Edition: December 2010 Part 1080: Rail Signalling

PART 1080

RAIL SIGNALLING

CONTENTS

1. General2. Signalling Infrastructure Plan3. Correlation Activities for Design4. Asset Condition Report5. Disconnection Activities6. Re-Connection Activities7. Testing and Commissioning Activities8. Hold Points

Appendix A: Certificate of Signalling – Conditional

Appendix B: Certificate of Signalling

1. GENERAL

This Part specifies the requirements for activities associated with signalling infrastructure.

Documents referenced in this Part are listed below and are contained at Appendix 21:

Draft – PTS WI - Installation of Track Connections

Draft - PTS WI - TI21 Tuning Units

Draft - PTS WI - Installation of Invensys M70 Point Machines

Draft - PTS WI - Installation of Train Automatic Warning Systems (PTS-R-10-SG-WKS-000000nn).

2. SIGNALLING INFRASTRUCTURE MANAGEMENT PLAN

The Contractor shall provide a Signalling Infrastructure Management Plan. The plan shall detail:

(a) the decommissioning and reinstatement method for the safe temporary disconnection and circuit modification, removal and protection of the existing line-side signalling infrastructure;

(b) the procedures for identifying the temporarily disconnected and removed equipment and its original position;

(c) re-instatement of the same temporarily disconnected and removed equipment in its original location following the track renewal works;

(d) the strategic approach to temporarily disable the active road and pedestrian crossings across the Adelaide Metropolitan Rail Network (AMPRN), track circuits and in addition to that, where applicable maintaining response level and the normal level crossing operation controlled by ARTC track circuits;

(e) the testing and commissioning strategy for re-commissioning the re-instated signalling equipment, signal interlocking and associated control circuits and level crossings;

(f) re-setting and re-adjusting the re-instated signalling equipment ready for normal service following the satisfactory completion of the track renewal works;

(g) where applicable the testing of the level crossing operation controlled by the ARTC track circuits as part of the full level crossing functional test; and

(h) how the interfaces between the Permanent Way and Signalling installation and testing work and personnel shall be coordinated and managed.

(i) as a separate document a Testing and Commissioning Plan for each applicable stage of the de-commissioning, reinstatement and recommissioning of the affected signalling equipment and cabling. This shall include applicable signalling work packages and associated programmes.

The Signalling Infrastructure Management Plan is a Controlled Document, vide Clause 140.4 “Document Control”. If not provided beforehand, the draft Signalling Infrastructure Management Plan (with the exception of

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the Testing and Commissioning Plan ), shall be submitted at least 4 weeks prior to the commencement of signalling disconnection works. Provision of the submission of the draft plan shall constitute a HOLD POINT.

The final Signalling Infrastructure Management Plan (with the exception of the Testing and Commissioning Plan ), shall be submitted at least 2 weeks prior to the commencement of signalling disconnection works. Provision of the submission of the final plan shall constitute a HOLD POINT.

3. CORRELATION ACTIVITIES FOR DESIGN

The master signalling plans, bonding plans, control tables, contact analysis sheets, circuit plans, location case wiring plans for the relevant sections of line are contained at Appendix 18. The Contractor shall verify the accuracy of the information provided. The Contractor may elect to conduct site surveys to validate track infrastructure / kilometerage and confirm “as-in-service status”. Any discrepancies found shall be reported to the Superintendent along with the Contractor’s proposal for rectifying the issue.

If discrepancy in the kilometerage for the line side signalling equipment is found between the signalling plans and the site survey, the site survey kilometerage shall be taken as the correct kilometerage and the Contractor shall update the plans to reflect the changes. The Contractor shall convert kilometerage to design chainage prior to any disconnection activity. The “as-in-service” locations with reference chainage shall be included in the Contractor’s design.All Signalling design shall be in accordance with the Signalling Design Criteria document as contained at Appendix 3.

4. ASSET CONDITION REPORT

2 weeks prior to disconnection activities the Contractor shall arrange and conduct a Signalling Line-Side Asset Condition Survey, along with:

- the Superintendent’s Representative

- a PTSOM representative

and provide a Signalling Asset Condition Status report for each item of signalling equipment as detailed on the Master Signalling plans for the relevant sections of line. This report shall detail the physical condition of all equipment including, but not limited to location cases, tuning units, AWS units, location case drawings, relays, termination points, signage, point machines, cable trunking, level and pedestrian crossing equipment. The report shall be augmented by photographic and/or video data to support the condition status.

Where any signalling infrastructure subject to the asset condition survey is altered or damaged as a result of the Contractor’s activities during the course of the Contract, the Contractor shall be responsible for returning the asset to the standard recorded at the commencement of work in the survey.

Provision of the submission of asset condition survey shall constitute a HOLD POINT.

In the event that signalling equipment is damaged by work activities and requires replacement the Contractor shall seek prior approval through the Superintendent for any alternative substitutes in lieu of a ‘like for like’ original replacement.

5. DISCONNECTION ACTIVITIES

5.1 Submission of Disconnection Documentation

The Contractor shall undertake the necessary disconnection design and plans shall be identified and marked accordingly as “Disconnection". The Contractor shall submit these plans with the associated Inspection and Test Plan to the Superintendent at least 2 weeks prior to the commencement of signalling disconnection works. The submitted plans shall be marked “For Construction”, and shall be provided in AutoCad format (providing the correlated version refer Clause 3, is provided in AutoCad), along with 2 x A3 colour copies. Provision of the submission of this information shall constitute a HOLD POINT.

The Contractor shall specifically address the disconnection activities in the Safety Management and Risk Management Plans as per the requirements of Part 161 Clauses 3 and 4 respectively.

5.2 ARTC Interface

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Where ARTC standard gauge track runs parallel to PTS broad gauge lines the Contractor shall maintain the normal level crossing operation on the standard gauge line at all times. The Contractor shall manage the ARTC Interfaces in accordance with the requirements of Part 174. Upon completion of the disconnection activities, a functional test shall be carried out on each level crossing to verify the operational integrity. This shall be specifically addressed in the Signalling Infrastructure Management Plan as per Clause 2(i).

5.3 Road Interface at Level Crossings with Traffic Signals

Locations of road traffic signals interfacing with rail signalling at level crossing are specified in the Contract Specific Requirements. Where these conditions exist, the normal operation associated with ARTC standard gauge line shall be maintained. Temporary modifications to the level crossing circuits shall include a common, manual mode of operation across both standard and broad gauge lines. This manual mode of operation shall also activate the road traffic light coordination circuits associated with the crossing operation on all lines.

5.4 Signalling Cables

Prior to the commencement of civil works, the position of the existing line-side and in-track signalling equipment that is to be temporarily disconnected and removed shall be clearly marked on site. Prior to disconnection and removal of the AWS permanent magnets and electro-magnets, the Contractor shall document the arrangement, orientation, position and shall identify and tag each piece of the equipment with its associated signal name and polarity of the cable terminations.

Prior to disconnecting the track circuit leads from the rails, the Contractor shall document each track lead polarity, lead colour and track-circuit identifier and its location. Each lead shall be identified and tagged or colour coded.

The Contractor is responsible for all equipment for the duration of the works. Following disconnection of signalling cables from rail the Contractor shall undertake Megger Testing of all cable for the purposes of identifying defective cable. The Contractor shall submit all cable test results and condition report to the Superintendent within 2 days after completion of conducting the tests. All signalling cable identified as having an insulation resistance value less then or equal to 5 MΩ shall be classified as defective and the Superintendent will provide direction to the Contractor as to the extent of cable to be replaced and the programming of these works.

5.5 Point Machines

Prior to disconnection of point machines and associated drive and detection rods, the Contractor shall document the arrangement, orientation, position and shall identify and tag each piece of the equipment with its location and point machine number.

The Contractor shall submit a part replacement list for each points machine to the Superintendent within 2 days after dismantling activities. The Principal will supply all replacement parts for points machines to the Contractor.

Cabling to the point machine and the termination arrangement shall be marked, tagged and recorded in accordance with the signalling circuit plans.

6. RECONNECTION ACTIVITIES

6.1 Submission of Reconnection Documentation

The Contractor shall undertake the necessary reconnection design and plans shall be identified and marked accordingly as “Reconnection". The Contractor shall submit these plans with the associated Inspection and Test Plan to the Superintendent at least 2 weeks prior to the commencement of signalling reconnection works. Provision of the submission of this information shall constitute a HOLD POINT.

6.2 AWS Installation

AWS track-mounted equipment position shall be re-installed by the Contractor at positions approximately at the same location as the original installation as detailed in the correlation survey unless otherwise specified by the Superintendent. The Contractor shall note that local adjustment to sleeper spacing maybe required in the vicinity of the AWS equipment in accordance with Part 1045 table 3.4 (c).

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Edition: December 2010 Part 1080: Rail Signalling

2 hours prior to the installation of AWS Units on new concrete sleepers the Contractor shall notify the Superintendent immediately following the completion of coring activities for a joint inspection on the sleepers. This inspection shall constitute a HOLD POINT.

AWS track-borne equipment shall be installed in accordance with the PTS Work Instruction for the Installation of Train Automatic Warning Systems (PTS-R-10-SG-WKS-000000nn).

6.3 Signalling Cables

Prior to reconnecting of any signalling cable (existing or new), to the signalling equipment all cable shall be Megger tested to verify that they have not been damaged as part of the Contractor work activities. Identified defective cable (in accordance with per Clause 5.4), shall replaced immediately by the Contractor and the Superintendent shall be notified.

6.4 Track Connections

Prior to reconnection of track circuits to the rail the Contractor shall identify each connection cable for each specific track circuit to ensure correct track polarities.

Track leads and bonding leads shall be installed in accordance with the PTS Work Instruction - Installation of Track Connections.

6.5 Point Machines

Due to the specific and unique nature of the points machines assemblies the Superintendent will arrange for a PTSOM Mechanical Fitter to witness assembly and advise of any unknown specific set up requirements. The Contractor shall provide minimum 3 days notice.

The PTS Work Instruction – Installation of Invensys M70 Electric Switch Machines, is provided to the Contractor for information only and shall not be interpreted as an implied work method statement.

On points, non complaint existing bonding shall be replaced with new bonding. When Erico 12/14 connections or equivalent cannot be fitted, CAD welding is to be used. Exposed bonds that could short-circuit must be insulated.

6.6 Tuning Units

Tuning units shall be installed in accordance with PTS Work Instruction - TI21 Tuning Units.

7. TESTING AND COMMISSIONING ACTIVITIES

7.1 Testing and Commissioning Plan

The Contractor is responsible for performing all Testing and Commissioning activities to reinstate all the affected signalling systems including (where applicable), active level crossings on the ARTC track.

The Contractor shall provide a Testing and Commissioning Plan as per the requirements of the Signalling Infrastructure Management Plan vide Clause 2 (i). The Contractor shall submit the Testing and Commissioning Plan to the Superintendent at least 6 weeks prior to the commencement of commissioning activities. Provision of the submission of this plan shall constitute a HOLD POINT.

7.2 Conditional Certificate of Commissioning

The Contractor shall notify the Superintendent 2 hours prior to the commencement of re-applying power to track circuits and signalling equipment. This notification shall constitute a HOLD POINT.

The Contractor shall reinstate the power feeds to the track circuits in the respective location box or relay room and close the links at the cable terminal associated with the track circuit and notify the Superintendent. On restoration of the power feeds and unless otherwise specified the Contractor shall adjust the track circuits in accordance with the manufacturer’s requirements and record the settings on the maintenance card and submit testing certification documentation. The Superintendent or his authorised representative reserves the right to check the setting and request that these be changed.

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The full functionality and integrity of each interlocking including re-instated line-side signals and active road and pedestrian crossing, to the extent applicable to each of the affected components of the overall signalling system, must be fully tested and certified by the Contractors qualified signal engineer. The Superintendent will provide a qualified independent signalling resource to witness the testing and commissioning activities and sign off on supporting documentation.

Upon completion of the testing and commissioning, the Contractor shall forward all signed testing documents, ITP’s and plans to the Superintendent for acceptance. The Contractor shall allow a minimum of 5 working days for this review. Upon satisfactory review the Superintendent will request the Contractor to submit a Conditional Certificate of Signalling, (refer Appendix A “Conditional Certificate of Signalling”), which shall be co-signed by

PTSOM Project Representative

Contractors Tester in Charge

Superintendents Independent Signalling Verifier

Any identified amendments to the certificate shall be hand marked on the original Conditional Certificate of Signalling. Provision of the submission of this certificate shall constitute a HOLD POINT. Test trains are not authorised to complete testing and commissioning activities until this certificate has been co-signed.

7.3 Test Trains and Certificate of Signalling

The Superintendent shall arrange with the PTSOM to provide test train(s) for validating the safety and integrity of the track and signalling system including active road and pedestrian crossings prior to reopening of the track for passenger services.

During test train(s) running, the Contractor shall appoint a Tester in Charge and fault-finding and rectification teams to log and rectify defects. These personnel are to be nominated in the Testing and Commissioning Plan.

The Superintendent will appoint an independent third party signal verifier to control the movements of the test train and verify the integrity of the signalling system. Upon successful completion of the test trains(s) running, rectification of agreed critical defects and the submission by the Contractor of the signed Inspection Test Plans and associated supporting documentation, a final certificate of signalling shall be issued from the Contractor to the Superintendent for co-signing. , (Refer Appendix B “Certificate of Signalling”).

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8. HOLD POINTS

The following is a summary of Hold Points; vide Part 140 "Quality System Requirements", referenced in this Part:

CLAUSE REF. HOLD POINT RESPONSE TIME

2. Submission of the draft Signalling Infrastructure Management Plan

4 weeks prior to disconnection activities

2. Submission of the final Signalling Infrastructure Management Plan

2 week prior to disconnection activities

4. Asset Condition Report Prior to disconnection activities

5.1 Submission of Disconnection Documentation 2 weeks prior to disconnection activities

6.1 Submission of Reconnection Documentation 2 weeks prior to reconnection activities

6.2 AWS Installation 2 hours

7.1 Submission of Testing and Commissioning Plan 6 weeks prior to Testing and Commissioning

7.2 Notification for pending reinstatement of signalling equipment 2 hours

7.2 Provision of Conditional Certificate of Signalling Same day

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Edition: December 2010 Part 1080: Rail SignallingAppendix A

CLIENT: Ref:

PROJECT:

LOCATION: DATE:

Purpose:This Conditional Certificate of Signalling exists to provide assurances that the Signalling System associated with the above mentioned project is tested and verified in accordance with the Testing and Commissioning Plan referenced above to the extent as described below:

The aforesaid signalling system is ready to be validated with a test train. This will be carried out on the __/ __/__. Upon satisfactory completion of the test train validation, a final Certificate of Signalling will be signed off by all responsible personnel involved in the testing and commissioning process including Validation with a Test Train.

Tester in Charge: Company:

I certify that the signalling system associated with the above mentioned project has been tested and verified in accordance with the Testing and commissioning plan referenced above and is ready to be validated with a test train.

Name: . . . . . . . . . . . . . . . .Signature: . . . . . . . . . . . . . .Date:. .. . . . . . . . Time:. . . . . . .

Rail Commissioners Representative:On behalf of the Rail Commissioner, I accept the Track circuits associated with the abovementioned project works, have been correspondence tested and verified in accordance with the agreed CTC Resource Plan and is ready to be validated with a test train.

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CERTIFICATE OF SIGNALLING- CONDITIONAL

Cert No:

Edition: December 2010 Part 1080: Rail SignallingAppendix A

Name: . . . . . . . . . . . . . . . . . .Signature: . . . . . . . . . . . . . . . Date:. .. . . . . . . . . . Time:. . . . . . . . .

OCC Representative:On behalf of PTSOM operations, I hereby testify that I have witnessed the correspondence testing of Track Circuits (as per the ITP) associated with the above mentioned project works. I certify that the signalling system has been tested and verified in accordance with the CTC Resource Plan and PTSOM practice. The signalling system is ready to be validated with a test train.

Name: . . . . . . . . . . . . . . . . . .Signature: . . . . . . . . . . . . . . . Date:. .. . . . . . . . . . Time:. . . . . . . . .

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Edition: December 2010 Part 1080: Rail SignallingAppendix B

CLIENT: Ref:

PROJECT:

LOCATION: DATE:

Purpose:This Certificate of Signalling exists to provide assurances that the Signalling System associated with the above mentioned project was previously tested and verified in accordance with the Test Train Plan and the integrity of the re-instated signal system has been validated.

Tester in Charge: Company: I testify that the operational integrity of the re-instated signalling equipment associated with the aforesaid project has been validated in entirety in accordance with the Test Train Plan and complies with Public Transport Service – Operations and Maintenance signalling practice. I hereby certify that the re-instated signalling system is fit and safe for the purpose of running trains.

Name: . . . . . . . . . . . . . . . .Signature: . . . . . . . . . . . . . . Date:. .. . . . . . . . . . Time:. . . . . . . . .

Independent Witness:On behalf of the Public Transport Service – Projects, I accept the re-instated signalling equipment associated with the aforesaid project is fit and safe for the purpose of running train, on the basis that the aforesaid signalling system has been validated in accordance with the Test Train plan referenced above and according to the agreed processes and supporting documentation.

Name: . . . . . . . . . . . . . . . . Signature: . . . . . . . . . . . Date:. .. . . . . . . . . Time:. . . . . . . . .

Public Transport Service – Projects Representative:On behalf of the Public Transport Service – Projects, I accept the aforesaid signalling system is fit and safe for the purpose of running trains, on the basis that the re-instated signalling system has been tested and verified in accordance with the Test Train Plan referenced above and according to the agreed processes and supporting documentation.

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CERTIFICATE OF SIGNALLING Cert No:

Edition: December 2010 Part 1080: Rail SignallingAppendix B

Name: . . . . . . . . . . . . . . . . Signature: . . . . . . . . . . . Date:. .. . . . . . . . . Time:. . . . . . . . .

Public Transport Service – Operations & Maintenance Representative:I hereby certify that I have witnessed that the re-instated signalling equipment associated with the aforesaid project has been validated in accordance with the Test Train Plan referenced above. I am satisfied that the operational integrity of the re-instated signalling system is fit and safe for the purpose of running trains.

Name: . . . . . . . . . . . . . . . . . Signature: . . . . . . . . . . . . . Date:. .. . . . . . . . . . Time:. . . . . . . . . .

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