ep 08 00 00 02 sp - overhead wiring maintenance standards · 2019-05-21 · subject: withdrawal of...

TN 013: 2015

For queries regarding this document

[email protected] www.asa.transport.nsw.gov.au

Technical Note TN 013: 2015 Issued date 12 March 2015 Effective date 12 March 2015 Subject: Withdrawal of EP 08 00 00 02 SP Overhead Wiring

Maintenance Standards

This technical note is issued by the Asset Standards Authority as a notification to remove from

use RailCorp document EP 08 00 00 02 SP Overhead Wiring Maintenance Standards, Version

4.0.

EP 08 00 00 02 SP is a legacy document and shall be used for reference purposes only. ASA

standard T HR EL 08011 ST Overhead Wiring Maintenance Standards, Version 1.0 supersedes

this document.

Authorisation

Technical content prepared by

Checked and approved by

Interdisciplinary coordination checked by

Authorised for release

Signature

Name Wilfred Leung Neal Hook John Paff Graham Bradshaw

Position Principal Engineer Overhead Lines and Cables

Lead Electrical Engineer

Acting Chief Engineer Rail

Principal Manager Network Standards & Services

Asset Standards Authority A4118698 © State of NSW through Transport for NSW of 1

mailto:[email protected]

http://www.asa.transport.nsw.gov.au/

Engineering Standard Electrical Overhead wiring

Engi

neer

ing

Stan

dard

EP 08 00 00 02 SP

OVERHEAD WIRING MAINTENANCE STANDARDS

Version 4.0

Issued June 2013

Owner: Chief Engineer Electrical

Approved by:

Neal Hook Chief Engineer Electrical

Authorised by:

Neal Hook Chief Engineer Electrical

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

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RailCorp Engineering Standard — Electrical — Overhead wiring Overhead wiring maintenance standards EP 08 00 00 02 SP

© RailCorp Page 2 of 23 Issued June 2013 UNCONTROLLED WHEN PRINTED Version 4.0

Document control

Version Date Summary of change July 2008 Last Technical Review

3.0 May 2010 Application of TMA 400 format 4.0 June 2013 See Table below

Summary of changes from previous version

Summary of change Section Document re-formatted and re-organised All Section on “Introduction” renamed “Scope and application” and expanded 1 References and definitions updated 2 & 3 Relevant provisions from EP08000006SP (now superseded) updated and included in this document 4

Relevant provisions from SRA document EP08010001ST updated and included in this document 6

Maintenance standards for conductor splices, dropper arrangements, section insulators, insulated knuckles, surge arresters and wood pole support structures added 7 - 12

Corrective maintenance triggers and base safety or operating limits re-organised and updated; maximum times to complete corrective actions added. Refer to supporting document in file for details.

13 & 14

Relevant provisions from EP08000003SP (now superseded) updated and included in this document 14

Base safety and operating limits added for • Twist in polymeric insulator • Vegetation clearance • Weight tension regulator wire rope

14

Base safety and operating limits removed for: Clearance from catenary to overline bridge – Covered by criteria in static and passing clearances, signs of arcing and damage to conductors

14

Requirements for data set associated with overhead wiring maintenance added 15

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Contents

1 Scope and application............................................................................................................4 2 References...............................................................................................................................5 2.1 Australian and international standards......................................................................................5 2.2 RailCorp documents..................................................................................................................5 3 Definitions................................................................................................................................5 4 Vegetation clearances ............................................................................................................6 5 Maintenance of overhead wiring to design ..........................................................................6 6 Contact wire.............................................................................................................................7 6.1 Contact wire material ................................................................................................................7 6.2 Contact wire wear .....................................................................................................................7

6.2.1 Measurements ...........................................................................................................7 6.2.2 Contact wire condemning size...................................................................................8 6.2.3 Removal of localised contact wire wear points..........................................................9 6.2.4 Contact wire elastic limits ..........................................................................................9

7 Conductor splices.................................................................................................................10 7.1 Catenary splices......................................................................................................................10 7.2 Contact splices........................................................................................................................11 8 Dropper arrangements .........................................................................................................11 9 Section insulators .................................................................................................................11 10 Insulated knuckles ................................................................................................................11 11 Surge arresters......................................................................................................................12 12 Wood pole support structures.............................................................................................12 13 Corrective maintenance triggers.........................................................................................12 13.1 General....................................................................................................................................13 13.2 Conductors..............................................................................................................................14 13.3 Conductor fittings ....................................................................................................................15 13.4 Switching and feeding arrangements......................................................................................16 13.5 Support and registration arrangements ..................................................................................17 13.6 Anchor arrangements..............................................................................................................17 13.7 Support structures...................................................................................................................18 14 Base safety or operating limits............................................................................................18 14.1 General....................................................................................................................................19 14.2 Conductors..............................................................................................................................20 14.3 Conductor fittings ....................................................................................................................21 14.4 Switching and feeding arrangements......................................................................................21 14.5 Support and registration arrangements ..................................................................................22 14.6 Anchor arrangements..............................................................................................................22 14.7 Support structures...................................................................................................................22 15 Data set associated with overhead wiring maintenance ..................................................23

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1 Scope and application Preventative maintenance of the RailCorp 1500V dc overhead wiring (OHW) system shall be done in accordance with the RailCorp Technical Maintenance Plan.

This document sets out maintenance policies and parameters associated with the OHW system including:

• Vegetation management • Maintenance tolerances with respect to design • Contact wire • Catenary and contact splices • Section insulators • Insulated knuckles • Surge arresters • Wood pole support structures

It also includes • OHW maintenance tolerances and conditions that trigger corrective maintenance

actions that do not require urgent repair work. The maximum times to complete the corrective actions are also specified.

• Base safety or operating limits , which are the threshold conditions at or below which urgent repair work to the overhead wiring work shall be carried out.

Except where immediate repair action is required as per this document, a risk analysis shall be carried out immediately after a breach of any of the base safety and operating limits is found. Restrictions on overhead wiring and/or train operations may have to be imposed prior to the completion of the repair work. Such restrictions may include:

• Track speed limits • Suspension of train services through the affected area • Removal of power from overhead wiring

This document does not include maintenance triggers for overhead wiring structures and their associated bonding arrangements. Overhead wiring structures are maintained by the Civil discipline. Maintenance triggers for structure bonding arrangements are covered in EP 12 20 00 01 SP “Bonding of overhead wiring structures to rail”. However, this document requires the overhead wiring maintainer to report obvious visual defects to the maintainers of these assets.

The following documents have been incorporated into this document and with the release of this document are withdrawn:

EP 08 00 00 03 SP Overhead wiring base safety and operating standards EP 08 00 00 06 SP Vegetation control near 1500V dc equipment (OHW) State Rail Authority document EP 08 01 00 01 ST Contact wire condemning size and measuring policy

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2 References

2.1 Australian and international standards EN 50119:2009 Railway applications – Fixed installations – Electric traction overhead contact lines EN 50122-1:2011 Railway applications – Fixed installations – Electrical safety, earthing and the return circuit – Part 1: Protective provisions against electric shock

2.2 RailCorp documents EP 00 00 00 00 MP Electrical Technical Maintenance Plan EP 00 00 00 13 SP Electrical power equipment – Design ranges of ambient conditions EP 08 00 00 12 SP Level crossings – OHW requirements EP 08 00 00 15 SP Overhead wiring construction and commissioning EP 08 00 00 16 SP Designations of overhead wiring conductor systems EP 08 00 00 24 SP Contact wire EP 10 01 00 01 SP Wood pole serviceability EP 10 01 00 02 SP HV aerial line maintenance standards EP 10 01 00 03 SP HV aerial line base safety and operating standards EP 10 01 00 05 SP Requirements for electric aerials crossing RailCorp infrastructure EP 12 20 00 01 SP Bonding of overhead wiring structures to rail EP 19 00 00 01 SP DCCB and Delta I relay setting calculation method ESC 210 Track geometry stability ESC 330 Overhead wiring structures and signal gantries ESR 0001-100 Minimum operating standards for rolling stock – General interface standards TMC 212 Survey TMC 331 Design of overhead wiring structures & signal gantries

3 Definitions Contact wire gradient

Ratio of the difference in height of the contact wire at two successive supports to the length of the bay.

Contact wire elastic limit

The elastic limit for a material is the stress beyond which permanent deformation will occur. For the purpose of this document, the elastic limit of a contact wire is the thickness of a contact wire at a localised wear point below which permanent deformation will result when the wire is subjected to the maximum tension at the limits of design operating conditions.

Heel height The vertical distance between the contact wire at the pull off arm and the pivot point at the heel of the pull off arm.

Passing clearance The minimum clearance required between live parts of overhead wiring equipment and any earthed material or rail vehicle, or between the pantograph and any earthed material, under any permissible conditions of operation and maintenance of vehicles, track and overhead wiring equipment.

Static clearance The minimum distance required between live parts of overhead wiring equipment (under any permissible conditions of maintenance when not subject to uplift from a pantograph) and a structure or earthed part of the overhead wiring equipment.

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4 Vegetation clearances Vegetation near overhead wiring shall be maintained and controlled so that it is not within:

• 3m of live exposed 1500V equipment • 1.5m of overhead wiring structures and guys, and dead overhead wiring

conductors

Vegetation that has been assessed to be at risk of falling into the overhead wiring shall also be removed, even if it is located outside of the clearance envelopes specified above.

Allowance for regrowth between inspection and maintenance cycles shall be made when undertaking vegetation control activities.

All vegetation control activities shall be undertaken in accordance with the requirements of RailCorp’s Environmental Management System and Safety Management System.

5 Maintenance of overhead wiring to design New or rebuilt overhead wiring shall be constructed and commissioned to the approved and accepted design, and within the tolerances stipulated in EP 08 00 00 01 SP.

After commissioning, the OHW shall be maintained so that deviations from the approved and accepted design are within the tolerances set out in 0. These tolerances are required to ensure pantograph security with an effective pantograph half-width of 700mm (see drawing CV 0131343), and with the allowable vehicle movement and track tolerances specified in ESR 0001-100 and ESC 210 (see drawings EL 0006421-2).

The OHW design geometry at a structure is defined with reference to the relevant Track Control Mark (TCM) for the structure. Within the Electrical discipline, this TCM is also referred to as the “reference nail” (when installed on a mast) or “brass bar” (when installed in rock foundation). Critical dimensions of the design track geometry relative to the TCM at the structure location are given in the survey plaque associated with the TCM. Refer to RailCorp documents ESC 210 and TMC 212.

If the track is positioned outside of tolerances, it may be necessary to temporarily adjust the overhead wiring outside of the tolerances specified in 0 to allow for train running. Under these circumstances, both track and overhead wiring shall be restored to within the specified tolerances from design as soon as practicable.

Parameter Maintenance tolerances to design Catenary height +/- 50mm Contact height +/- 50mm, subject to minimum contact height

conditions in section 13.2Contact stagger +/- 50mm Pull off arm heel height +/- 25mm

Table 1 - OHW maintenance tolerances to design

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6 Contact wire

6.1 Contact wire material Contact wire material is identified by means of grooves provided at the upper lobe of the wire. The number of identification grooves provided for each type of material is:

• Cadmium copper – Nil • Hard drawn copper – 1 • Tin bearing copper – 2

Except as noted below, tin bearing copper contact wire in accordance with EP 08 00 00 24 SP shall be used for replacement of existing contact wires.

Settings of relevant dccb’s shall be checked, and adjusted where necessary, in conjunction with all contact wire replacement / renewal if the existing contact wires are not tin bearing copper. Where the dccb settings do not allow the replacement of existing hard drawn copper contact wires by tin bearing copper wires, hard drawn copper contact wires in accordance with EP 08 00 00 24 SP shall be used for the replacement.

Replacement of localised worn hard drawn copper contact wire by a short piece (< 10m) of tin bearing copper contact wire is permissible.

6.2 Contact wire wear

6.2.1 Measurements The severity of localised contact wire wear is generally determined by measuring the contact wire thickness at the thinnest point of the localised wear area. The thickness is measured along an axis perpendicular to the bottom (wearing surface) of the contact wire. However, where contact wire side wear (eg at wire junctions) is also observed, a measurement along the axis perpendicular to the side wear surface shall also be made and recorded. The cross section area of the contact wire at the thinnest point, and the corresponding safety factor at limiting operating conditions, shall be determined from these two measurements for contact wire with side wear.

Contact wire thickness measurement shall be taken with an instrument with an accuracy of ± 0.05mm, and recorded in units of millimetres to the first decimal place, eg 8.9mm.

Contact wire thickness measurements shall be taken periodically in accordance with the RailCorp Electrical Technical Maintenance Plan. Measurements shall be made at the thinnest point as close as practicable at the following locations:

• Pull off arms • Contact wire full splices • Kinks in the contact wire • Contact wire knuckles • Pantograph forking in points • Section insulators • Wearing strips – Measurements shall be made for both the contact wire and the

wearing strip wire • Other localised thin spots observed from sighting along the contact wire between

the above measurement locations

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6.2.2 Contact wire condemning size The contact wire condemning size is the contact wire thickness at a localised wear point below which the localised wear has to be removed. See Table 8.

Condemning sizes of contact wires in the RailCorp overhead wiring network are given in Table 2 and Table 3. The condemning sizes are determined with the following criteria:

• A minimum factor of safety of 2.0 at the limit operating conditions • A margin of 10% is added to the maximum calculated conductor tensions, as

determined by the conductor system details and ambient conditions stipulated in EP 00 00 00 13 SP and EP 08 00 00 16 SP. This margin is made to allow for tolerances such as those in tension regulator weights and contact wire dimensions.

• The condemning contact wire thickness shall not be less than 8.1mm for 137mm2 contact wire, and 9.7mm for 193 mm2 contact wire. These dimensions correspond to the thickness of a contact wire with the semi-circular section fully worn, plus a safety margin of 1.5mm. See RailCorp Drawings EL 0040770 and EL 0189852.

• A margin of 0.6mm is added to the calculated condemning sizes for installations inside tunnels to allow for difficulty in detecting thin wire spots from patrols

The nominated contact wire condemning sizes are not applicable to conductor systems 26 and 35 (fixed anchored with 137mm2 contact wire at a tension of 12.46kN at 21oC). Refer to RailCorp Engineering if such systems are encountered in maintenance.

The values given in Table 2 and Table 3 are only valid for contact wires with no side wear. For contact wires with side wear, the cross section area shall be determined using the two measurements as set out in section 6.2.1. The wire shall be "condemned" if the cross section area is less than or equal to the "Section area at condemning" listed in Table 2 and Table 3.

It is unlikely to have a contact wire run to be uniformly worn down to the “50% worn” section area in accordance with EP 19 00 00 01 SP before part or all of the wire run has to be replaced to remove localised wear points. Contact wire resistance is therefore not considered in the determination of condemning sizes.

Material Configuration Location Condemning

size (mm)

Section area at condemning

(mm2)

Hard drawn copper Regulated All 8.1 81.1 Regulated All 8.1 81.1

Fixed twin contact All 8.8 90.7 Tin bearing copper

Fixed single contact All 9.0 93.1 Regulated All 8.1 81.1

Fixed twin contact All 8.8 90.7 Cadmium copper

Fixed single contact All 9.0 93.1

Table 2 - Condemning sizes for 137 mm2 contact wire with no side wear

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Material Configuration Location Condemning

size (mm)

Section area at condemning

(mm2)

Hard drawn copper Regulated All 10.9 130.9 Regulated All 9.7 111.8

Fixed single contact All areas

except City and ESR tunnels

11.6 141.5 Tin bearing copper

Fixed single contact City and ESR tunnels 10.7 127.7

Regulated All 9.7 111.8

Fixed single contact All areas

except City and ESR tunnels

11.2 135.5 Cadmium copper


Table 3 - Condemning sizes for 193 mm2 contact wire with no side wear

6.2.3 Removal of localised contact wire wear points Localised contact wire wear points at or below the condemning size are to be removed by replacing a length of the contact wire containing the wear point. The replacement length shall be spliced into the existing contact wire run by approved contact wire splices in accordance with section 7.2.

Where it is not practicable to have the localised wear point removed within the time specified in Table 8, a contact wire wear strip may be installed in accordance with RailCorp Drawing EL 0026992 as a temporary measure.

6.2.4 Contact wire elastic limits For the purpose of this document, the elastic limit stress of contact wire is taken to be 55% of the ultimate tensile stress, and is the base safety or operating limit for localised contact wire wear. Elastic limits of contact wires in the RailCorp overhead wiring network are given in Table 4 and Table 5.

Refer to EP 08 00 00 02 SP for the identification of contact wires and the applicable maximum conductor tensions.

The nominated elastic limits are not applicable to conductor systems 26 and 35 (fixed anchored with 137mm2 contact wire at a tension of 12.46kN at 21oC). Refer to RailCorp Engineering if such systems are encountered in maintenance.

The nominated limits are also not applicable to contact wires with side wear. For contact wires with side wear, the cross section area of the wire shall be determined in accordance with section 6.2.1. The maximum stress at the localised wear point shall be calculated to determine if the elastic limit has been exceeded.

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Material Configuration Location Elastic limit

(mm)

Section area at elastic limit

(mm2) Hard drawn copper Regulated All 7.6 74.2

Regulated All 6.8 63.1 Fixed twin contact All 8.2 82.4 Tin bearing copper

Fixed single contact All 8.4 85.1 Regulated All 6.7 61.7

Fixed twin contact All 8.1 81.1 Cadmium copper

Fixed single contact All 8.2 82.4

Table 4 - Elastic limits for 137 mm2 contact wire with no side wear

Material Configuration Location Elastic limit

(mm)

Section area at elastic limit

(mm2) Hard drawn copper Regulated All 10.1 118.3


Fixed single contact All areas except

City and ESR tunnels

10.7 127.7 Tin bearing copper



Fixed single contact All areas except

City and ESR tunnels

10.4 123.0 Cadmium copper


Table 5 – Elastic limits for 193 mm2 contact wire with no side wear

7 Conductor splices

7.1 Catenary splices Approved helical fittings (RailCorp stock codes 1567627, 1059393 and 1567643) shall be used for splicing 165mm2, 270mm2 and 327mm2 catenaries. These fittings may also be used to repair damages to these catenaries if less than 25% of the wires in the outermost layer have been severed or have other equivalent damage.

Droppers, in-span feeders, and other fittings that clamp on the catenary wire may have to be relocated so that they are clear of the helical fitting.

Splicing of 510mm2 catenary shall be done by terminating the conductors, installing a suitable link between the terminating clamps and connecting the “tails” of the catenary conductors together, in a manner similar to that shown in RailCorp drawing EL0011035. The termination clamp shall be RailCorp fitting number 281/9 (drawing EL 0034083).

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7.2 Contact splices “In running” contact wires shall be spliced by RailCorp fitting number 462/8 (stock code 1023894) with suitable wedges and shims in accordance with drawing EL 0002017.

For worn contact wires, copper shims are installed in the mouth of the splice fitting to ensure that the running edge of the contact wire is flush with the underside of the splice. Table 6 gives a guide to the number of shims to be used. The contact wire splice is not suitable for contact wires with a thickness less than 9.9mm. Hence contact wire replacement may have to be extended beyond the localised wear point.

As contact wire splices are “hard spots” for pantograph running, no more than 3 contact splices shall be installed between two adjacent support structures.

Number of shims (Drawing EL 0034703) Contact wire thickness

(mm) Fitting 462/6 (Long) Fitting 462/16 (Short)

16.4 – 15.5 (New 193mm2)

0 0

15.4 – 14.6 1 0 14.5 – 13.5 (New 137mm2)

2 0

13.4 – 12.5 1 1 12.4 – 11.5 2 1 11.4 – 10.5 1 2 10.4 – 9.9 2 2

Table 6 – Guide to shim installation requirements for contact wire full splice

8 Dropper arrangements Where existing droppers have to be replaced, they shall be replaced by insulated droppers in accordance with EP 08 00 00 01 SP.

9 Section insulators Where existing section insulators have to be replaced, they shall be replaced by “Type 6” section insulators in accordance with EP 08 00 00 01 SP.

10 Insulated knuckles There is currently no suitable replacement for insulated knuckles with timber beams. Existing overhead wiring with such insulated knuckles may need to be re-configured when the knuckles are no longer suitable to remain in service. The Maintainer shall plan the required modifications with sufficient time allowed for design and construction.

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11 Surge arresters Surge arresters had been installed on the overhead wiring at approximately mid-way between substations in some areas of the RailCorp network. This practice is no longer required. Existing “mid-way” surge arresters shall be removed at the next hands-on inspection or when the overhead wiring in the area is modified.

Surge arresters are still required at cable to aerial feeder junction locations. See EP 08 00 00 01 SP.

12 Wood pole support structures Refer to EP 10 01 00 01 SP for serviceability criteria of wood poles.

Where an existing overhead wiring wood pole support structure has to be replaced, it shall be replaced by one or more structure(s) satisfying the requirements of ESC 330 and TMC 331.

13 Corrective maintenance triggers Common conditions that trigger corrective maintenance actions are listed in the sub-sections below. Care shall be exercised by the Maintainer to ensure that base safety and operational limits (see section 14) are not breached before the completion of corrective actions.

The values listed under “time to complete corrective action” are maximum allowable times. Depending on the nature and extent of the defect, shorter time periods may need to be applied for individual cases to ensure that the risks to personnel safety and train operations caused by failure of the identified defect(s) are as low as reasonably practicable. Longer time periods to complete corrective action may be approved by the relevant Maintenance Engineer Electrical on a case by case basis if the time extension is justified by a risk analysis.

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13.1 General

Parameter Corrective maintenance trigger Time to complete corrective action

Cracked or chipped porcelain 3 months

Excessive pollution build up 6 months

Corroded cap or tongue 3 months

Twist in polymeric insulator greater than 30o but less than 40o 3 months Insulators

Insulator skirt clearance above in running contact wire –

< 300mm for porcelain insulators

< 200mm for composite insulators

3 months

Small parts steelwork

Signs of excessive corrosion, deformation (bending, cracks), etc 6 months

Fasteners Loose, missing or corroded fasteners that are not critical to the functioning of the fittings / assemblies (eg those with redundancies in the number of fasteners)

6 months

Vegetation clearance

Vegetation within the clearance envelopes specified in section 4, or assessed to be potentially at risk of falling into OHW

6 months

(Note 1)

Static clearance (normal) < 150mm 3 months

Static clearance to non-conductive material (eg non-reinforced concrete or brickwork) < 120mm 3 months

Passing clearance (normal) < 200mm 3 months

Passing clearance to non-conductive material (eg non-reinforced concrete or brickwork) < 150mm 3 months

Clearances

(Note 2)

Vertical clearance from catenary to overline bridge less than the minimum values stipulated in EP 08 00 00 01 SP. 3 months

Signs Missing, obscured or wrong information on signs due to vandalism, corrosion or degradation 3 months

Table 7 – Corrective maintenance triggers - General

Note 1 – An assessment should be made of the rate of vegetation growth. A shorter time frame for completion of corrective action may be required as a result of the assessment.

Note 2 – Passing clearance to pantographs may be analysed and determined by the RailCorp “PanGauge.xlt” spreadsheet program.

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13.2 Conductors


Signs of conductor stranding, annealing, burning, abnormal wear, kinks, etc 3 months

Catenary / contact alignment across track at a dropper > 20% of dropper length (except where the wires are designed to be not aligned with each other, eg Liverpool to Glenlee)

6 months

Clearance of span wire above in running contact wire (without fender fitting 395 or 395/1 as per drawings EL0251310-1) < 300mm

3 months

Clearance between 2 parallel wires of different electrical sections (eg mid-bay in open overlaps on tight curves) under worst case of blowout < 150mm

6 months

General

Clearance to HV aerial lines less than that stipulated in EP 10 01 00 05 SP 6 months

< 4.75m in open route 6 months

< 4.65m at low bridges and tunnels 6 months Contact wire height

(Note 1) Contact wire height less than minimum stipulated in EP 08 00 00 12 SP at a level crossings 6 months

Contact wire stagger

> 460mm (Priority 2 exceedence for OHW geometry measuring vehicle) 6 months

Contact wire gradient

Contact wire gradient exceeds maximum values listed in Table 1 of EP 08 00 00 15 SP. 6 months

Contact wire thickness

Contact wire thickness at or below condemning size. See section 6.2 6 months

Overlaps Signs of poor running performance such as arcing, burning and excessive wear;

Contact wire “scissor” in excess of 50mm 6 months

Catenaries crossing Clearance between catenary conductors < 20mm 3 months

Auxiliary feeder

Clearance of auxiliary feeder at support < 400mm above tie rod chain or portal boom 6 months

Table 8 - Corrective maintenance triggers – Conductors

Note 1 – For fixed anchored overhead wiring, minimum contact height at the maximum design conductor temperature (generally 55oC for open route and 45oC in tunnels) shall be determined by height and temperature measurements. RailCorp program MinCont may be used to calculate the minimum contact height from these measurements.

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13.3 Conductor fittings


General Signs of stranding, annealing, burning, abnormal wear, looseness, etc for feeding jumpers, potential jumpers and in-span feeders.

3 months

Dropper broken or detached from contact wire with no objects below contact 3 months

Dropper rubbing against another conductor or fouling sliding knuckle 1 week

Vertical alignment of standard dropper along track > 20% of dropper length (drifted droppers) 3 months

Droppers

Vertical alignment of short dropper along track > 10mm 3 months

Vertical alignment of in-span feeder along track > 20% of in-span feeder length 6 months In-span

feeders In-span feeder rubbing against another conductor 3 months

Contact wire full splice

Excessive wear indicated by the development of a “V” shape at the point where the contact wire enters the body 6 months

Signs of poor running performance such as arcing, burning and excessive wear 3 months

Section insulators

Bent or damaged arcing horns, damaged or skewed runners, guy slackness, loose attachment bolts, damaged insulator.

If a risk assessment determines that pantographs may suffer damage then the base safety parameters are to apply.

1 week

Knuckles Signs of excessive degradation or corrosion, out of adjustment, loose attachment bolts, etc (Note 1) 3 months

Over-run protection Signs of damage or incorrect alignment 3 months

Table 9 - Corrective maintenance triggers – Conductor fittings

Note 1 – Consideration should be taken for possible long lead times to implement corrective maintenance actions for insulated knuckles with timber beams. See section 10.

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13.4 Switching and feeding arrangements


General Signs of stranding, annealing, burning, abnormal wear, looseness, etc for feeders and jumpers. 3 months

Signs of burning or overheating.

Misalignment of blade with jaws.

Blade not fully engaged with jaws when switch is in closed position.

3 months

Surface deterioration or contamination of insulated operating rod 6 months

Operating handle mechanism damaged or not operating freely and smoothly

Parts of mechanism loose or missing.

Operator platform damaged or missing

Bonding between switch handle and operator platform damaged or missing

Rail connection cable (where applicable) missing, damaged, or disconnected from mast or rail.

3 months

(Note 1)

Switches

Labels (switch identification and switch handle position) incorrect, missing, obscured or not securely attached.

3 months

(Note 2)

Clearance of aerial feeder to adjacent track < 1.5m when they are of different electrical sections 3 months

Minimum electrical clearance of aerial feeders from other conductors at crossing under worst case (wind, wire movement, temperature, etc) < 150mm

3 months Aerial feeders

Feeders do not have sufficient slack to allow for full range of conductor movement 3 months

Surge arresters Damaged or missing connection to earth electrode 1 week

Structure earthing and bonding

Switch or feeding structure not earthed or bonded to rail in accordance with design

3 months

(Note 2)

Table 10 - Corrective maintenance triggers – Switching and feeding arrangements

Note 1 – Arrange for switch operation to be disabled immediately by appropriate locking mechanism in accordance with the RailCorp Safety Management System, and arrange for Advice of Alteration to Electrical Operating Diagrams.

Note 2 – Install temporary signs or warning labels immediately.

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13.5 Support and registration arrangements


Pull off arm Heel height negative but heel is clear of pantograph running from observation of the passage of trains 3 months

Catenary support

Deviation from design along track position > 100mm, having due regard to conductor temperature and distance from fixed anchor

6 months

Table 11 - Corrective maintenance triggers – Support and registration arrangements

13.6 Anchor arrangements


Excessive corrosion (with more than 10% loss in section) or damage to guy rods, fittings or wires 6 months Guy

arrangement Lugs or fittings buried by ballast 6 months

Fixed midpoint arrangement

Signs of conductor movement through clamps 3 months

Weights unable to move freely up and down with conductor temperature changes 3 months

Movement of weight stack through the design conductor temperature range (as determined by RailCorp program “WeightSet.xlt”) is impeded due to the presence of obstructions or incorrect position of weight stack.

To be determined from extent of

allowable travel and consideration

of time of year

Weight tensioner arrangement

Yoke plate of combined weight tensioner arrangement jammed 3 months

Damage (eg excessive corrosion or stranding) to tension regulator wire rope 3 months

Table 12 - Corrective maintenance triggers – Anchor arrangements

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13.7 Support structures


Clearance to HV aerial lines

Clearance to high voltage aerial lines less than that stipulated in EP 10 01 00 05 SP 6 months (Note 1)

Structure deformation

Deformation of structures, eg twisting of mast or drop vertical

Report to Civil discipline within 1 day

Signs of movement in ground Report to Civil discipline within 1 day Structure and

guy foundation Corroded steel work, eg bridge and tunnel supports, anchor lugs, etc

Report to Civil discipline

Drop verticals Clearance of drop vertical to superelevated centreline of adjacent track < 1500mm 3 months

Labels Incorrect, missing, or obscured structure labels 3 months (Note 2) Structure bonding

Missing, damaged, or incorrect installation of structure bonding arrangement 3 months

Wood poles See EP 10 01 00 02 SP

Table 13 - Corrective maintenance triggers – Support structures

Note 1 – Temporary warning signs and / or access barriers to be in place within one day

Note 2 - Temporary labels to be in place for critical structures (eg structure with switch) within one day

14 Base safety or operating limits Common base safety or operating limits, as well as maximum allowable time to complete repairs, are listed in the sub-sections below.

The values listed for “time to complete corrective action” are maximum allowable times. Immediate action should be initiated if there is a risk of imminent failure. The maximum allowable times may be varied by the Maintenance Engineer Electrical as a result of a risk analysis with consideration given to the applicable site specific operating environment and/or the implementation of temporary measures.

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14.1 General

Parameter Base safety or operating limit

Immediate checks and / or temporary measures

Time to complete corrective action

Loss of insulation (eg broken porcelain) Stop trains Immediate

Sustained arcing across insulator Stop trains Immediate

Insulator at risk of detachment failure due to excessive corrosion of tongue or cap

1 day

Twist in polymeric insulator > 40o 1 day Insulators

Insulator skirt clearance above in running contact wire –

< 150mm for porcelain insulators

< 75mm for composite insulators

1 day

Small parts steelwork

Risk of component failure due to excessive corrosion 1 day

Vegetation clearance

Vegetation touching live overhead wiring or pantograph Stop trains Immediate

Signs of arcing across an air gap Immediate

Static clearance to “earthed” metalwork < 50mm

Install bonding to rail via a spark gap if metalwork may be touched

1 day Static clearances

Static clearance to “earthed” non-conductive material < 20mm

1 day

Signs of striking by or arcing from pantograph Stop trains Immediate

Passing clearance to “earthed” metalwork < 50mm

Install bonding to rail via a spark gap if metalwork may be touched

1 day Passing clearance

(Note 1) Passing clearance to “earthed” non-conductive material < 20mm

1 day

Table 14 – Base safety or operating limits – General

Note 1 – Passing clearance to be pantographs shall be determined by the RailCorp “PanGauge.xlt” spreadsheet program.

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14.2 Conductors




Clearance between 2 parallel wires of different electrical sections (eg midbay in open overlaps) under worst case of blowout < 100mm

Advise Electrical Operating Centre (EOC) immediately

As per instruction from EOC

Clearance of span wire above in running contact wire (without fender fitting)

< 75mm at support structure

< 150mm at mid bay

Impose speed restriction under continuous observation 1 day

General

Object hanging below the in running contact wire Stop trains Immediate

< 4.47m Check with the EOC to see if the relevant DCCB’s are tripping. Perform immediate repairs if so.

1 day

< 4.9m at a public road level crossing, or at a service road level crossing without a warning frame

Advise Police (for public road level crossings) and use traffic controllers to exclude high vehicles from the level crossing.

1 day Contact wire height

< 0.3m above the maximum permissible vehicle height at a service road level crossing with a warning frame.

Use traffic controllers to exclude high vehicles from the level crossing.

1 day

Contact wire stagger

> 500 mm (Priority 1 exceedence for OHW geometry measuring vehicle)

Observe passage of trains, and impose speed restrictions (Note 1) if contact wire is within 100mm of the pantograph horn.

1 day

Contact wire thickness

Contact wire thickness at or below elastic limit. See section 6.2.4.

Repairs may be deferred by up to one day if the temperature remains sufficiently high for fixed anchored systems, or if the contact wire tension is reduced temporarily by removing sufficient number of weights from the tension regulator.

Immediate

Damaged conductors

Signs of damage (eg stranding) with less than half the original conductor cross sectional area remaining.

1 day

Table 15 – Base safety or operating limits – Conductors

Note 1 – Do not reduce speed on curve if excessive stagger is at structure but midbay stagger is acceptable.

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14.3 Conductor fittings




General

Any damaged equipment (eg broken / detached droppers, in-span feeders, wear strips, jumpers, knuckles, etc) hanging below the contact wire

Stop trains Immediate

Cast tension fittings

Cracked or fractured cast tension fittings Stop trains Immediate

Excessive wear with the the distance from the end of the splice to the vertex of the “V” shape > 135mm

1 day Contact wire full splice

Deformation along the edge of the “V” shape opening 1 day

Section insulators

Broken / detached runner or guy or any outcome from a risk assessment that determines an unacceptable risk in damage to pantographs.

Stop trains, except that trains may proceed under continuous observation if approved by the Maintenance Engineer Electrical

Immediate

Electrical connections

Signs of excessive burning that may cause imminent failure of the conductors

Stop trains Immediate

Table 16 – Base safety or operating limits – Conductor fittings

14.4 Switching and feeding arrangements




Aerial feeders hang below contact wire Stop trains Immediate

Aerial feeders

Feeder displaced and bridging two electrical sections (electrical protection compromised)

Advise EOC 1 day, unless immediate repair is required by EOC

Table 17 – Base safety or operating limits – Switching and feeding arrangements

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14.5 Support and registration arrangements




Dislodged pin or fastener which may cause fitting (eg pull off arm) to fall below contact wire and/or in front of train

Stop trains Immediate Pins / fasteners

Partially dislodged pin / fastener

Monitor and observe passage of trains Immediate

Signs of striking by pantograph Immediate Pull off arm heel height Clearance of pantograph to

heel of pull off arm < 20mm Impose speed restriction 1 day

Table 18 – Base safety or operating limits – Support and registration arrangements

14.6 Anchor arrangements




Weights bottomed or pulley blocks in contact with each other

Patrol tension length and observe performance of OHW with passage of trains. Impose speed restriction if required.

1 day, if no other critical issue is identified by the patrol.

Weights “top out” at pulley

Patrol tension length and observe performance of OHW with passage of trains. Impose speed restriction if required.

1 day, if no other critical issue is identified by the patrol.

Weight tensioner arrangement

Damage (eg excessive corrosion and/or stranding) to more than half of the strands of the wire rope

1 day

Table 19 – Base safety or operating limits – Anchor arrangements

14.7 Support structures




Guy foundation

Guy foundation moving in ground

Stop trains. Report to Civil Discipline immediately.

Bond wire hangs below contact wire Stop trains Immediate

Bond wire hanging and touching or near live equipment

Check spark gap arrangement. Repair immediately if arcing or if spark gap has been activated.

1 day, if there is no arcing and spark gap has not been activated

Structure bonding

Damage to bond wire insulation at crossing with rail Immediate

Wood poles See EP 10 01 00 03 SP

Table 20 – Base safety or operating limits – Support structures

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15 Data set associated with overhead wiring maintenance The Maintainer shall ensure that the data set associated with overhead wiring, as stipulated in EP 08 00 00 01 SP is up to date and in accordance with the as-built configuration.

Any deviations from standard operating conditions, such as a maximum conductor temperature higher than 60oC for regulated overhead wiring with “short” tension lengths, shall be clearly indicated on the relevant layout drawing(s).

Where urgent repairs are carried out, the maintainer shall ensure that the data set associated with the overhead wiring is updated in accordance with the as-built configuration as soon as practicable, and not less than one month after the completion of the repairs.

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ep 08 00 00 02 sp - overhead wiring maintenance standards · 2019-05-21 · subject: withdrawal of...

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