NAT REP MPI ENG EP 3736860 Issue 4 Generic Technical Workscope - Design Installation of Electric Points Heating Equipment

NAT/REP/MPI/ENG/EP3736860

Issue: 04 Date: 1st June 2011

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Revision History

Issue Date Reason for change 01 19.07.05 New Issue

02 23.06.06 Removal of orange pipe, HPSA reference, Removal of Remote Condition Monitoring and associated update of drawings.

03 20.04.07 Document and drawings extensively revised following requirements harmonisation between MP&I and Engineering Function led by Louis Nel.

04 01.06.11 New section 6.2 Update of sections 6.1, 6.3,6.4,6.6,7.1,7.2,7.3,7.57.7,7.10 Document Distribution

Copy Recipient 01 Document Control Master.



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Contents

1. Introduction................................................................................................................................. 4

2. Scope........................................................................................................................................... 4

3. Definitions and Abbreviations................................................................................................... 5

4. Standards and Relevant Documentation.................................................................................. 6

5. Performance requirements ........................................................................................................ 7 5.1. Service Life ..................................................................................................................... 7 5.2. Product Acceptance........................................................................................................ 7

6. General Design Requirements .................................................................................................. 7 6.1. Equipment Layout........................................................................................................... 7 6.2. Electrical Design ............................................................................................................. 8 6.3. Earthing and Bonding ..................................................................................................... 9 6.4. Track circuit Compatibility............................................................................................... 9 6.5. Electromagnetic Compatibility (EMC) ........................................................................... 10 6.6. DNO Supplies ............................................................................................................... 11

7. Equipment Design .................................................................................................................... 11 7.1. DNO Supply Cabinet .................................................................................................... 11 7.2. Point Heating Control Cubicle....................................................................................... 12 7.3. Point Heating Transformers.......................................................................................... 13 7.4. Portable Tool Transformers. ......................................................................................... 14 7.5. Trackside Connection Boxes ........................................................................................ 14 7.6. Heaters ......................................................................................................................... 14 7.7. Cabling.......................................................................................................................... 17 7.8. Labels and Signs .......................................................................................................... 18 7.9. Cubicle Construction..................................................................................................... 18 7.10. Remote Condition Monitoring ....................................................................................... 19 7.11. Rail Temperature Probes.............................................................................................. 20

8. Removal of Redundant Materials ............................................................................................ 20

9. Documents and Drawings........................................................................................................ 22

10. Asset Recording ....................................................................................................................... 23

11. Training...................................................................................................................................... 23

12. Testing and Commissioning.................................................................................................... 23

Appendix A - Example Factory Commissioning and Testing Schedule for Points Heating Control Cubicles .................................................................................................................. 24

Appendix B - Signage and Labels .................................................................................................... 28

Appendix C - Padlocks and keys: Network Rail Maintenance Areas ............................................ 30



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Appendix D - Drawings of Typical Arrangements for Points Heating Installations..................... 33

1. Introduction

This document provides the generic Network Rail technical requirements for the design and installation of electric points heating equipment and forms an integral part of the design requirements for site specific detailed design. The Standard Detail Drawings of points heating installations are included in Appendix D.

2. Scope

This document applies to all new and replaced electric points heating equipment installed by Network Rail. The scope includes electrical supply, distribution, control and track mounted equipment. This document mandates the requirements of NAT/TW/InfraInv/ENG/EP6248683 Design and Installation of New, Renewed or Refurbished Distribution Network Operators (DNOs) Intakes and Consumer Facilities in respect of the DNO electrical supplies. The Standard Detail Drawings for points heating installations are included in Appendix D and form part of these design requirements.



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3. Definitions and Abbreviations

CPC Circuit Protective Conductor

DNO Distribution Network Operator

EMC Electromagnetic Compatibility

MP&I, E&P Major Projects and Investment, Electrification and Plant

RCD Residual Current Device

RMU Remote Monitoring Unit

SCADA Supervisory Control and Data Acquisition

WMCU Weather Monitoring Control Unit

PME Protective Multiple Earth

PHCC Points Heating Control Cubicle

MCB Miniature Circuit Breaker

MCCB Moulded Case Circuit Breaker

DC Direct Current

AC Alternating Current

TCB Trackside Connection Box

UTX Under Track Crossing

URX Under Road Crossing

ELR Engineers Line Reference

O&M Operation and Maintenance



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4. Standards and Relevant Documentation

This document shall be read in conjunction with:

1) Relevant European and British Standards.

2) Relevant Railway Group and Company Standards.

3) NR/SP/ELP/40045 (Issue 5) Network Rail Business Process Document

Electric Points Heating.

4) NR/GN/ELP/45002 : Network Rail Company Code of Practise The installation

of Electric Points Heating.

5) NR/SP/ELP/21085 : Specification for the Design of Earthing and Bonding

Systems for 25kV AC Electrified Lines.

6) BS 7671 : Requirements for Electrical Installations.

7) BS EN 50122: Railway Applications Fixed Installations Part 1: Protective

provisions relating to electrical safety and earthing.

8) BS 5395-3 : Stairs, ladders and walkways. Code of practice for the design of

industrial type stairs, permanent ladders and walkways.

9) HSE Railway Safety Guidelines and Principles.

10) NR/SP/SIG/19812: Cross Track Cable Management

11) NR/SP/CIV/044 : Design and Construction of Undertrack Crossings.

12) NR/SP/ELP/27224 : Specification for the installation of cable routes forming

part of the traction distribution system.

13) NR/SP/ELP/27300 : Specification for Computer Aided Design Formats for

Electrification and Plant Documentation.

14) NR/GN/CIV/008: Model clauses for specifying Civil Engineering.

15) NAT/TW/InfraInv/ENG/EP6248683: Design and Installation of New, Renewed

or Refurbished Distribution Network Operators (DNOs) Intakes and Consumer

Facilities

16) PAN-E-EP-PRO-0035 Issue 3: Project Advice Note BS7671 17th Edition

Compliance

17) Network Rail Procedure for Arranging New Utility Supplies and Disconnections

18) The relevant site specific Technical Workscope.

Any requests for departures from the requirements of this document or relevant standards shall be submitted in writing to the Employers Representative,



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together with justification for the request, including any efficiency benefits that may be achieved.

In the event of any apparent conflict between the requirements of this document and other relevant standards or Network Rail documents, the matter shall be referred to the Employers Representative for clarification.

5. Performance requirements

5.1. Service Life

The service life shall be at least 20 years, except for strip heaters which shall have a service life of at least 15 years.

Where existing equipment is considered to have a remaining service life of ten years or more, the Employers Representative may chose to retain such equipment as part of the new installation. Where existing equipment is to be retained the Employers Representative will inform the Contractor and the sponsor.

5.2. Product Acceptance

Only product accepted equipment shall be used. If novel equipment is proposed, prior agreement from the Employers Representative must be sought and an application made by the Contractor for trial acceptance before the equipment is installed.

6. General Design Requirements

6.1. Equipment Layout

All points heating equipment is to be located adjacent to the running lines or on the track apart from the DNO supply cubicle and associated cabling which is generally to be located remotely dependant upon access constraints. The location of cabinets for the incoming electrical supplies from Distribution Network Operator shall be in accordance with the document NAT/TW/InfraInv/ENG/EP6248683 Design and Installation of New, Renewed or Refurbished Distribution Network Operators (DNOs) Intakes and Consumer Facilities. Where DNO cubicles are located in areas of high vandalism, the Contractor shall where required by the Employers representative make provision for the installation of a fenced compound and access gate complete with dual lock



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arrangement. Provision of this facility shall be considered on a site by site basis by the Employers Representative. The design shall ensure that transformers and Point Heating Control Cubicles are located at least 3.5m from the nearest rail with cubicle doors facing away from the track. Excluding the DNO cubicle, equipment shall not normally be located further than 5m from the nearest running rail. Where existing equipment, e.g. transformers, is to be retained, and is presently located closer than 3.5m to the nearest rail, the Contractor shall re-site the equipment incorporating necessary alterations to the electrical design. Where possible the transformer is to be placed in line with the Trackside Connection Box keeping trackside cabling to a minimum. Trackside connection boxes are to be located a minimum of 1.469m from the running rail and shall be positioned such that heater tail lengths are kept to a minimum. The connection boxes shall be positioned adjacent to sleeper ends with the lid facing away from the track. Where no clearance exists for the installation of trackside connection boxes in accordance with the above specified requirements alternatives may be proposed to the Employers Representative. In these cases the Contractor shall submit the necessary design information and receive approval in writing from the Employers Representative, on a site by site basis, prior to implementation. Where it is not possible to locate equipment at least 3.5m to the running rail, appropriate barrier protection is to be installed at a minimum of distance of 1.469m from the running rail. Where the line speed is greater than 100mph the barrier shall be installed at a minimum of 2m from the nearest running rail. Where space is limited due to constraints such as cuttings or embankments and the specified clearances can not be achieved with the provision of barrier protection, support platforms are to be used. These platforms shall comply with BS 5395-3. Support platforms are to be sited in accordance with the HSE Railway Safety Guidelines and Principles. Civil Engineering design approval shall be obtained for all structural works. All works shall comply with the requirements of NR/GN/CIV/008. Where there is a risk of equipment being damaged by road vehicles a simple collision resistant barrier or posts shall be provided to segregate equipment from areas to which vehicles have access. When sighting any barriers, appropriate consideration is to be given to equipment access ensuring no barriers prevent full and normal access to the equipment.

6.2. Electrical Design

The electrical design shall be compliant with BS7671 Requirements for Electrical Installations (IEE 17th Edition Wiring Regulations) with an overriding requirement that accessible touch voltages as a function of time are within the



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limits set out in BS EN 50122-1 Railway Applications - Fixed Installations - Part 1: Protective provisions relating to electrical safety & earthing. However, if agreed with the Employers Representative, compliance with the conventional BS 7671 Requirements for Electrical Installations accessible touch voltage limits and disconnection times may be deemed to meet the above requirement. The 110V IT circuit from the secondary of the transformer to the track mounted heater strip is to be designed to be compliant with volt drop and current rating requirements. In accordance with Group Standard GI/RT7007 there is to be no earth reference connected to the running rails and therefore earth faults need not be considered. An insulation monitor is not required; maintenance routines are used to confirm insulation integrity. The current edition of Network Rail document PAN-E-EP-PRO-0035 BS7671 17th Edition Compliance provides the definition of final circuits to be used in the design with respect to the BS7671 Requirements for Electrical Installations (IEE 17th Edition Wiring Regulations). The document is available from the Employer Representative. Low voltage electrical distribution systems shall be designed and operated as 240 or 400 Volt single phase or 400 Volt three phase earth referenced systems. The design shall be based on a TN system, however, with the agreement of the Employers Representative a TT incoming system may be used if a TN supply is not available in accordance with NAT/TW/InfraInv/ENG/EP6248683 Design and Installation of New, Renewed or Refurbished Distribution Network Operators (DNOs) Intakes and Consumer Facilities. Circuit protection shall be by overcurrent devices in the form of electronic protection relays, fuses or moulded case circuit breakers.

6.3. Earthing and Bonding

In areas of AC overhead electrification, or those identified by the Employers Representative as a potential electrification area using the AC overhead system, Distribution Cabinets and Points Heating Control Cabinets shall be bonded to the traction system according to Network Rail standard NR/SP/ELP/21085 Specification for the Earthing and Bonding Systems for 25KV AC Electrified Lines. The means of bonding shall be dependent upon whether the bond is for equipotential reasons or as a potential traction fault current carrying conductor. Incoming DNO supplies shall only be gapped if necessary. Distribution Cabinets and Points Heating Control Cabinets shall, where possible, be located outside the overhead line contact zone.

6.4. Track circuit Compatibility



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The equipment design shall be compatible with the track circuits installed. Written approval shall be obtained from the Employers Representative to confirm the required type of electric points heating and that interdisciplinary coordination checks have been satisfactorily carried out such that the proposed design is compliant with regard to track circuit compatibility as specified in section 7.1 of standard NR/SP/ELP/40045 prior to implementation works commencing on site.

6.5. Electromagnetic Compatibility (EMC)

Cubicles shall be designed in accordance with current best practice to minimise the effects of electromagnetic interference. Independent certification by a recognised EMC specialist shall be provided for each particular cubicle design. Any subsequent changes shall be assessed re-certified.



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6.6. DNO Supplies

When replacing existing gas fired points heating systems with electrically operated systems the proposed design shall address the requirement to obtain a new DNO connection point and the location of the required electrical distribution equipment. A comprehensive supply assessment is to be carried out on all sites where the equipment is to be renewed or modified to confirm the suitability of the existing DNO supply. Where it is identified that an increase in supply capacity is required or provision of a new supply is necessary, the Contractor shall at the early design stage undertake negotiations with the relevant DNO to establish a robust order of cost for the proposed changes. Where new or upgraded supplies are to be provided, the DNO supply must be installed or modified in accordance with NAT/TW/InfraInv/ENG/EP6248683 Design and Installation of New, Renewed or Refurbished Distribution Network Operators (DNOs) Intakes and Consumer Facilities Changes with regard to DNO supplies shall be carried out in accordance with the Network Rail Procedure for Arranging New Utility Supplies and Disconnections. Where tenants electricity supplies are derived from the DNO cubicle, including supplies to Train Operating Companies, a meter shall be provided to record the tenants electricity consumption.

7. Equipment Design

7.1. DNO Supply Cabinet

Where new or upgraded supplies are to be provided, the DNO supply cabinet must be installed or modified in accordance with NAT/TW/InfraInv/ENG/EP6248683 Design and Installation of New, Renewed or Refurbished Distribution Network Operators (DNOs) Intakes and Consumer Facilities.



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7.2. Point Heating Control Cubicle

Points heating control cubicles shall include in addition to the requirements of NR/SP/ELP/40045, an hours run meter. Typical schematic and equipment layout arrangements for points heating control cubicles are shown on drawings GENERIC/000/6.7/ET/018 and GENERIC/000/6.7/ET/039. Equipment shall not be fixed to any cover which is removable for maintenance or access purposes. Items of equipment fixed to doors shall be kept to a minimum with due regard to maintenance requirements. Grouped terminal blocks of sufficient size and capacity shall be provided for the termination of all relevant cables.

All final circuit protective devices shall be of the MCB or MCCB type. These shall be vibration resistant and it shall be demonstrated that they are suitably rated and installed such that full load current can be drawn for the operating environment. RCD devices are only to be used where it is demonstrated that the specified level of protection can not be obtained by other means. A bulkhead type light fitting and an anti-condensation heater with thermostatic control shall be provided. A manual/auto switch to bypass the control system is to be incorporated. This shall be capable of bypassing the control system and contactors so that in the event of a contactor or control system failure the points heating can be manually energised to operate continuously. When the control system is in bypass mode the temperature controller and the hours run meter shall remain energised. Specific attention is also to be given to the type of MCBs used on the outgoing circuits to the points heating transformers. The proposed design shall take account of the transformer inrush characteristics and the associated risk of false tripping which shall be avoided. The cubicle lighting switch is to be sited away from any control switches such as the Summer / Winter Switch. Where the bypass switch is incorporated within the control panel along with the main isolator, the bypass switch is not to be interlocked with the control panel door.

All temperature sensor and data cable terminals shall be housed in an enclosure separate from and electrically screened from all the other terminal chambers.



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7.3. Point Heating Transformers

Point Heating Transformers shall be continuously rated at either 5kVA or 10kVA with dual wound 110V secondary windings. Proposals to use Point Heating Transformers of other power ratings will be subject to the approval of the Employers Representative. The voltage rating shall be single phase 230V/110V or single phase 400V/110 V as stated in the site specific Technical Workscope.

The transformers shall be petroleum jelly filled and fitted with a protective cover that can be secured by a padlock. Padlocks shall be provided in accordance with the information listed in Appendix C. The transformer tank, terminal box and cover shall be constructed using either stainless steel sheet type 316L with a minimum thickness 2.5 mm or steel sheet hot dip galvanised with all nuts bolts and washers being brass or zinc coated. Where constructed of stainless steel, the stainless steel sheet shall be mill finish to ensure sunlight glare is kept to a minimum. The construction shall be in accordance with the relevant European and British standards. A double pole isolator shall be provided on the primary side of the transformer which is accessible at all times. As a result the transformer lid is to be lockable separately to the isolator cover. The isolator cover shall have the necessary lugs for fitting a pad lock. The secondary of the transformer shall be dual wound providing two electrically separated windings. Each winding will be terminated on a busbar to which the independently fused outgoing circuits are to be connected. The transformers shall be fitted with the correct number of fused outgoing circuits. This will vary with the number of heater strips fed from any single transformer and whether or not Clamp Lock heaters are fitted. Typical connections for heating transformers are shown on drawing GENERIC/000/6.7/ET/039. Where DC heating strips are required to achieve track circuit immunity the associated transformers shall incorporate bridge rectification. Identification labels shall be mechanically fixed to both the body and the cover of all transformers. Drawing EEPH63/000/6.7/ET/039 provides typical foundation and other relevant civil construction details.



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7.4. Portable Tool Transformers.

Portable Tool Transformers shall not be provided as part of new of renewed installations.

7.5. Trackside Connection Boxes

Trackside connection boxes shall be post mounted, weatherproof to IP65 and suitable for the termination of point heating and rail temperature probe cables. Connection boxes shall be provided complete with fixed termination blocks, links to allow circuit disconnection for testing and the appropriate glands. Trackside connection boxes shall be constructed from high quality, high impact resistant material. The lid shall be hinged at the top of the box so that it can not be left open. The box shall be of sufficient size with adequate space around the terminals to facilitate easy cable termination. Separate trackside connection boxes shall be provided for hot and cold rail probe connections Typical arrangements of trackside connection boxes are shown on the following drawings:

GENERIC/000/6.7/ET/023 GENERIC/000/6.7/ET/026 GENERIC/000/6.7/ET/027 GENERIC/000/6.7/ET/028

7.6. Heaters

Rail, in-bearer and supplementary detector heaters shall be either of the constant wattage strip type rated at 200 watts per metre, or of the self regulating strip type with equivalent heat output capability. Where Clamp Lock systems are used, they shall be heated with additional cartridge type heater elements individually rated at 200W. Allowance shall be made for the fact that Mk Clamp Lock and in-bearer detectors are padlocked to prevent unauthorised access to the Clamp Lock and in-bearer detector heaters which can only be fitted by competent Signalling personnel. Strip heaters shall have a minimum sheath thickness of 0.8mm. In DC third and fourth rail electrified areas strip heaters shall be of the insulated type. Rail clips used for fixing heaters shall be product approved. Heater leads are to be kept as short as possible and shall not exceed 20m. Typical details for the installation of strip heating elements are shown on drawing GENERIC/000/6.7/ET/025. Drawings GENERIC/000/6.7/ET/026, GENERIC/000/6.7/ET/027 and GENERIC/000/6.7/ET/028 provide details relating to



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heater locations, designations and connections. Requirements for heater lengths and are ratings are detailed in Tables 1 to 4 below:

113 LB or Bullhead Rail and Mechanical Frame, HW or equivalent Point motor

Switch Type

Stock Rail Heater Strip

Switch Rail Heater Strip

Clamp Lock Cartridge Heater

Bearer Heater Strip

Supplementary Heater Strip Transformer Size

AV 2 x 4m 2 x 4m N/A N/A N/A 5kVA

BV/CV 2 x 5m 2 x 5m N/A N/A N/A 5kVA

DV 2 x 6m 2 x 6m N/A N/A N/A 5kVA

EV 4 x 4m 4 x 4m N/A N/A N/A 10kVA

FV 4 x 5m 4 x 5m N/A N/A N/A 10kVA

SGV 4 x 6m 4 x 6m N/A N/A N/A 10kVA

GV 4 x 5m + 2 x 4m 4 x 5m + 2 x 4m N/A N/A N/A 1 x 10kVA +1 x 5kVA

HV 6 x 6m 6 x 6m N/A N/A N/A 1x10kVA +1x5kVA

Table 1 Requirements for 113lb Bullhead Rail and Mechanical Frame, HW or equivalent Operating Mechanism

113LB or Bullhead Rail and Clamp Lock Operating Mechanism

Switch Type




Bearer Heater Strip


AV 2 x 4m 2 x 4m 2 x 200W N/A N/A 5kVA

BV/CV 2 x 5m 2 x 5m 2 x200W N/A N/A 5kVA

DV 2 x 6m 2 x 6m 2x200W N/A N/A 10kVA

EV 4 x 4m 4 x 4m 2x200W N/A N/A 10kVA

FV 4 x 5m 4 x 5m 2x200W N/A N/A 10kVA

SGV 4 x 6m 4 x 6m 2x200W N/A N/A 10kVA

GV 4 x 5m +2 x 4m 4 x 5m +2 x 4m 2x200W N/A N/A 1x10kVA + 1x5kVA

HV 6 x 6m 6 x 6m 2x200W N/A N/A 1x10kVA + 1x5kVA

Table 2 Requirements for 113lb Bullhead Rail and HW or equivalent Operating Mechanism



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CEN 60 Rail and HY-drive Operating Mechanism

Switch Type




Bearer Heater Strip


C 2 x 5m + 2 x 4m 2 x 5m + 2 x 4m 2 x 200W N/A N/A 10kVA

D 2 x 5m + 2 x 4m 2 x 5m + 2 x 4m 2 x 200W N/A N/A 10kVA

E 2 x 6m + 2 x 5m 2 x 6m + 2 x 5m 2 x 200W N/A N/A 10kVA

F 2 x 5m + 4 x 4m 2 x 5m + 4 x 4m 2 x 200W N/A N/A 1x10kVA + 1x5kVA

SG 2 x 6m + 2 x 5m + 2 x 4m 2 x 6m + 2 x 5m +

2 x 4m 2 x 200W N/A N/A 1x10kVA + 1x5kVA

G 2 x 6m + 6 x 5m 2 x 6m + 6 x 5m 2 x 200W N/A N/A 2x10kVA

H 4 x 6m + 4 x 5m + 2 x 4m 4 x 6m + 4 x 5m +

2 x 4m 2x200W N/A N/A 2x10kVA + 1x5kVA

Table 3 Requirements for CEN 60 Rail with HY-drive Operating Mechanism

CEN 60 Rail and HPSS Operating Mechanism

Switch Type




Bearer Heater Strip


C 4 x 4 m 4 x 4m N/A 380W 104W 10kVA

D 2 x 5m + 2 x 4m 2 x 5m + 2 x 4m N/A 380W 104W 10kVA

E 2 x 6m + 2 x 5m 2 x 6 m + 2 x 5m N/A 380W 104W 10kVA

F 2 x 6m + 2 x 5m 2 x 6m + 2 x 5m N/A 380W 104W 10kVA

SG 2 x 6m + 2 x 5m + 2 x 4m 2 x 6m + 2 x 5m +

2 x 4m N/A 380W 104W 1 x 10kVA + 1 x 5kVA

Table 4 Requirements for CEN 60 Rail with HPSS Operating Mechanism



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7.7. Cabling

All external cabling shall be of the steel wire armoured type with the exception of the cabling from the trackside connection boxes to the heater strips and temperature probes which shall be unarmoured. All cabling installed on the track shall therefore be unarmoured and unscreened. Unless specifically advised otherwise by the Employers Representative, cabling shall be installed in concrete troughing where practically possible and the use of buried cable routes shall be kept to a minimum. Where troughing is installed the open end shall be sealed and made rodent proof using rigid setting expanding aerosol foam. In accordance with NR/SP/SIG/19812, where a cable carrying a voltage above 110 V is required to cross under running lines of track category 1, 1A or 2, it shall be installed within a full depth Under Track Crossing in compliance with NR/SP/CIV/044, Design and Construction of Under track Crossings. Where cables are required to cross under a road, vehicular access track or hard standing, within Network Rail property, the cables shall be installed in ducts at a minimum depth of 500mm from the wearing course to the top of the duct. At each Under Road Crossing two spare ducts shall be provided complete with a draw ropes. Following installation of cables, ducts shall be sealed with rigid setting expanding foam. Draw pits or bell mouths shall be provided at each end of the URX except where terminating directly into the concrete base of a cubicle. All URX installations shall comply with the requirements of NR/SP/ELP/27224. All point heater connection cables between the trackside connection boxes and heating elements shall be installed in concrete troughing terminating adjacent to sleepers. Cables shall then cross the ballast to the sleeper where they shall be clipped to the top of the sleeper towards the longitudinal edge. Where there multiple cables are routed along a sleeper edge they shall be secured in flat formation. Drawing GENERIC/000/6.7/ET/024 provides typical details with regard to the appropriate fixing of cables to sleepers. Orange pipe traditionally used for the protection of cables crossing tracks shall not be used. 110 Volt point heater connection cables are allowed to cross a maximum of 4 tracks with the heaters installed on the fourth track. Where longer runs are required, a full depth UTX shall be used where available. Where this is not possible cables shall be clipped to the sleepers with additional lengths of concrete troughing installed where appropriate. After crossing to the 10ft nearest to the point to be heated or the far cess if nearer to the point to be heated, the cables shall terminate at a second trackside connection box. Heater element cable tails shall then be routed back to the heater element concerned. Where cables are clipped to the sleeper and pass underneath the running rail, an approved cable protector shall be installed to protect the cable against damage from the running rail.



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7.8. Labels and Signs

Labels shall be provided in accordance with the requirements as outlined in Appendix B. All labels shall be made from engraved 2 or 3 ply, laminated plastic, legible for the entire life of the installation and be UV stable. All Identification labels shall be mechanically fixed in a location that shall not affect the integrity of the enclosure. Electrical Hazard Warning Labels shall be fitted to all cubicles doors (inside and outside) and the lids of all transformers. Where the voltage contained within the enclosure is in excess of 230V the label must also state the voltages contained within the enclosure in line with the requirements of BS7671. Warning labels shall be a minimum of 50 mm high x 40 mm wide for transformers and 200 mm High x 150 mm wide for cubicles. Identification label lettering shall be legible and indelible with a minimum letter height of 6mm for distribution board circuits and 10 mm for all other equipment. Cubicle designations shall have the following information.

Local Name e.g. Station Name or area; Cubicle Name prefixed with a letter e.g. B Cubicle; ELR.

7.9. Cubicle Construction

Cubicles shall be rigidly constructed from type 316L folded stainless steel sheet to the relevant European and British standards with a minimum thickness 2.5 mm. The cubicle shall be constructed using stainless steel with a mill finish to ensure sunlight glare is kept to a minimum. Panels or doors larger than 1800mm x 1200mm shall be suitably reinforced. The cubicles shall be weatherproof to IP 54 and independent certification by a testing authority shall be provided for each particular design of cubicle. Sufficient ventilation shall be provided to allow for natural convection and to prevent the internal temperature from rising above the operating temperature of the equipment within the cubicle. The welding of stainless steel shall be carried out by welders qualified to the relevant European and British standards. Door sealing edges shall be suitably prepared, butt welded, dressed flush and burnished. Appropriate seals shall be fitted to the doors. The cubicle shall have sufficient ventilation to prevent condensation without compromising the specified IP rating. Finished panels shall be without sharp edges and all screws, bolts, washers and similar fastenings shall be of a suitable grade of stainless steel or brass to prevent corrosion for the design life of the equipment. During manufacture, due care shall be taken to ensure that clean conditions apply to prevent cross



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contamination with mild steel processes and resultant appearance of corrosion to the cubicle. Where dual access to a cubicle is required a dual padlock locking bar shall be fitted to the door opening onto the public highway and this must be fitted initially with two approved railway padlocks as detailed in Appendix C. The locking bar shall be 20mm in diameter and drilled to allow the designated padlocks to be fitted to both ends. All cubicles are to be locked through a single lockable handle. The locking mechanism is to be of the multipoint type, which simultaneously locks the top and bottom of the door on operation of a single handle. Once locked the cubicle doors must not be able to come ajar. When cubicles have double doors the door with the locking handle is to overlap the non-locking door so that only one locking mechanism is required to lock both doors. Wooden back boards shall be marine grade ply with a minimum thickness of 18 mm. Where practicable, cables and wiring shall be accommodated in trucking. Cables and wiring shall not obscure labels or prevent access for maintenance including testing.

Each cubicle shall contain the facility to store a set of drawings. This shall take the form of a black plastic drawing tube, which is to be fitted to the inside of the cubicle door complete with a retaining clip to allow easy removal of the tube.

Typical cubicle foundation and other relevant civil construction details are shown on drawings in appendix D: GENERIC/000/6.7/ET/034, GENERIC/000/6.7/ET/035 and GENERIC/000/6.7/ET/036.

7.10. Remote Condition Monitoring

Remote Condition Monitoring shall not be provided in new locations or if the existing cubicle that is to be replaced is not already fitted with Remote Condition Monitoring equipment.

Where an existing point heating cubicle is fitted with Remote Condition Monitoring equipment that is fully functional and reporting to a working monitoring station the monitoring equipment shall be replaced. The Remote Condition Monitoring system type shall be agreed with the Employers Representative and shall be compatible with the existing system. All associated modifications to the master station to ensure compatibility as a result of changes within the points heating control cubicle shall be carried out.

Where an existing point heating cubicle is to be replaced which is fitted with Remote Condition Monitoring equipment that is not fully functional, replication of the remote monitoring system is not to be provided.



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If the Employers Representative specifies that space is to be provided to allow future installation of Remote Condition Monitoring equipment, the space provision shall be no less than 450mm width x 500mm height x 350mm depth.

7.11. Rail Temperature Probes

Hot and cold rail sensor probes shall be installed on the common rail in areas where single rail track circuits are installed. Where track circuits are installed on both rails then the sensor probes shall be installed in the same track circuit section and not bridge an insulated rail joint. The positioning of the sensor probes shall be in accordance with the requirements of NR/SP/ELP/40045 and NR/GN/EP/45002.

8. Removal of Redundant Materials

All redundant equipment and materials shall be removed from site upon completion of works including:

cubicles; power distribution equipment; fencing and gates; concrete troughs; ground material; concrete bases; gas bottles and storage tanks; gas manifolds and regulating apparatus; gas pipe work; rail mounted gas burners; electric equipment; scrap materials.

Redundant Electricity Supply Industry connections and associated equipment shall be fully decommissioned and removed. Arrangements shall be made for the removal of all gas storage tanks and bottles from site in accordance with current Gas Safety Regulations and Acts, British Standards and Codes of Practice to meet the requirements of the Health and Safety at Work Act. All redundant pipe work and equipment above ground shall be removed from site. Abandoned gas pipe work below ground shall be accurately plotted on As-built drawings. Where the gas supply originates from a local gas supply company via a piped system passing onto Network Rail property, arrangements shall be included to remove the metering installation and permanently cap the gas supply. Where the gas points heating system incorporates a power supply connection derived from the signalling infrastructure, the power supply shall be decommissioned in accordance with the



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method as specified by the relevant Signalling Engineer and the Employers Representative. Unless agreed otherwise with the Employers Representative, where oil filled transformers are to be disposed of, these shall be tested prior to disposal to ensure that there are no PCBs present.



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9. Documents and Drawings

The Standard Detail Drawings forming part of this document shall be followed unless alternative arrangements have been approved by the Employers Representative. A full set of as built drawings are to be provided in each Operation and Maintenance (O&M) Manual. Drawings shall be produced in accordance with the requirements of NR/SP/ELP/27300 and shall include as a minimum:

Site Layouts; DNO Cubicle Layout; Sub-distribution Cubicle Layout; Points Heating Control Cubicle Layout; Schematics of all Cubicles; Transformer Details; Foundation Details; Track Equipment Layout; Termination Diagrams.

Unless otherwise specified, standard BSI symbols are to be used on all drawings. Details of points heating specific symbols are provided in drawing GENERIC/000/6.7/ET/041. A set of as-built layout and schematic drawings are to be provided in each cubicle. The site drawings shall be of the non-degradable type, both water and tear resistant. The drawings are to be issued with the O&M manual to the Area Maintenance Organisation for them to control and install at each site. All drawings shall be of a minimum size providing the information can be easily read. A full O&M manual is to be produced using standard Microsoft Office applications.


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The O&M package shall contain as a minimum the following information:

All manufacturers literature and details associated with equipment

installed; Design Documents including calculations; Layout Drawings of Cubicles, Transformers, Track Equipment; Schematic Drawings; Test Certificate; Relevant track circuit information Commissioning documentation; Circuit charts; Updated Circuit charts when part renewal is performed; A full parts list with part numbers, which is to include a list of

suppliers, contact telephone numbers and business addresses.

One hard copy of the O&M documentation shall be provided. Four CD-Rom copies of the O&M documentation shall be provided. CDs are to be labelled with a unique reference number, date of issue, version number and the locations to which they apply.

10. Asset Recording

All Network Rails asset recording and maintenance systems including Ellipse are to be updated by the project covering all asset changes.

11. Training

Training shall be provided where equipment which is new or novel to an area is provided. This shall include 2 half day sessions for each maintenance area in which the equipment is installed. The training shall include as a minimum how to set up the equipment, how to maintain the equipment, testing requirements and fault finding.

12. Testing and Commissioning

A number of typical testing and commissioning check lists and test sheets are included in Appendix A.



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Appendix A - Example Factory Commissioning and Testing Schedule for Points Heating Control Cubicles

PART 1 - VISUAL CHECKS No. Description Expected

Results Result Pass / Fail

Comments / Remedial Action

1 Cabinet, constructed as cubicle layout drawing

Refer to Site Drawing = 1

2 Income Isolator Correct Size 1

3 Fuses Correct Size & Type 1

4 Terminals Correct Size & Type 1

5 Labelling Internal 1

6 Labelling External 1

7 Door Mechanism 90 & 180 Securing Visual

8 Quality of Panel Construction Visual

9 External Probes/Aerials Visual

10 Lifting Eyes and Mounting Holes Visual

11 Doors open and close correctly Visual

12 Presence of panel schematic Visual

13 Magnetic Door Switch Operational Visual

14 Earth Bonding Visual

15 Cable Identification Visual

16 Terminal Identification Visual

17 Protection Against Direct Contact Visual

18 Single/Three Phase Refer to 1

19 Protective Devices Correct Refer to 1

Phase Supply ................................................ Test Actual Voltage ................................................ Test Engineer ................................................ Cubicle Serial No. ................................................ Test Date ................................................ Customer Approval ................................................ Location of Test ................................................



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Note: Test Schedules will only be signed following remedial corrective actions

and successful retest.



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PART 2 - Live Tests

No. DESCRIPTION ACTION EXPECTED

RESULTS

RESULT

Pass / Fail

COMMENTS

1 Supply Voltage 1ph-

3ph Check Phase

Lamps Lamps On

2 Monitoring Voltage

110 v A.C

Check

Voltmeter

Voltage

Correct

3 Bulkhead Light Switch on Correct

operation

4 Panel Heater Switch On Correct

operation

5 Override Button Operate Correct

operation

6 Timed light Short control

terminals

Circuit energises

and timers off

7 Control circuits

connected to correct

MCB

Energise

individual

MCBs

Connected

correctly

8 Sensor Moisten

probe

Icelert

Phase Supply ................................................ Test Actual Voltage ................................................ Test Engineer ................................................ Cubicle Serial No. ................................................ Test Date ................................................ Customer Approval ................................................ Test Instrument ................................................ Calibration Certificate ................................................ Location of Test ................................................ Note: Test Schedules will only be signed following remedial corrective actions and successful retest


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PART 3 - Temperature Sensing Tests For these tests set Icelert cold (wet+2) cold (dry-0) hot (wet +15) hot (dry + 7) delay 0 No. Circuit Under

Test Action Expected

Result Results Pass / Fail

Comments

1 Precipitation Sensor

Spray with water to activate

Icelert shows wet condition

2 Rail temperature sensor

Compare with ambient then heat sensors one at a time

Check Icelert displayed values show ambient then rises as sensors are heated

3 DRY CONDITION Icelert operation

Lower hot and cold probes below settings to energise. Raise again to de-energise

Energise and de-energise at correct temperatures

NOTE:- When heating is ON change summer/ winter switch to summer. Heating off (return to Winter)

4 WET CONDITION: Icelert operation

Lower hot and cold probes below settings to energise. Raise again to de-energise with delay

Energise and de-energise at correct temperatures delay will be 30 sec.

5 Reset Icelert to specification

Phase Supply ................................................ Test Actual Voltage ................................................ Test Engineer ................................................ Cubicle Serial No. ................................................ Test Date ................................................ Customer Approval ................................................ Test Instrument ................................................ Calibration Certificate ................................................ ................................................ ................................................ Location of Test ................................................ Note: Test Schedules will only be signed following remedial corrective actions and successful retest.


Issue: 04

Date: 1st June 2011

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Appendix B - Signage and Labels

Label Fitted Type

S

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p

p

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Designation & Location External Engraved 3 3 Designation Point No External Engraved 3 3 3 Designation Circuit Engraved 3 3 Fuse Ratings Circuit Engraved 3 Project Name, Number & Installed Date Internal Engraved 3 3 Danger Safety Electrical Connection - Do Not Disconnect. Internal Engraved 3 3 GPS Reference External Engraved 3 3 Supply Fed From Internal Engraved 3 3 RED Reference RTE Number (Where DNO Supply) Internal Engraved 3 Supply Fed From External Engraved 3 Supply Fed From Internal Engraved 3 Supply Feeds To Circuit Engraved 3 3 Heater Connection (i.e. H1, H2, H3, H4 , CHL 1, CHL2 , BH1, BH2 ) Internal Engraved 3 3 Due To Signalling Immunity Wiring Must Not Be Altered Internal Engraved 3 3 This Installation Is Earth Free And Must Not Be Connected Directly To Any Earthing System External Engraved 3

Electrical Warning & Voltage External Printed 3 3 3 3


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Label Fitted Type

S

u

p

p

l

y

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S

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D

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Heaters On (Fit Under Lamp) External Engraved 3 Remove Hot And Cold Rail Probes Prior To Tamping External Engraved 3

NAT/REP/MP&I/ENG/EP3736860


NAT REP MPI ENG EP 3736860 revision Draft rev 12.0ORG.doc

Page 30 of 34

Appendix C - Padlocks and keys: Network Rail Maintenance Areas

Thames Valley, West Country, Wales & Marches Application Locking arrangement Pass Key No/ Padlock details Electrical Power Supply single sided cubicle

20mm dia dual locking bar BR(W) EZZ326 bronze pin tumbler 3102

Electrical Power Supply double sided cubicle

20mm dia locking bar. Locking handle Network Rail side

BR(W) EZZ326 bronze pin tumbler 3102 BR(W) EZZ326 bronze pin tumbler 3102

Control cubicles Locked handle RKB 222 Transformers

Locked cover plate BR(W) EZZ326 bronze pin tumbler 3102

Great Northern Application Locking arrangement Pass Key No/ Padlock

details Electrical Power Supply single sided cubicle

20mm dia dual locking bar LT 205



LT 205

Control cubicles Locked handle JW 442 Transformers

Locked cover plate JW 442

North Eastern Application Locking arrangement Pass Key No/ Padlock


20mm dia dual locking bar JW 442



JW 442

Control cubicles Locked handle JW 442 Transformers

Locked cover plate JW 442


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Application Locking arrangement Pass Key No/ Padlock details

Electrical Power Supply single sided cubicle

20mm dia dual locking bar RC 27



RC 27

Control cubicles Locked handle RC 27 Transformers

Locked cover plate JC 27

East Anglia Application Locking arrangement Pass Key No/ Padlock


20mm dia dual locking bar LT 205



LT 205

Control cubicles Locked handle LT 205 Transformers Locked cover plate RKB 222

Kent, Sussex, Wessex Application Locking arrangement Pass Key No/ Padlock


20mm dia dual locking bar CCC 2



CCC 2

Control cubicles Locked handle CCC 2 Transformers Locked cover plate RKB 222

London, North West Application Locking arrangement Pass Key No/ Padlock


20mm dia dual locking bar RC 27



RC 27

Control cubicles Locked handle BPH Transformers Locked cover plate BPH


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Scotland Application Locking arrangement Pass Key No/ Padlock


20mm dia dual locking bar PS 1



PS 1

Control cubicles Locked handle PS 1 Transformers Locked cover plate PS 1


Issue: 04

Date: 1st June 2011


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Appendix D - Drawings of Typical Arrangements for Points Heating Installations

Drawing Number Title GENERIC/000/6.7/ET/018 Points Heating Control Cubicle Typical General Layout

GENERIC/000/6.7/ET/023 Typical Trackside Connection Box Arrangement

GENERIC/000/6.7/ET/024 Typical Cable Route Crossing Track

GENERIC/000/6.7/ET/025 Typical Positioning of Heating Strips

GENERIC/000/6.7/ET/026 Typical Arrangement for Points Requiring 4 Heater Strips



GENERIC/000/6.7/ET/031 Single Sided DNO Supply Cubicle Typical General Layout

GENERIC/000/6.7/ET/034 Points Heating Control Cubicle Typical Plinth Arrangements

GENERIC/000/6.7/ET/035 Typical Civil Details at Cuttings & Embankments

GENERIC/000/6.7/ET/036 Typical Details of Points Heating Control Cubicle & Barriers

GENERIC/000/6.7/ET/037 Typical Points Heating Transformer Barrier Detail

GENERIC/000/6.7/ET/039 Typical Points Heating Control Cubicle Schematic

GENERIC/000/6-7/ET/041 Points Heating Specific Symbols

NR-EP/4002 Arrangement Of Point Heater Strips for HY - Drive C Switch NR60

NR-EP/4003 Arrangement Of Point Heater Strips for HY - Drive D Switch NR60

NR-EP/4004 Arrangement Of Point Heater Strips for HY - Drive E Switch NR60

NR-EP/4005 Arrangement Of Point Heater Strips for HY - Drive F Switch NR60

NR-EP/4006 Arrangement Of Point Heater Strips for HY - Drive SG Switch NR60

NR-EP/4007 Arrangement Of Point Heater Strips for HY - Drive G Switch NR60

NR-EP/4008 Arrangement Of Point Heater Strips for HY - Drive H Switch NR60

NR-EP/4102 Arrangement Of Point Heater Strips for HPSS C Switch NR60

NR-EP/4103 Arrangement Of Point Heater Strips for HPSS D Switch NR60

NR-EP/4104 Arrangement Of Point Heater Strips for HPSS E Switch NR60

NR-EP/4105 Arrangement Of Point Heater Strips for HPSS F Switch NR60

NR-EP/4106 Arrangement Of Point Heater Strips for HPSS SG Switch NR60


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Date: 1st June 2011


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Left Blank for CEN 54/56 and CEN 56/56 drawings

Pnts Htg 3736860 4 Front CoverNAT REP MPI ENG EP 3736860 revision Draft rev 12.0ORGIntroduction2. Scope3. Definitions and Abbreviations4. Standards and Relevant Documentation5. Performance requirements5.1. Service Life5.2. Product Acceptance

6. General Design Requirements6.1. Equipment Layout6.2. Electrical Design6.3. Earthing and Bonding 6.4. Track circuit Compatibility6.5. Electromagnetic Compatibility (EMC)6.6. DNO Supplies

7. Equipment Design 7.1. DNO Supply Cabinet7.2. Point Heating Control Cubicle 7.3. Point Heating Transformers 7.4. Portable Tool Transformers.7.5. Trackside Connection Boxes7.6. Heaters7.7. Cabling7.8. Labels and Signs7.9. Cubicle Construction7.10. Remote Condition Monitoring 7.11. Rail Temperature Probes

8. Removal of Redundant Materials9. Documents and Drawings10. Asset Recording11. Training12. Testing and Commissioning