e. gen. requirement _133-165

8/14/2019 e. Gen. Requirement _133-165

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No. IRCON/9030/MAL.SGDT/S&T/Commn./Pkg.III Date:04.01.2010

Stamp & Signature of Tenderer/s

133

GENERAL REQUIREMENTS


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Stamp & Signature of Tenderer/s

134

1.0 GENERAL

1.1 This document sets out the general technical and related requirements for theSystems Works and covers the Signalling, Communications, Electrification andother 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 andinternational railway practice.

2.2 Except where otherwise stated, the Works shall comply with the relevantstandards, regulations, codes of practice, recommendations etc. of recognisedorganisations and authorities as stated below: -

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

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 Keretapim) Suruhanjaya Multimedian) Tenaga Nasional Berhad (TNB)o) All current laws in Malaysia.

2.3 The National or International Standards referred to above represent the minimumrequirements 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 thespecific approval of the S.O.

2.4 The Contractor shall maintain consistency in the adoption of, and conformanceto, 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) applicablestandards, the matter shall be referred to the S.O for determination.


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Signature & Stamp of Tenderer/s 135

2.6 The works shall conform to standard Minimum Structure Diagram for Single andDouble 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 protectionrequirements.

2.8 Metric standards and SI units shall be utilised unless otherwise approved.

2.9 Where KTMBs Standards or British Standards or other standards arementioned in these documents, the editions and amendments thereto currentat the date of this document shall apply, unless otherwise specified herein or agreed by the S.O.

2.10 Where KTMBs Standards or British Standards or other standards arementioned in these documents, the equivalent ISO or IEC Specifications or Recommendations may be substituted, subject to the S.O.'s approval in eachcase.

2.11 In the event of any conflict between such approved equivalent specificationand any Malaysian or British Standard or similar document, the specificationor standard stipulated in these documents shall prevail.

3.0 COMPATIBILITY

3.1 It is the Contractors responsibility to provide systems, plant and equipment, soas to ensure that the Works are fully compatible within themselves and also thatthe Works are fully compatible with associated Works and adjacent KTMB and3rd party systems, plant and equipment.

3.2 Accordingly it is the Contractors responsibility to ensure that all matters of interfacing, immunity and interference are satisfactorily addressed and resolvedin respect of the Works and such associated Works and adjacent KTMB and 3rdparty systems, plant and equipment taking into account normal and abnormaloperation and fault conditions.

3.3 In respect of the Works, associated Works and 3rd Parties, it is the Contractorsresponsibility to conduct such negotiations, dialogue, discussions etc. as arenecessary and to exchange such information as is necessary to ensure thesuccessful implementation of the Works.

3.4 The Contractors 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 KTMBs Relay Automatic

Block Tokenless Block System(f) Adjacent Telecommunications systems(g) Adjacent Rapid Transit electric traction systems.


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(h) Relationship between signals and electrification masts and overhead wirepull-offs.

(i) Relationship between the location of trap points, buffer stops etc. and theposition 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 provenand tested in the service of an internationally recognised railway system as wellas with substantial satisfactory service history. Full and complete technical andoperational 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 faxnumbers 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 BetweenFailure (MTBF) figures for performance of main components and systems shallbe given in the proposal.

5.1.2 Condition monitoring techniques shall be employed, where possible, such thatdegradation of system performance is automatically detected and alarmed wellbefore system failure occurs.

5.1.3 Integrated system diagnostics shall be incorporated to continuously check thecondition of hardware, data links etc. Failure of diagnostics shall not affectsystem operation.

5.1.4 Multiplicated system architecture shall be employed for microprocessor basedand solid state systems etc utilising fully updated standby systems configured ina truly hot-standby mode, redundant data links, etc. and automatic changeover facilities. Changeover between such systems shall be fully automatic requiring nomanual actions whatsoever.

Changeover between systems shall have no effect whatsoever on systemoperation or the status of controls or indications etc. and shall be imperceptible tooperators. Such facilities shall be provided in respect of, but not limited to, thefollowing systems:-

(a) CTC Control and Indication Systems(b) Signalling telemetry systems(c) Microprocessor Interlocking(d) Train Describer Systems(e) Train Timetable System


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(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 urgentalarms 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 toaccommodate track layout and associated system changes etc.

5.2.2 Software shall be modular and structured such that system software andapplication 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 insystem response to operators. System reaction to operator interfaces shallappear as virtually instantaneous to operators. Transmission of controls to thefield without status change shall be effected not exceeding two (2) sec. unlessspecified otherwise. Events occurring in the field shall be reported back tooperators 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 newinformation, 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 andequipment to facilitate future changes to the railway network. The precise natureof 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, systemsworks and associated facilities shall be allowed for.

6.3 Cables shall have a minimum of 25% spare cores or pairs subject to a minimumof 2 cores/pairs.


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6.4 Power supplies, UPS and Transmission Multiplexing Systems shall haveminimum spare capacity of 25% unless otherwise specified.

6.5 It is anticipated that spare capacity shall be included in, but not limited to thefollowing:-

a) Cablingb) Transmission Multiplexing Systemsc) Power supply systemsd) Microprocessor interlocking systemse) Equipment housings and racksf) Trunk Radio Systemg) Automatic Fare Collection Systemh) 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 Worksin every respect.

7.2 Copies of all such designs, documentation and drawings shall be submitted to theS.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 detailsso as to facilitate provision of the Works and to permit KTMB to eventuallymaintain, 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 anddrawings 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 ROMs.

7.6 The Contractor shall handover to KTMB two (2) copies of licensed full versionsoftware for the latest release of AutoCAD (as used for the drawings) at leastthirty (30) days before the submission of the drawings.

7.7 Hard copies of documentation shall be presented and bound in a fashion whichwill allow easy use, maintenance and updating and will be hard wearing such thatit shall last for the lifetime of the system. Books of design details shall be of


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maximum A3 size unless otherwise approved by the S.O. Prints of drawingsshall be substantially mounted in hard covers in such a manner as to readilypermit 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 endorsedwith its current status.

7.10 Unless otherwise specified numbers of copies of documentation and drawings tobe submitted to the S.O. shall be as follows:-

Issue Nos. of CopiesInspection/Approval 2Testing Records 1Commissioning Maintenance Copies 2Final 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 tobe submitted to the S.O. shall be as follows:-

Issue Nos. of CopiesInspection/Approval 6Testing Records 3Test Certificates 3Commissioning Maintenance Copies 4Final As-Built Records 5 (plus 3 CD ROM)Final Manuals, Handbooks etc 10 (plus 3 CD ROM)(including operational manuals)

7.12 The bidders financial offer should be inclusive of the cost of all such drawings &documentations including software etc. mentioned above. No separate costtowards this shall be payable.

8.0 STANDARDISATION

8.1 The numbers of different types of systems and equipment provided under thecontract shall be kept to an absolute minimum.


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8.2 To minimise KTMBs spare holding, staff retraining etc., all equipment to besupplied shall be types which are of current design and already approved for inuse within KTMBs railway network. Any proposal for new equipment or systemshall be subjected to specific approval by the S.O.

8.3 In respect of the following, only KTMB standardised systems and equipment arepermitted, such systems and equipment to be provided must be compatible andfully 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 thespecification under all environmental conditions experienced in Malaysia. For each of the environmental conditions specified the Contractor shall state therange, 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 tropicalisedparticularly 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 tracksideinstallation in tropical countries without provision of environmentalconditioning: -

(a) Processor based interlocking equipment.

9.3 Temperature and Humidity

9.3.1 Systems and equipment shall operate correctly under all temperature andhumidity conditions.

9.3.2 Account shall be taken of condensation, which may occur under a combination of temperature and humidity conditions.


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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 internaltemperature rise and shall include the necessary features to maintain adequate

ventilation. They may require extra panels to act as sunshades and or heatdissipaters.

9.4 Pollution

9.4.1 Systems and equipment will be in contact with the atmosphere which willgenerally be polluted. Pollutants may be either chemically active or inert such asdust.

9.4.2 All systems and equipment shall operate correctly in a polluted and dust ladenatmosphere. 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 inindustrial areas. In the latter case gases may dissolve in condensation or condense in or on equipment. Equipment shall be protected against the effectsof 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 shallbe shielded from direct solar radiation.

9.6 Electromagnetic Effects

9.6.1 All equipment and systems which are susceptible to electromagnetic affectsshall be suitably protected with electromagnetic noise free screenedenclosures to ensure correct operation and avoid permanent degradation.

9.6.2 Vital control equipment shall be accredited by internationally acclaimedorganisations for compliance with Electromagnetic Compatibility which shallinclude, 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


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9.7.1 As the project area is in a region with a high incidence of thunderstorms with verysevere lightning, adequate protection against damage or malfunctioning of systems, plant and equipment, cable etc. due to high transient voltages andcurrents shall be incorporated. Equipment to be connected to the power supplymains and items to be connected to or mounted close to the railway track shouldreceive special attention.

The importance of providing adequate safeguards for prevention of damage bylightning cannot be too strongly stressed; details of high voltage surge arrestors,fuses, chokes, etc. being provided for this purpose must be included in theproposal.

9.7.2 The specific protection requirements mentioned in this section shall be regardedas only the minimum requirements, which may not necessarily be adequate inparticular situations.

9.7.3 For protection against transient high voltages and currents introduced via themains 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 atthe 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 transientsfrom the supply lines.

(c) Incorporate high energy clamping devices and filtering components withlow 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 shallbe so protected that any surge arriving via the neutral conductor will alsobe diverted to earth.

First (1st) level protection for the power supply mains in buildings will benormally be provided at the main power supply switch-board by the partyresponsible for the buildings electrical system.

9.7.4 For protection against transient high voltage and high current surges introducedvia the communications lines, data lines, and other lines connected to equipmenthaving electronic components, the minimum protection shall be by TransientProtection Units (T.P.U.) of appropriate size fitted to the external lines and havingthe following features:-

(a) For balanced lines (for example, 600 Ohm balanced telephone or datalines) the T.P.U. shall be of the balanced type and provide protectionagainst both differential and common mode transients.

(b) For unbalanced lines, the T.P.U. shall be of the corresponding type, andprovide protection against transient voltages between the line and thereturn connection and also between the lines, return connection and earth(ground).


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(c) Two stages of protection shall be incorporated in each T.P.U., withseparate modules being used for the primary and secondary protectionso as to facilitate testing and replacement, and the two modules securelyconnected together with high grade connectors.

(d) Connection pins or terminals shall have adequate current carryingcapacity to withstand the high transient currents in addition to the normalcurrent.

(e) The secondary protection module shall include a matching attenuator or filter and high energy clamping devices (with a response time less than100 Pico seconds). For protection of balanced lines, such clampingdevices shall be equally effective against surge voltages of either polarityappearing 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. Theclamping 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 bepossible without having to disconnect the lines.

9.7.5 For protection against transient high voltage and high voltage and high currentsurges introduced from the railway track via the track circuit connections, theminimum 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 andbetween each line and earth (ground).

(b) One or more stages of protection incorporated in each T.P.U. accordingto the requirements of the particular track circuit equipment.

(c) Connection pins or terminals shall have adequate current carryingcapacity to withstand the high transient currents in addition to the normalcurrent.

(d) The T.P.U. shall be designed to allow easy installation and connection.Removal and insertion of the protection modules should be possiblewithout having to disconnect the lines.

9.8 Vibration

All systems and equipment shall be capable of satisfactory operation andpermanent storage without deterioration or damage in vibration conditions whichare consistent with the passage of trains.

9.9 Waterproofing

9.9.1 The project area is in a region which experiences severe tropical rainstorms.


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9.9.2 All equipment installed external to permanent buildings must be proofed againstingress of water caused by such rainstorms or other liquids not only in the verticalplane but also in any other direction.

9.10 Wind

Systems and equipment shall be able to withstand, and shall operate correctlyunder, the most onerous wind conditions. Wind effects shall be suitablyfactorised 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, ATPtransponders, 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 constructedto 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 cablesshall enter through close fitting cable glands to prevent ingress of reptiles, insectsand rodents.

9.13 Environmental Conditioning

9.13.1 It is preferred that all systems and equipment shall operate and performsatisfactorily in accordance with performance specification without any relianceon environmental conditioning.

9.13.2 Any cases where environmental conditioning is necessary or recommended inrespect of systems and equipment performance, shall be fully detailed by theContractor for the Systems. Provision of such environmental conditioning withinbuildings shall be the responsibility of the Contractor who is responsible for thebuilding works. The Systems Contractor shall satisfy himself and furnishconfirmation as to the adequacy in provision of environmental conditioning.


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(c) Third Level Maintenance

Off-site diagnosis and repair of modules which have been removed andreplaced under 1st level or 2nd level maintenance.

10.3 Equipment shall be laid out in equipment rooms, compounds and other housingsin a logical and consistent manner. The spacing between equipments,equipment modules, cable terminations, plugs/sockets etc shall be such as toallow easy access for maintenance purposes and shall be subject to an absoluteminimum 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 areinvolved.

10.4 Comprehensive maintenance, diagnostic and faultfinding facilities shall be

provided with clear and concise status and failure indications etc. Systemperformance/fault logging storage, display and hard copy printing facilities shallbe provided for microprocessor and solid-state systems.

10.5 To minimise Mean Time to Rectification and simplify procedures for maintenancestaff, all systems and equipment shall be installed on a modular basis.Preference will be given to systems utilising a plug-in method of connectingmodules.

10.6 The number of different types of module in the system shall be kept to aminimum. Maximum use shall be made of interchangeablity of modules.

10.7 There shall be a mechanism which physically prevents insertion of an incorrectmodule or plug into a location.

10.8 Where adjacent cable plug/socket terminations are utilised, physical means shallbe provided to prevent cables from being erroneously interchanged.

10.9 Where a module requires replacement, an indication system must make it easilyand immediately apparent to the maintainer to identify which module should bereplaced.

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 theweight shall be evenly distributed.

10.11 Where appropriate equipment modules shall be fitted with handles by which theycan be removed from the equipment rack and carried.

10.12 All modules shall be indelibly marked with both a unique serial number and aversion number/modification status code. The marking shall be so located that itcan be easily seen and read.


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distributed so as to limit and localise failure of equipment resulting from theoperation 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 personnelwho 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 andRegulations.

11.1.8 Power cables shall be rated such that the maximum volt drop from the supplypoint 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 neutralconnection of the mains power supply.

11.1.10 Power supplies feeding vital signalling interlocking and control circuits shall beself contained, shall not feed other equipment or systems and shall be isolatedfrom other power supplies by double wound isolation transformers.

11.1.11 Independent isolated supplies (e.g. North, South etc.) shall be provided for eachdirection to feed vital line side signalling control circuits where such circuitsemanate from equipment rooms or lineside apparatus cases.

11.1.12 Suitable stationery standby power supply equipment in the form of storagebattery/inverter sets (UPS Systems) shall be provided by the Contractor at eachmains power supply point to supply power to systems so that systems shallfunction normally, during interruption of mains power.

11.1.13 Interface circuitry shall be provided by the Contractor to extend themains/standby generator indications and manual controls, the status of the mainspower 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, theContractor shall also provide for the mains/standby generator indications andmanual controls, the status of the mains power supply, UPS, etc at Halts to beextended the local control and indication VDU facility at the nearest station and tothe CTC.

11.1.14 Tests shall be carried out to demonstrate that power supply wiring shall be ableto 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 variesbeyond acceptable limits, such that equipment and systems will continue tooperate normally and without any disturbance. The UPS system shall includestorage 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 suchthat a single component failure will not cause any interruption of the power supply. The UPS shall have built-in automatic and maintenance bypass facilities.


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11.2.3 The storage battery used for the UPS system shall be an industrial grademaintenance free type stationery battery, and shall, as far as possible, beinstalled indoor in a ventilated room (battery room). The battery charging systemshall operate from the mains supply and from the standby generator set, so thatunder 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 eachphase), 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 controland indication.

11.2.5 UPS systems shall be rated to supply power for all equipment and systemsforming part of the Contract which require to run from the UPS system during aninterruption of the power supply, plus an allowance of at least 25% for additionalloads 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 equipmentand 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 soconstructed or bonded so that all parts are maintained at the same potential andshall be connected to an earthing system.

12.1.2 Within any one equipment room, building, equipment case, enclosure etc. asingle earthing system shall be employed so as to eliminate personnel hazards,which would otherwise arise, as a result of differing earth potentials appearing onexposed 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 permanentseparation of at least 2.5 m, or shall be separated by a wall or other physicalbarrier to prevent simultaneous contact. Where this cannot be achieved suchcircuits, links, terminals, equipment, etc., shall be insulated, shrouded and fittedwith warning labels.

12.1.4 Earthing distribution systems shall be star configured equi-potential bondingsystems and shall utilise a prime earth bus bar from which individual earthconductors shall be radially distributed to the various points to be earthed toprevent 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 serviceswhich extend into or pass through such equipment or operational rooms, cases,


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enclosures, etc., shall be gapped at the entry and exit. Such gapping shall beprovided at the exit/entry wall. However, should this not be possible, thengapping shall be such that a minimum of 2.5m separation is provided betweenthe earthed and unbonded metalwork, or between metalwork bonded to differentearthing systems. Earth segregation of incoming power supplies shall beachieved 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 beinsulated, shrouded and labelled as follows:-

"WARNING - INDEPENDENT TEST EARTH".

12.1.7 Earth resistance values shall be sufficiently low to ensure adequate protection topersonnel and proper operation of equipment and systems includingsurge/lightning arrestor devices. In any case, unless otherwise specified, earthresistance values shall not exceed 10 ohms. In exceptionally difficult areasdispensation may be allowed in respect of earthing values but only with thespecific approval of the S.O.

12.1.8 Lightning protection earths shall be fast transient earths, connected with cablingwhich 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 highestvalue of earth fault current to be expected, due regard being given to theoperation 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 anddriven vertically into the ground, selecting a damp area for this purpose wherepossible. Longer rods or additional rods, earth farm arrangements etc shall beused to obtain the necessary low earth resistance value. If a different method isto 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 isapproximately 15 cm below ground level and enclosed by a suitable concreteenclosure provided with an inspection cover (at ground level) to mark thelocation. The enclosure cover shall be easily removed for inspection and earthtesting 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 thatground coupling between independent earth systems and traction earth systemsshall 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-currentcarrying metalwork is bonded in such a manner that no dangerous potentialsexist either under normal operating or fault conditions.


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12.2.2 Earthing means effectual connection to the general mass of the earth by meansof a suitable earth electrode. The foundations of the overhead line structures,connected in parallel by means of the earth wire or traction return rail, constitutesuch an electrode. Except where otherwise stated, these are the electrodes to beused, connection being made to the impedance bonds, traction return rail, earthwire or overhead line structure as appropriate and convenient.

12.2.3 The traction return system shall be through connected and bonded so as toensure its continuity.

12.2.4 Electrification continuity cross bonding between tracks in track circuited areasshall be applied in such a manner as to ensure that there are no detrimentaleffects 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 to25KV 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 thegeneral mass of earth through the rails, overhead line structure foundations andother means which maybe considered necessary.

12.2.7 The rise in potential, with respect to the general mass of earth, of the tractionreturn system and all exposed metalwork bonded thereto, together with allassociated 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 andthe maximum value of earthing resistance is not stated, the principles to befollowed in determining the value of earthing resistance to provided are:-

(a) To hold the potential of exposed metal to a value not exceeding 60Vunder normal operating conditions or 430V under traction system faultconditions, 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 beundertaken which shall determine the spacing to be applied to tractionintermediate earth connections in double rail track circuit areas. Such a studyshall clearly demonstrate that, with the spacing chosen, the specified maximumlimits in respect of step and touch potential and induced voltage shall not beexceeded. The study shall also analyse the sensitivity of the earthing system tovariations in ground resistance and in intermediate earth connection spacing.The study and report shall be submitted to the S.O. for inspection. Oncompletion of installation the study results shall be verified as part of the systemtesting 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.


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12.2.11 Bonds which form part of the traction return path shall be clearly identified asdisconnection of such bonds can result in exposure to high potentials. Suchbonds shall be provided utilising distinctive red-sheathed cable. Red-sheathedcable 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 runningrails.

Note : Red sheathed cable shall be applicable to impedance bond side leads atlocations (a) and (b) above.

(c) Side leads and transition leads connected to impedance bonds/rails atdouble 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 thedisconnection or where the disconnection of the bond would separate twoearthing systems, e.g. bonding of external power supply earths to thetraction return/earth system.

12.2.12 Where non-metallic or reinforced concrete structures are so close to liveequipment that they are at risk from flashover, arrangements shall be made toensure 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 whereflashover is likely as a result of interference by birds.

12.2.13 Arrangements shall be made to ensure that surface or buried metal pipes, earthelectrodes and other metallic objects do not develop hazardous potentialsthrough induction from the traction current or voltage, and are not damaged byany traction return current which may flow in them. Special arrangements shallbe required in respect of metalwork which is fitted with cathodic protectionsystems.

12.2.14 At locations where external power supplies enter railway premises, such as atStations, Depots, Halts etc, and such power supplies encroach close to the 25KVtraction system so that there are risks of interference between the two systemsincluding:-

(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/earthsystem. In such cases the contractor shall obtain the necessary approval of thelocal supply authority. Where such approval is not forthcoming suitableinsulation, screening and other measures shall be provided as necessary.

12.2.15 At the boundary of the electrification system all tracks shall be electrically isolatedfrom the non-electrified portions of the railway system. This shall be achieved bythe provision of insulated rail joints (IRJ's) in each rail. Two (2) sets of such IRJ's


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shall be provided, and separated so that they cannot be simultaneously bridgedout by the longest train. Any track circuiting arrangements in the area shall takesuch requirements into account.

12.3 Bonding / Isolation of Sidings

12.3.1 KTMB sidings which are not track circuited shall be continuity bonded to thenearest traction return rail and shall include all necessary track to track and rail torail cross bonding to maintain specified limits of rail potential under normal,broken rail, disconnected bond etc. conditions. Buffer stops shall not constituterail-to-rail connections.

12.3.2 Non-wired Private Sidings shall be electrically isolated from the 25KVtraction/earth system by the provision of IRJ's in each rail. Two (2) sets of suchIRJ's shall be provided located the maximum distance apart allowable by siteconditions.

12.3.3 In situations where adequate separation of the private sidings from the tractionreturn/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 sidingsto a 25KV electrified railway system or where such installations are situatedadjacent to such a railway system they shall be subject to special isolation,earthing and bonding arrangements to be determined by the S.O for eachparticular case.

12.5 Main Signalling and Communications Equipment Rooms, and OperationalRooms and Buildings

12.5.1 Main signalling and communications equipment rooms and operational roomsand buildings containing active solid state signalling or communications systemsshall employ an independent earthing system which shall be entirely separatefrom the traction return and other earthing systems or latest international practiseemployed by Railway operators in the world. The main earthing system for thebuilding at stations and halts will be provided by the contractor responsible for thebuilding 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 whichshall not exceed one (1) ohm. The earth farms shall be independently connectedvia maintenance disconnection links to the Prime earth bus bar.

12.5.3 All exposed metalwork etc within such rooms or buildings which requires an earthshall 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 andbuildings.

12.6 Signalling and Communications Line side Equipment Cases, Walk-inEquipment Cases, Enclosures etc.


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12.6.1 Lineside signalling and communications equipment cases, enclosures etc. shallnot be located within 2.5m of any traction return or earthed equipment. Suchcases 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 anindependent fast transient earth. This fast transient earth shall be installedimmediately adjacent to the equipment case and shall be bonded with leadswhich shall be as short as possible, contain the minimum number of bends andshall be free of coiling. Such fast transient earths shall have a maximum valueof four (4) ohms and should be located such that ground coupling with thetraction earthing system is minimised.

12.6.3 Where track circuit feed and relay circuits, which are directly connected to thetraction return system, are installed in equipment cases then the wiring shall beinstalled 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 andlabelled as follows:-

WARNING - TRACTION EARTH POTENTIAL EXISTS ON TCCONNECTIONS".

12.7 Lineside Cabling Systems

12.7.1 Lineside communications screening cables shall be earthed at nominal 1 kmintervals utilising earth electrode systems of 4 ohms of less. Such earthelectrode systems shall generally be installed at locations coincident with cable

joint positions, they shall not however, be installed within 50m of any equipmentrooms, line side equipment cases, track section locations, return conductor/railconnections nor within 100m of any traction feeder stations.

12.7.2 Screening cable earth electrode systems shall be independent and shall not bebonded to the traction return/earth or any other earth systems and shall not betaken into any line side equipment rooms, buildings or cases etc.

12.7.3 Metallic sheaths, armouring etc of cables shall, prior to entering equipmentrooms, operational rooms, buildings, line side equipment cases, equipmentenclosures etc, be gapped such that electrical continuity does not exist betweenthe 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 30mfrom the associated room, building or case etc and shall be enclosed in a non-conductive joint closure. Alternatively metallic sheaths/armouring shall bestripped 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 bemaintained earth free. They shall be brought into equipment rooms, buildings,


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cases etc, terminated on an insulated terminal, suitably labelled and treated as aspare cable conductor.

12.7.7 All metallic cable sheaths, moisture, barriers, brass tapes etc shall be suitablyisolated and sectionalised to ensure that maximum specified induced voltagelevels 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 areasand 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 notbe 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 beinstalled along the length of the arm and shall be bonded, together with thesupporting post, to the traction return earth system.

12.8.4 Aerial towers shall be bonded to the traction return/earth system unless suchtowers 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/earthsystem 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 wallsor 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, thenassociated fixed radio equipment shall be located such that simultaneous contactwith both radio equipment and structure is not possible. In such cases aerialfeeder cables shall be isolated from the fixed radio equipment by 2KV isolatingdevices. Isolating devices shall provide isolation of both inner and outer conductors and shall be insulated and installed in such a manner thatsimultaneous 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 shallbe earth free.

12.9.2 Such circuits in Main equipment rooms shall employ earth leakage detectiontogether with associated alarm facilities in respect of:-


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(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 suppliesetc. shall be mounted within weatherproof equipment cases. Such cases shall besupplied pre-wired as far as possible.

13.2 Out-door equipment cases and disconnection boxes shall be fabricated from highquality stainless steel.

13.3 Boxes shall be designed to have good accessibility for maintenance. Equipmentcases 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 partof the box will not be less than 20 cm above ground level. A layer of soft butdurable plastic material shall provided between the bottom of the box and theupper surface of the concrete base. The upper surface of the concrete baseshall slope away from the base of the box so that any rainwater flowing down thesides 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 goodaccess and preferably near the cable entry areas, to enable a good electricalconnection to be made to the box.

13.6 Every box shall be given its own distinctive identification number or code whichshall be clearly visible. The same number or code shall be used in the drawingsto refer to the box.

14.0 CABLE ROUTES AND CABLING

14.1 Prior to starting any cable laying work, the Contractor shall ensure that sufficientlabourers, machines, and tools, as well as all specialised materials andequipment required are available at site, so that the cables can be laidimmediately after the cable route has been prepared.

14.2 During the installation of cables, cable routes shall be left open for an absoluteminimum period of time in order to prevent accidents and contamination of the

route and to afford maximum protection of cables. Unless otherwise approvedthe absolute maximum period any portion of a route may be left open shall beone (1) week.

14.3 Cable laying in concrete trough routes, trenches and drawing the cable intopipes, conduits, tubes etc. may be done from rail borne vehicles. If the areaspermit, the cable can also be rolled out alongside the route and then laid. Cableprotection measures, cable jacks, rollers and other suitable equipment shall beused as necessary.


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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 trackwithin turnout areas shall be avoided.

14.6 Where cables are required to be buried, cable trenches shall be such that theburied cables shall be not less than 0.80m deep below ground level. Thetrenches shall not be more than 0.20m wide. In rocky ground the cables may beburied at 0.60m depth, but over a short distance only. The trench bottom shall beof soft soil or sand with a maximum grain size of 5 mm. If the bottom is rocky, alayer of sieved soil or sand shall be put in, before the cable is laid. If the requiredminimum depth below ground level cannot be attained without incurring undulyhigh 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 inplace 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 becompacted by layers of 0.20 to 0.30 m. A durable plastic tape (yellow colour) atleast 40 mm wide and 0.1 mm thick shall be laid at a depth of 0.30 m to 0.40 mabove 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 intoconsideration when digging and laying the cables. Disturbance to existing earthdrains, cables, pipes, and other services shall be avoided as far as possible.Care shall be taken when excavating cable trenches close to electrification mastsso 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, wherethe cables would be otherwise exposed, they shall be protected by galvanisedmild 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, pointmachine, and the like, or otherwise within the an equipment room.

14.12 All incoming cables into equipment rooms, line side equipment cases etc. shallbe 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 internalequipment for the purpose of testing the cables without having to actually removethe cable from the terminals.


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16.5 All labels shall be clearly visible when the equipment is fixed into its workingposition. They shall also correspond to the naming of equipment on drawingsand 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 besuitably 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 uniqueunit number which shall include the modification state. This number shall beengraved on the unit's handle and on the cabinet label associated with thenormal unit position.

16.8 Where identical units have their function changed by program the unit handleshall carry a common number.

16.9 The rack label shall carry the same number plus additional classification for theequipment state required for that slot.

16.10 Where a unit's function is determined by subsidiary plug-able components, theplug-able components shall carry a label that corresponds to the additionalclassification given on the rack label.

16.11 Where more than one but not all units in one housing form a working group, thegroup 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 endplug or socket to which they should be connected.

16.13 Individual cable conductors shall be identified with their individual terminationpoint by the fitting of suitably inscribed cable tags or markers.

16.14 Distinctive earthing cables terminated on racks and equipment etc, where theyare obvious, shall not be labelled. However earth cables terminated on earth busbars shall be individually labelled with the far end identification.

16.15 Labelling shall conform to the same number/character/number scheme as isutilised 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 onenergisation of the 25kV Overhead Line system. Verification that specificationscriteria in respect of the following have been satisfactorily achieved shall beclearly demonstrated: -

(a) Step and touch potentials(b) Earth potential rise(c) Induced voltage and noise(d) Interference and immunisation


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17.2 The Contractor shall provide a comprehensive report detailing all tests which areconducted, instrumentation used, test methods etc together with a full set of testresults and conclusions.

17.3 The Contractor shall take adequate precautionary measures to liase andcoordinate 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 surveyshall be conducted jointly by representatives of the Contractor, KTMB and S.O. toidentify and verify the condition of all the existing materials and equipment in theproject area, which will become redundant (or re-used) under the project. Allparties concerned shall duly endorse the records of the survey.

18.2 All redundant materials and equipment dismantled and recovered shall beremoved 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 bedesignated by KTMB within the Works site area and unloaded and stackedneatly in a place designated by KTMB.

(b) Reusable Items

Reusable items shall be carefully recovered, suitably packed, delivered to aDepot to be designated by KTMB within the Works site area and unloadedand 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 withinthe 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 abovecategory.

(b) Certification Document verifying receipt of all items at the KTMB receivingdepot including correlation, with the Recovery Schedule.

18.4 Before recovering any items the contractor shall obtain the S.O.s approval to theRecovery Schedule.

19.0 TRAINING

19.1 The contractor shall provide full and comprehensive training for KTMB staff. Theaims of the training shall be such as to ensure that KTMB staff shall be capableand fully competent to maintain, rectify, operate and modify the particular


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systems provided. Training courses shall cover, but not be limited to thefollowing:-

(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 theexposure of the staff concerned.

19.3 Training shall cover the whole range of KTMB staff including, but not limitedto:-

(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 theability for KTMB to continue own training programmes.

19.5 Training shall include both theoretical and practical experience. Practical trainingshall be integrated into project design, construction, testing, commissioning andmaintenance 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 andcertification.

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-trainingprogramme 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


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19.10 The Contractor shall clearly set out any facilities, requirements or obligationsplaced 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 withrequirements stipulated under ISO 9000 series of specifications which shallprovide documented evidence of quality system compliance and ensure that allactivities related to quality of items and workmanship shall be in accordance withthe 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 andprocesses 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 alsoclearly identify the QA organisation.

20.2.2 The Contractor shall implement written procedures, including at least thefollowing, copies of which shall be issued to the S.O.

a) Control of Sub-Contractorsb) Control of Suppliersc) Receiving, First Article, In-Progress and Final Inspectiond) Production and Process Controle) Functional Testf) Control of Non-Conformances and Corrective Actiong) Calibration of Test and Measuring Equipmenth) Design Controli) Document and Drawing Control

j) QA Recordsk) Quality Audit

20.3 Certificates of Compliance

20.3.1 When approved by the S.O., certificates of compliance for equipment, materialsand products may be accepted in lieu of the specified sampling and testingprocedures.

20.3.2 Certificates of compliance shall include as a minimum,a) The batch, lot or serial number to provide traceabilityb) Test results including datesc) Name and address of test organisationd) Specification requirementse) Quantity tested


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(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 providedocumented 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 inspectionrecords:-

(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 toverification 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 andprocedures 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. Basicdesign and engineering may also be carried overseas at by the relevantsystems suppliers premises, if necessary.

21.2 The equipment shall be designed, manufactured and tested in accordancewith the best modern practice to the approval of the S.O.


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21.3 Materials, design and installation shall be in every respect of the utmostquality.

21.4 Particular attention shall be paid to the design of assemblies and componentsto ensure that visual intrusion of the equipment is minimised.

21.5 Due regard shall be paid to the prevention of corrosion with attention todesign, especially for structures, in accordance with BS 5493.

21.6 All components, assemblies and materials used shall comply with therelevant Malaysia Standards specification.

21.7 Where technical matters are not covered by specification or elsewhere in thecontract documents, compliance with a relevant recognised internationalstandard or specification shall be considered.

21.8 All equipment shall be designed and installed with due regard to the safety of KTMBs operational/maintenance personnel and the public. Particular care

shall be taken to avoid undue visual intrusion of the equipment in stationareas, 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 theequipment and the safety of persons nearby. Appropriate warning notices shallbe erected.

22.2 On-site construction works shall be conducted in a safe manner at all times toensure the safety of the railway system and staff, public and constructionworkers according to OSHA Act.

22.3 The equipment installed shall comply with the requirements of all relevant Lawsof 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 dulyconstituted authority that shall be applicable to the Works, and liability of everykind 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 deemincluded in Contract sum.