuously throughout its length.
14.8 Existing cables and other underground equipments are to be taken into
consideration when digging and laying the cables. Disturbance to existing earth
drains, cables, pipes, and other services shall be avoided as far as possible.
Care shall be taken when excavating cable trenches close to electrification masts
so as not to undermine the foundation. Any earth dug up must be placed clear of
the track and drains. Every care shall be exercised to avoid contamination of
ballast and any damage or disturbance to the track and its drainage system.
14.9 Cable trenches on the face of slopes are not permitted.
14.10 Where cables have to be run along bridges, or in other out-door situations, where
the cables would be otherwise exposed, they shall be protected by galvanised
mild steel pipes clamped to the bridge or other structure in a satisfactory manner.
14.11 Every out-door cable shall terminate at each end within an equipment case,
junction box, disconnection box, or equipment such as a signal head, point
machine, and the like, or otherwise within the an equipment room.
14.12 All incoming cables into equipment rooms, line side equipment cases etc. shall
be directly connected to insulation displacement type connector irrespective of
whether it is used or not, with isolating links, on terminal banks in a cable rack or
frame. It must be possible to easily isolate the external cables from the internal
equipment for the purpose of testing the cables without having to actually remove
the cable from the terminals.

14.13 Cable used for power supply purposes shall be a PVC insulated and bedded,
galvanised steel wire armoured, PVC, sheathed, multi-core copper cable
conforming to MS 4.18.1975. The insulation shall be rated for 650/1000V. The
size of conductors shall be adequate for reliable performance, taking into account
the current flow, voltage drop, and prevailing temperatures.
14.14 The use of cable joints shall be subject to approval by the S.O. in each specific
case and will be permitted only under exceptional situations, for example, very
long sections. Such joints, where approved, shall be absolutely waterproof and
resistant to corrosion and termites etc.
15.0 RAIL CONNECTIONS
15.1 Drilling of holes in rails for bonding or attaching electrical connections shall be
avoided. Such bonding or connections shall be made by thermit-welded bonds
taking care to avoid introducing any undue weakness in the rails.
15.2 The Contractor is reminded that such a process is a very high temperature
operation and shall be carried out strictly in accordance with the manufactures
instructions by fully trained personnel who are equipped with the necessary
protective safety wear.
15.3 The location for a welded stud shall be identified which must not be closer than
125mm to any other weld (bond weld, flash butt weld or thermit weld) or any
failed or rejected welds.
15.4 The rail-bonding surface shall be cleaned thoroughly using a grinding disc with
vitrified wheel (not a resin bonded type) or in difficult confined situations, using a
rasp or scraper. In all cases a bright surface must be achieved.
15.5 In cases where metal has splashed or run out from the mould onto the head or
foot of the rail details of the location must be noted and given to KTMB to permit
the necessary checks and inspection to be carried out.
16.0 LABELLING
16.1 All equipment shall be clearly and permanently labelled.
16.2 Labelling shall be provided in respect of:-
(a) Identification
(b) Safety and warning aspects
(c) Operation
16.3 Labels shall be of engraved material which shall be screwed or riveted in

position. Printed labels suitably sleeved or varnished may be provided on
equipment or cables when wear is likely to be minimal.
16.4 All labels shall be made and fixed by a method that will ensure they remain
legible and in position for the life of the equipment.

16.5 All labels shall be clearly visible when the equipment is fixed into its working
position. They shall also correspond to the naming of equipment on drawings
and documentation. Minimum text height on any label shall be easily read.
16.6 Labelling in respect of plug-able modules, printed circuit cards etc shall be
suitably applied to both the module, card etc itself and also to its respective
position on the equipment rack.
16.7 Each type of plug-able module, printed circuit card etc. shall be given a unique
unit number which shall include the modification state. This number shall be
engraved on the unit's handle and on the cabinet label associated with the
normal unit position.
16.8 Where identical units have their function changed by program the unit handle
shall carry a common number.
16.9 The rack label shall carry the same number plus additional classification for the
equipment state required for that slot.
16.10 Where a unit's function is determined by subsidiary plug-able components, the

plug-able components shall carry a label that corresponds to the additional
classification given on the rack label.
16.11 Where more than one but not all units in one housing form a working group, the
group and its function shall be identified on the rack label.
16.12 Cables shall be identified individually by labels which shall identify the location of
the far end. Where any confusion may exist, they shall also identify the near end
plug or socket to which they should be connected.
16.13 Individual cable conductors shall be identified with their individual termination
point by the fitting of suitably inscribed cable tags or markers.
16.14 Distinctive earthing cables terminated on racks and equipment etc, where they
are obvious, shall not be labelled. However earth cables terminated on earth bus
bars shall be individually labelled with the far end identification.
16.15 Labelling shall conform to the same number/character/number scheme as is

utilised in associated diagrams and drawings to identify equipment.
16.16 Label types, letter sizes, affixation etc, shall be applied consistently.
17.0 25KV ENERGISATION TESTS
17.1 Traction system Short Circuit and Steady Current tests will be conducted on
energisation of the 25kV Overhead Line system. Verification that specifications
criteria in respect of the following have been satisfactorily achieved shall be
clearly demonstrated: -
(a) Step and touch potentials

(b) Earth potential rise
(c) Induced voltage and noise
(d) Interference and immunisation

17.2 The Contractor shall provide a comprehensive report detailing all tests which are
conducted, instrumentation used, test methods etc together with a full set of test
results and conclusions.
17.3 The Contractor shall take adequate precautionary measures to liase and
coordinate with all parties involved in the energisation of the 25kV Overhead
Line system for conducting the above tests.
18.0 RECOVERIES
18.1 Within 60 days from the date of Letter of Award, inspection and condition survey
shall be conducted jointly by representatives of the Contractor, KTMB and S.O. to
identify and verify the condition of all the existing materials and equipment in the
project area, which will become redundant (or re-used) under the project. All
parties concerned shall duly endorse the records of the survey.
18.2 All redundant materials and equipment dismantled and recovered shall be
removed from site and disposed of in accordance with the following:-
(a) Cables and Overhead Pole Route Wires
Wires and cables shall be recovered, coiled, delivered to a Depot to be

designated by KTMB within the Works site area and unloaded and stacked
neatly in a place designated by KTMB.
(b) Reusable Items
Reusable items shall be carefully recovered, suitably packed, delivered to a

Depot to be designated by KTMB within the Works site area and unloaded
and stacked neatly by type in places designated by KTMB.
(c) Scrap Items
Scrap items shall be delivered to a Depot to be designated by KTMB within

the Works site area
18.3 Auditable records shall be kept for the recovery process including the following:-
(a) Recovery Schedule containing a list of all items to be recovered by above

category.
(b) Certification Document verifying receipt of all items at the KTMB receiving
depot including correlation, with the Recovery Schedule.
18.4 Before recovering any items the contractor shall obtain the S.O.’s approval to the
Recovery Schedule.
19.0 TRAINING
19.1 The contractor shall provide full and comprehensive training for KTMB staff. The
aims of the training shall be such as to ensure that KTMB staff shall be capable
and fully competent to maintain, rectify, operate and modify the particular

systems provided. Training courses shall cover, but not be limited to the
following:-
(a) Concepts, design and engineering.

(b) Testing and Commissioning.
(c) 1st, 2nd and 3rd. Level maintenance.
(d) Emergency maintenance.
(e) System alterability
(f) Operational interfaces
(g) Driver interfaces
(h) Software
19.2 Training courses shall include and emphasise safety matters appropriate to the
exposure of the staff concerned.
19.3 Training shall cover the whole range of KTMB staff including, but not limited
to:-
(a) Training Instructors

(b) Technicians and Supervisors
(c) Technical and Engineering Staff
(d) Operations Staff
19.4 Training shall include training of KTMB's trainers. Such training shall ensure the
ability for KTMB to continue own training programmes.
19.5 Training shall include both theoretical and practical experience. Practical training
shall be integrated into project design, construction, testing, commissioning and
maintenance activities whenever possible.
19.6 For each course the contractor shall define the following:-
(a) Syllabus
(b) Course Objectives
(c) Trainee Entrance Criteria
(d) Instructor/Trainee Ratio
(e) Maximum Number of Trainees
(f) Location
(g) Accommodation Arrangements
19.7 All training courses shall incorporate formal trainee assessment, reporting and
certification.
19.8 The Contractor shall provide all training aids, training modules, films, materials,
parts, tools, manuals and other documentation required for training purposes.
19.9 The proposal shall include outline course syllabuses and an outline-training
programme together with details of the location of training including:-
(a) Training conducted within KTMB's premises

(b) Training conducted within the Contractor's premises in Malaysia
(c) Training outside Malaysia

19.10 The Contractor shall clearly set out any facilities, requirements or obligations
placed on KTMB in respect of provision of training.
20.0 QUALITY ASSURANCE
20.1 General
20.1.1 The Contractor shall operate a quality assurance (QA) system in accordance with
requirements stipulated under ISO 9000 series of specifications which shall
provide documented evidence of quality system compliance and ensure that all
activities related to quality of items and workmanship shall be in accordance with
the contract requirements.
20.1.2 A quality assurance manual shall be provided and submitted to the S.O for
approval. Such a manual shall fully describe methods, procedures and
processes which form the QA system.
20.2 System Implementation
20.2.1 The Contractor shall provide and maintain a QA programme to regulate methods,
procedures and processes as shown in the QA plan. The QA plan shall also
clearly identify the QA organisation.
20.2.2 The Contractor shall implement written procedures, including at least the
following, copies of which shall be issued to the S.O.
a) Control of Sub-Contractors
b) Control of Suppliers
c) Receiving, First Article, In-Progress and Final Inspection
d) Production and Process Control
e) Functional Test
f) Control of Non-Conformances and Corrective Action
g) Calibration of Test and Measuring Equipment
h) Design Control
i) Document and Drawing Control
j) QA Records
k) Quality Audit
20.3 Certificates of Compliance
20.3.1 When approved by the S.O., certificates of compliance for equipment, materials
and products may be accepted in lieu of the specified sampling and testing
procedures.
20.3.2 Certificates of compliance shall include as a minimum,

a) The batch, lot or serial number to provide traceability
b) Test results including dates
c) Name and address of test organisation
d) Specification requirements
e) Quantity tested

20.4 Design and Proposals
The contractor shall implement QA methods for control of production, checking,

approval and amendments for designs and proposals. Arrangements for review
by the S.O. of project designs and proposals shall include, but not be limited to,
submission, by the contractor, of the following:-
(a) Project programme

(b) Specifications and standards
(c) Method statements
(d) Design principles
(e) Detailed designs
(f) Construction drawings
(g) Samples
(h) Testing/commissioning and as-built drawings
20.5 Inspection and Testing Programme
20.5.1 The Contractor's inspection and testing programme should, as a minimum,

include the physical inspection and testing of items in the process of
manufacture, delivered items and construction works.
20.5.2 The Contractor shall ensure that inspections and acceptance tests are based
upon the latest revision or change to drawings and specifications.
20.5.3 Requests by the Contractor for attendance by the S.O. at inspections and tests
shall be in writing or by telephone notification, followed by written confirmation, a
minimum of 14 days prior to the event. Except as otherwise agreed, inspections
and tests to be witnessed shall be performed during regular business hours.
20.5.4 Certificates of compliance or formal test reports shall be provided for completed
work.
20.5.5 Inspection shall occur at appropriate points in the manufacturing and installation
sequence to ensure compliance with drawings, test specifications, process
specifications, and quality standards.
20.5.6 The S.O. may designate inspection hold points in manufacturing, installation and
testing processes.
20.5.7 Whenever modifications, repairs, or replacements are required the Contractor

shall re-inspect the affected characteristics and re-submit specified results.
20.5.8 Final inspection shall be based on completion of inspections and/or tests, as

appropriate. Verification of final inspections and tests will be subject to review by
the S.O. at his convenience.
20.5.9 Testing of construction works shall apply to each phase of the works.
The contractor shall submit and execute comprehensive testing proposals which
shall include, but shall not be limited to:-
(a) Testing standards, regulations, codes etc.

(b) Performance requirements

(c) Unit testing
(d) System testing
(e) Commissioning testing
(f) Final acceptance testing
20.6 QA Records
20.6.1 The Contractor shall maintain QA records in a retrievable manner to provide

documented evidence of quality and accountability.
20.6.2 QA records shall include, but not be limited to, the following:-
(a) Results of inspections and tests

(b) Process controls
(c) Certification of processes and personnel
(d) Non-conforming materials (including records of disposition)
(e) Other quality requirements defined in the Contract
20.6.3 As a minimum, the contractor shall indicate the following on inspection

records:-
(a) Inspection instructions reference

(b) Nature of the observation
(c) Number of observations made
(d) Number and types on non-conformances found
(e) Specified requirements
(f) Acceptability of work or products
(g) Action taken in connection with the correction or disposition of non-
conformances
20.7 Verification
20.7.1 The QA operations of the Contractor and any sub-contractors shall be subject to
verification by the S.O. at any time.
20.7.2 Verification will include, but not be limited to:-
(a) Surveillance of the operations to determine that practices, methods and

procedures of the QA programme are being properly applied.
(b) Inspection to measure quality of items to be offered for acceptance.
(c) Inspection of items awaiting release for shipment.
(d) Audit to ensure compliance.
21.0 DESIGN, MANUFACTURE AND WORKMANSHIP
21.1 The Contractor shall undertake all detailed design work in Malaysia. Basic
design and engineering may also be carried overseas at by the relevant
systems suppliers premises, if necessary.
21.2 The equipment shall be designed, manufactured and tested in accordance

with the best modern practice to the approval of the S.O.

21.3 Materials, design and installation shall be in every respect of the utmost
quality.
21.4 Particular attention shall be paid to the design of assemblies and components
to ensure that visual intrusion of the equipment is minimised.
21.5 Due regard shall be paid to the prevention of corrosion with attention to
design, especially for structures, in accordance with BS 5493.
21.6 All components, assemblies and materials used shall comply with the
relevant Malaysia Standards specification.
21.7 Where technical matters are not covered by specification or elsewhere in the
contract documents, compliance with a relevant recognised international
standard or specification shall be considered.
21.8 All equipment shall be designed and installed with due regard to the safety of
KTMB’s operational/maintenance personnel and the public. Particular care
shall be taken to avoid undue visual intrusion of the equipment in station
areas, particularly at the stations and halts.
21.9 The equipment shall be designed to resist and withstand acts of vandalism.
22.0 SAFETY
22.1 All equipment installed by the Contractor shall be adequately earthed, insulated,
screened or enclosed, as may be appropriate, to ensure the protection of the
equipment and the safety of persons nearby. Appropriate warning notices shall
be erected.
22.2 On-site construction works shall be conducted in a safe manner at all times to
ensure the safety of the railway system and staff, public and construction
workers according to OSHA Act.
22.3 The equipment installed shall comply with the requirements of all relevant Laws
of Malaysia and Malaysian Ordinance, Rules, Regulations and Orders.
23.0 STATUTORY LAWS
23.1 The Contractor shall, in all matters arising in the performances of the Contract,
conform in all respect with the provisions of any National or State Statute,
Ordinance other law or any Regulations or By-law of any local or other duly
constituted authority that shall be applicable to the Works, and liability of every
kind for breach of any such Statute, Ordinance, Law, Regulations or by Law.
23.2 All cost associated in complying with the regulations and laws shall deem
included in Contract sum.

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No. IRCON/9030/MAL.SGDT/S&T/Commn./Pkg.III Date:04.01.

Stamp & Signature of Tenderer/s

2.0 PRACTICES AND STANDARDS

a) Keretapi Tanah Melayu Berhad (KTMB) (Technical Standards and

Stamp & Signature of Tenderer/s

2.7 The work shall conform to manufacturers instructions, safety requirements,

2.9 Where KTMB’s Standards or British Standards or other standards are

2.10 Where KTMB’s Standards or British Standards or other standards are

3.1 It is the Contractor’s responsibility to provide systems, plant and equipment, so

3.2 Accordingly it is the Contractor’s responsibility to ensure that all matters of

3.4 The Contractor’s attention is drawn particularly to the following: -

(a) Interference effects of the electrification systems.

Signature & Stamp of Tenderer/s 135

4.0 PROVEN SYSTEMS

5.0 SYSTEM ARCHITECTURE AND PERFORMANCE

5.1.3 Integrated system diagnostics shall be incorporated to continuously check the

5.1.4 Multiplicated system architecture shall be employed for microprocessor based

Changeover between systems shall have no effect whatsoever on system

(a) CTC Control and Indication Systems

Signature & Stamp of Tenderer/s 136

(f) Automatic Train Reporting System

5.3 Operational Performance

6.0 SPARE CAPACITY AND MAINTENANCE TOOL

Signature & Stamp of Tenderer/s 137

7.0 DOCUMENTATION AND DRAWINGS

7.1 Documentation and drawings shall consist of a series of diagrams, schematics,

7.4 Maintenance documentation shall be structured and presented in such a manner

Documents : WinWord (Latest release)

and shall be issued in hard copies and on CD ROM’s.

Signature & Stamp of Tenderer/s 138

maximum A3 size unless otherwise approved by the S.O. Prints of drawings

(a) Main Title

7.10 Unless otherwise specified numbers of copies of documentation and drawings to

Issue Nos. of Copies

7.11 Unless otherwise specified numbers of copies of documentation and drawings to

Issue Nos. of Copies

Signature & Stamp of Tenderer/s 139

(a) Automatic Train Protection (ATP) system.

9.0 ENVIRONMENTAL CONDITIONS AND ASSOCIATED REQUIREMENTS

(a) Function normally in accordance with the specification.

(a) Able to withstand ambient temperature encountered in Malaysia.

(b) Proof against condensation and deterioration arising there from.

(c) Protection against corrosion.

(d) Proof against development of fungi.

(e) Precautions against electrolytic or bimetallic corrosion.

(a) Processor based interlocking equipment.

9.3 Temperature and Humidity

Signature & Stamp of Tenderer/s 140

9.3.4 Lineside equipment cases shall be designed specifically to limit internal

9.4.4 Equipment exposed to the weather shall be resistant to attack by detergents,

9.5 Solar Radiation

9.6 Electromagnetic Effects

9.6.2 Vital control equipment shall be accredited by internationally acclaimed

(a) Processor based interlocking equipment

Signature & Stamp of Tenderer/s 141

The importance of providing adequate safeguards for prevention of damage by

Signature & Stamp of Tenderer/s 142

(c) Two stages of protection shall be incorporated in each T.P.U., with

(d) Connection pins or terminals shall have adequate current carrying

(e) The secondary protection module shall include a matching attenuator or

(b) One or more stages of protection incorporated in each T.P.U. according

(c) Connection pins or terminals shall have adequate current carrying