SPG 0714 ver 1

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RailCorp Infrastructure Engineering Specification - Signalling

SPG 0714 SPECIFICATION COMPRESSED AIR SYSTEMSVersion 1.0 Issue Date February 2008

Prepared By Owner Approved By:

GHD Pty Ltd Chief Engineer Signals Authorised By:

Version 1.0 Issue Date: 26 February 2008 RailCorp 2008 Page 1 of 39

RailCorp Infrastructure Engineering Specification Signalling Construction Specification

Compressed Air Systems

SPG 0714

Revision Control TableRevision 1.0 Date of Approval 26 February 2008 ECP/DCN No. Summary of change New document

This standard replaces Signalling Design Principle No SC 09 20 00 00 SP, Version 2.0 of November 2001.

Table of Contents1. Scope ..........................................................................................................................................3 1.1. Introduction ....................................................................................................................... 3 1.2. Reference Documents, Standards and Codes ................................................................. 3 1.3. Installer Supplied Data...................................................................................................... 6 2. Design .........................................................................................................................................6 2.1. Design Inputs.................................................................................................................... 6 2.2. Design Documentation ..................................................................................................... 7 3. Fluid Parameters and Site Details...............................................................................................8 3.1. Fluid Parameters .............................................................................................................. 8 3.2. Environmental and Site Factors........................................................................................ 8 4. Equipment Supply .......................................................................................................................9 4.1. Compressors .................................................................................................................... 9 4.2. Receivers.......................................................................................................................... 9 4.3. Dryers ............................................................................................................................... 9 4.4. Expansion Joints............................................................................................................... 9 4.5. Miscellaneous Equipment................................................................................................. 9 5. Pipework ...................................................................................................................................10 5.1. Piping Classes ................................................................................................................ 10 5.2. Pipework Arrangement ................................................................................................... 10 5.3. Steel Piping..................................................................................................................... 10 5.4. Insulation Joints .............................................................................................................. 11 5.5. Manifolds ........................................................................................................................ 11 5.6. Flexible Hose .................................................................................................................. 11 5.7. Identification and Painting............................................................................................... 12 6. Installation .................................................................................................................................14 6.1. Equipment / Compressor House..................................................................................... 14 6.2. Pipework Installation....................................................................................................... 14 6.3. Cleaning.......................................................................................................................... 15 6.4. Safety Equipment ........................................................................................................... 16 7. Testing and Commissioning......................................................................................................17 7.1. Testing ............................................................................................................................ 17 7.2. Precommissioning .......................................................................................................... 17 7.3. Commissioning ............................................................................................................... 18 Appendix 1 Typical System Documentation ...................................................................................19 Appendix 2 Drawings .....................................................................................................................22 Appendix 3 Data Sheets.................................................................................................................32

Version 1.0 Issue Date: 26 February 2008

RailCorp 2008

Page 2 of 39

RailCorp Infrastructure Engineering Specification Signalling Construction Specification

Compressed Air Systems

SPG 0714

1.

ScopeThis specification details the design, fabrication, installation, testing and commissioning of compressed air systems for railway signalling use, and is to be used for both new and altered systems. The compressed air system includes, but is not limited to, air compressor houses (consisting of air compressors, dryers, and controls), air receivers, pipe-work and associated piping components such as manifolds and valves. The compressed air systems will be used to operate track turnouts (points) and train stops, both of which are actuated by pneumatic cylinders.

1.1. Introduction

1.2. Reference Documents, Standards and CodesThe following reference documents form part of this specification.Drawing number SPG 0714/01a Title Standard Air System Drawing Symbols (A) Standard Air System Drawing Symbols (B) Pit Drainage Arrangements Compressed Air Piping Arrangements Connection Single Trainstop to Main Anchor Points Steel Air Main Bracket Label Holder Installation, Part: Carrington Tang Clamp, 1/2 and Label Holder Installation Example on General Manifold Arrangement Drawings produced from design phase

SPG 0714/01b

SPG 0714/02 SPG 0714/03 SPG 0714/04 SPG 0714/05 SPG 0714/06 SPG 0714/07a

SPG 0714/07b

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Version 1.0 Issue Date: 26 February 2008

RailCorp 2008

Page 3 of 39

RailCorp Infrastructure Engineering Specification Signalling Construction Specification

Compressed Air Systems

SPG 0714

Data Sheet Number DS-P-001 DS-P-002 DS-P-003 DS-P-004 DS-EQ-001 DS-EQ-002 DS-EQ-003

Title GMS01 Piping MS01 Piping SS01 Piping Halogen Free Flexible Piping Air Compressor Compressed Air Dryer Air Receiver

Specification Number SPG 0705

Title Construction of Cable Route and Associated Civil works Compressed Air Systems Signalling Documentation and Drawings

ESG 100.25 SPG 0703

Version 1.0 Issue Date: 26 February 2008

RailCorp 2008

Page 4 of 39

RailCorp Infrastructure Engineering Specification Signalling Construction Specification

Compressed Air Systems

SPG 0714

The following Australian Standards and statutory codes form part of this specification.Standard Code AS 1074 Title Steel Tubes and Tubulars for Ordinary Service Pressure Vessels Identification of the Contents of Piping, Conduits and Ducts PVC Pipes and Fittings For Pressure Applications External Extruded High-density Polyethylene Coating System for Pipes Flanges for Pipes, Valves and Fittings Hose and Hose Assemblies for Air Hose and Hose Assemblies Air/water For Underground Coal Mines Pressure Piping Hot-dip Galvanized (Zinc) Coatings on Fabricated Ferrous Articles Hot-dip Galvanized (Zinc) Coatings on Ferrous Hollow Sections, Applied by a Continuous or a Specialized Process Occupational Health and Safety Act 2000 Rail Safety Act 2002

AS 1210 AS 1345

AS/NZS 1477

AS/NZS 1518

AS 2129 AS/NZS 2554 AS 2660

AS 4041 AS/NZS 4680

AS/NZS 4792

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Version 1.0 Issue Date: 26 February 2008

RailCorp 2008

Page 5 of 39

RailCorp Infrastructure Engineering Specification Signalling Construction Specification

Compressed Air Systems

SPG 0714

1.3. Installer Supplied DataRefer to Appendix 1 for Installer supplied data.

2.

DesignThe following data shall form part of the design inputs, along with other data listed in the Particular Specification (eg scope of work) and RailCorp Design Principles document: Reference documents, standards and codes (refer section 1.2); Available information on the existing air reticulation system and pneumatic signalling equipment in the project area to which the new work is to be connected; and/or plans showing the proposed location of the new pneumatic signalling equipment; Available information on the location of existing cable routes and any existing air reticulation system which is to be replaced by the new work; Available information on the current noise, air and waste emission approva