VRIOGS 010.4 RevA - Public Transport Victoria

VRIOGS 010.4 Revision AvSECTION 17.0 PRIMARY EQUIPMENT INSTALLATION .................................... 2517.1 Equipment Grouping...................................................................................... 2517.2 General Requirements................................................................................... 2517.3 Prohibited Material ......................................................................................... 2517.4 AC Switchgear (22kV And Signal Switchgear).............................................. 2617.5 Transformers.................................................................................................. 2617.6 Rectifier Units................................................................................................. 2717.7 1500V DC Circuit Breaker Cubicles .............................................................. 2717.8 1500V Line Isolators ...................................................................................... 27SECTION 18.0 INSTALLATION OF CABLES ....................................................... 2818.1 High Voltage Power Cables........................................................................... 2918.2 Jointing ........................................................................................................... 3018.3 Cable Identification ........................................................................................ 3118.4 Electrical Testing............................................................................................ 31SECTION 19.0 NEGATIVE BUS ............................................................................ 32SECTION 20.0 TESTING AND COMMISSIONING............................................... 33SECTION 21.0 DOCUMENTATION of ELECTRICAL WORK .............................. 3421.1 As Constructed Documentation..................................................................... 3421.2 Additional Documents.................................................................................... 34SECTION 22.0 REGULATIONS AND PUBLISHED STANDARDS ...................... 35NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

2 VRIOGS 010.4 Revision ASECTION 2.0DEFINITIONSTerminology used and/or applied in this Standard is defined as follows:DepartmentDOTHigh Voltage (HV)MAINCOPrimary EquipmentDOT or its representative. (This includes the InfrastructureMaintenance provider for the Victorian Rail Traction ElectricalNetwork Assets)Department of Transport.For the purpose of these Standards, High Voltage is definedas a voltage exceeding 650V AC and 1500V DC.Infrastructure Maintenance provider for the Victorian RailTraction Electrical Network. (For the purposes of thisstandard MAINCO is a representative of the Department ofTransport)All equipment operating at High Voltage and 1500V DC. Thisincludes switchgear, transformers & rectifiers.RailwayElectrical(RTEN)TractionNetworkAssets required to supply, switch and protect the 1500V DCsupplies to electrified trains. Assets may take the form of:SubstationsAn Electrical Installation equipped totransform and rectify HV AC suppliesbefore distributing it through 1500V DCCircuit Breakers to the overhead system.TiestationAn Electrical Installation not equipped totransform and rectify HC AC supplies, butequipped with 1500V DC circuit breakersto distribute traction power through theoverhead system.Switching Station An Electrical Installation equipped withmore than one HV AC circuit breaker, butnot to transform and rectify tractionpower.OverheadElectricalNetworkThe overhead electrical equipment thatincludes the contact wire and catenarythat runs over each track to supply powerto the electric rolling stock.Road AuthorityThe entity responsible for the road that the Level Crossingaccommodates. For public roads, the Road Authority isusually Vic Roads or the local council. For private roads, it isusually the landowner.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 3SCADA(Supervisory Controland Data AcquisitionSystem)SecondaryEquipmentService ChangeVRIOGTerm used to describe a system of remote control andindication of substation equipment. SCADA systems involveone or more Control rooms, communication systems andsubstation-based Remote Terminal Units.All low voltage equipment used to control, monitor andprotect the primary equipment. i.e. protection and controlrelays, battery banks & chargers, 415V switchboards, lightingetcChanges to the timetable, new trains, electrification of newand existing railway lines, extensions to existing railway linesetc that will result in an increased demand on the tractionelectrical network.The Victorian Rail Industry Operators’ Group comprising thefollowing members:• Australian Rail Track Corporation (ARTC)• Metro Trains Melbourne• VicTrack• V/Line• Yarra Trams• Public Transport Division of the Department of TransportNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

4 VRIOGS 010.4 Revision ASECTION 3.0SCOPE AND GENERAL3.1 SCOPEThe purpose of this standard is to provide the framework for the construction at aGreenfield or a Brownfield railway traction substation. This standard provides thegeneral requirements and considerations for the building and installation of asubstation.Detailed Construction specifications/procedure are not provided in the standard. Thecontractor shall use its own construction procedures while adhering to all statutoryand regulatory requirements.This standard shall be read in conjunction with the Substation Design Standardswhere the contractor is to perform a design function prior to construction.The works under the contract comprise but are not limited to, establishment of theworks site, provision of the necessary permanent building and structures, supply ofthe fittings, fixtures and hardware incidental to these works, installation, testing andcommissioning works.It is the intention of the Department that the works of the contract include all that isnecessary to successfully complete all works defined in the design to the satisfactionof the Department or its representative.The electrical fit-out typically involves the installation of the following primaryequipment:• H.V. A.C. switchgear (typically 22kV or 11 kV).• Rectifier transformer.• Auxiliary transformer.• Signal transformer.• Rectifier cubicle and associated control cubicle.• 1500V DC switchgear.• 1500V line isolators.• Transformer to rectifier connections.• Power cables.The contract also involves the supply and installation of the following secondaryequipment:• Ventilation equipment installation.• Alarm and Surveillance equipment.• All fault protection equipment.• Batteries and charger.• Distribution boards 415/240V AC and 110V DC.• SCADA pilot cables and cable heads.• Lighting and power equipment and fixtures.• Negative and electrolysis buses.• All interconnecting control, light and power cables.• Earthing arrangements.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 5The contractor shall supply all brackets, plinths, conduits, wiring and any othergeneral hardware necessary to complete the works of the contract.The contractor shall also supply cranes, excavation equipment, tools, test equipmentand any other such equipment required.3.2 APPLICATIONIn addition to the fundamental standard of construction and installations inaccordance with the best engineering practices with full regard being paid topersonnel and general public safety, economic factors, energy conservation andmaintenance requirements, the design shall comply with the relevant standards andrecommendations. All construction activities shall conform with the applicableclauses of recognised Standards, rulings and recommendations. Wherever a conflictexists in the requirements of these Standards, rules and recommendations, thefollowing order of precedence will be observed in ascending order:• Victorian Rail Industry Operator’s Group Standards (VRIOGS), thisConstruction Standard and related rail industry standards.• Most recent relevant Australian Standards.• Most recent relevant British Standards.• Most recent relevant US Standards.• Most recent European (EN) Standards.• Most recent recommendations of the International Electro-technicalCommission.All construction and installation activities undertaken by the contractor on electricalequipment that does not directly supply the overhead traction network shall complywith all legislation and regulations of Energy Safe Victoria when working on LVequipment.See appendix A for a list of standards.3.3 SAFETY AND ENVIRONMENTAL REQUIREMENTSAll contractors and their employees shall observe and comply with the safety andenvironmental requirements of state and federal legislation. In particular, thecontractor shall comply with the following statutory requirements.• Transport Act, Regulations and Codes of Practice;• Occupational Health and Safety Act, Occupational Health and SafetyRegulations;• Environment Protection Act, Regulations and Codes of Practice;• Flora and fauna Guarantee Act;• Heritage Act;• Electricity Safety Act, Regulations and Codes of Practice.All work shall comply with the regulations of the applicable Electrical NetworkOperator, except for those special requirements specified in the design.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

6 VRIOGS 010.4 Revision AAll work shall comply with the Public Transport Corporation’s regulations for safety,the HV Rules and the regulations of any other body having jurisdiction over the work.3.4 BACKGROUNDPrior to the development of this standard, substation construction was specified onthe basis of the standards produced by the Public Transport Corporation who are nolonger in operation. Therefore the construction requirements are being updated inthis new standard which incorporates all existing information as well as bringing it upto the current technical and statutory requirements.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 7SECTION 4.0INTRODUCTIONA single rectifier unit Substation typically consists of equipment listed below:A 3 phase 22kV AC feeder is run from the 22kV isolator/switch (mounted on a poleoutside the Substation) in conduit to the AC busbar.The AC busbar distributes the AC supplies to one 2MW rectifier transformer, oneauxiliary supply transformer and one signal supply transformer located in thesubstation.The rectifier transformer steps-down the 22kV supply to approximately 581V ACwhich is passed to the rectifier stack where it is rectified to a nominal 1500V DC. Thepositive side of the rectifier is connected to the overhead wire catenary via a DCbusbar, DC circuit breakers and line isolators. The negative return from the runningrails is provided through the wall mounted negative busbar back to the rectifier.The auxiliary transformer supplies power at 415V, 3 phase to the 415/240Vswitchboard which then supplies the local auxiliary services which include batterycharging, lighting control and protection equipment.The substation is generally remotely operated by the Supervisory Control and DataAcquisition (SCADA) System. Local operation of all equipment is also available.An earthing grid is installed beneath the substation building and transformer yard.The DC traction circuit has no direct connection with earth. Stray return currents canbe controlled by the use of Electrolysis Mitigation Equipment which is designed tokeep electrolytic corrosion to a minimum. This will be fitted by others if required, afterthe location has been commissioned and placed into service. Tie stations andSubstations have similar layouts, but not necessarily all the equipment mentionedabove.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

8 VRIOGS 010.4 Revision ASECTION 5.0SITE SAFETYThere are many hazards in a substation environment that could lead to explosions,burns, electric shock and death. The contractor shall use work practices andsafeguards to prevent such incidents from affecting its personnel, the Departmentspersonnel, the Departments representatives, general public and livestock.All applicable codes and guidelines published by Energy Safe Victoria shall beadhered to. Particular attention shall be paid by the contractor to the followingrequirements.• The contractor shall maintain Safety Management standards and procedure thatcomply with AS 4292.2.• The use of personal protective equipment that comply with Australian standards,such as but not limited to safety footwear, hardhats, eye protection, high visibilityclothing is compulsory.• The contractor shall provide its employees with a safe and healthy workingenvironment as per the requirements of WORKSAFE. In particular WORKSAFErequirements for confined spaces, falls, manual handling, noise, plant &machinery, removal of asbestos 1 and hazardous substances shall be adhered to.• All the contractors’ employees shall be medically fit, have a zero blood alcohollevel and authorized by the Department to work at the site and shall be suitablytrained in the aspects of the work to be carried out.• All personnel shall also be trained in Train Track Safety Awareness.• Safety and environmental inductions shall be held for all personnel that will comeon to the site. The inductions shall provide all necessary information, instructionsand training for the personnel to carryout their duties in a safe andenvironmentally friendly manner.• The contractor shall maintain a risk register that includes safety related risks.Risks shall be identified and mitigation measures shall be put in place.• Prior to commencing any work the contractor shall supply to the Department aSite Safety and Environmental Plan for review.• The safety and environmental plan shall include Emergency Response plans forany foreseeable events.• Prior to starting a work shift all site employees shall be briefed of the hazards atthe site. The hazards list shall be clearly displayed for viewing by all site staff.Any newly identified hazards shall be put on the hazard list and any previoushazards that no longer exist shall be removed.• The contractor shall comply with the “HV Rules”. All permits requirements andprocedures as specified in the HV Rules shall be followed. All mobile andstationary equipment used in the substation during construction and installationshall be suited to a substation environment and shall be used as per the “HVRules”.• All clearances from vehicles and mobile plant to exposed live equipment shall bein accordance with the HV Rules.• The contractor shall ensure that all substation structures maintain arecommended clearance from other traction equipment or any other structures.Where work is to be carried out in the vicinity of railway tracks, the contractor shall beaware of the following requests:1 This is only if removal of asbestos is required from an existing substation. Materials or equipmentcontaining asbestos shall not be used under any circumstance.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 9• Special conditions relating to Working of Cranes Near Power Lines andElectrical Apparatus.• Railways of Australia Code and AS4799 that govern the installation of cablesnear and under rail tracks.• Rail safety requirements of the Department.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

10 VRIOGS 010.4 Revision ASECTION 6.0RISK MANAGEMENTThe contractor shall maintain a risk management process that includes works fromthe planning phase until the completion and handover of the constructed substation.The risk management process shall comply with AS 4360. The following essentialaspects of risk management shall be included in the contractor risk managementprocess.• Communicate and consult with the Department, designer, maintenancecontractor, sub consultants and any other stakeholder• Establish the context in which the risk management process is to be carriedout.• Identify when, where, why and how undesirable events could occur tojeopardise construction.• Analyse the identified risks, consequences, level of risk and evaluate how tocontrol them.• Evaluate the levels of risk against pre-established criterion and decide onextent, treatment and priorities of the risks.• Develop strategies and action plans to reduce risks.• Monitor the effectiveness of the risk management process and review therisks, strategies and action plans.Risks related to safety, environmental impact, quality of construction, reliability, ontime construction & future maintainability shall be among the risks considered by thecontractor.The contractor shall document its risk management process and also maintain an upto date risk register that documents the risks as per its risk management process.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 11SECTION 7.0ENVIRONMENTAL IMPACTa) All Environmental Protection Agency guidelines shall be followed during theconstruction of the substation. In particular the following guidelines shall befollowed.• Guideline related to noise.• Guidelines related to handling of waste.b) Residents shall be notified of all work to occur during construction and theimpact on them.• Noise level during construction.• Impact on traffic flow.• Safety of commuters.• Impact on any bushes/trees in the vicinity.c) Assessment of environmental impact shall be part of the risk managementframework used by the contractor.d) The Department shall be notified of any environment related issues withoutdelay.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

12 VRIOGS 010.4 Revision ASECTION 8.0COMMUNICATIONS8.1 GENERAL REQUIREMENTSThe contractor shall keep in close contact with the Department or its representativeduring the construction and installation of the substation works. The Departments(DOT) representative can be an external contractor assigned with defined functionsto carry out on behalf of the DOT. The contractor assigned with the maintenance ofthe electrical infrastructure is also a representative of the DOT for the purposes ofthis standard.All required communication shall be carried out in an effective and reliable way. Inparticular communication between both parties is important in the followinginstances;• The contractor shall immediately advise the Department and Energy SafeVictoria of a death, injury or any other emergency situation. Incident/Accidentnotification procedures shall be followed.• Damage to electrical equipment, structures, building or any other property orequipment shall be reported to the Department immediately.• The ability to meet approaching milestones and any potential risks or delaysshall be communicated to the Department well in advance.• Any issues with the design or construction shall be notified to the Departmentwell in advance of any work slippage occurring.• The Department shall be notified of any requirement of the contractor todeviate from the detailed design drawings.• Regular meetings shall be held between the contractor and the Departmentand its representatives to discuss the progress of the work. All risks, potentialdelays, OH&S issues and environmental issues shall also be discussed atthese meetings.8.2 PROJECT PROGRESS REPORTINGThe contractor shall issue a progress report either weekly or fortnightly depending onthe requirement of the Department. The report shall at a minimum include thefollowing information.• Progress since the last project report.• Work to complete until the next project report.• Any new issues and outstanding issues from previous progress report.• A summary from the risk register maintained by the contractor.• OH&S related incidents.• Costs to date reported against a Work Breakdown Structure nominated by theDepartment.• Expected costs to complete.• Expected delivery date.• An updated Gantt chart showing the progress of the project.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 13SECTION 9.0DESIGN OF SUBSTATION9.1 DETAILED DESIGN OUTCOMESThe Department in consultation with a design contractor determines the systemdesign as well as the detailed design of the substation.The detailed design outcomes will be provided to the construction contractor in theform of; (only a summary is provided below)• All civil outline and layout drawings and plans.• All primary and secondary electrical equipment outline drawings, schematicsand diagrams.• All power, control and lighting schedules.• Detail design instructions ( instructions and advise on how to logically carryout the construction )• Technical Maintenance Plans for equipment that is new in the network.The contractor shall review the above mentioned information to determine therequirements for the construction of the substation.9.2 REVIEW OF THE DETAILED DESIGNThe contractor shall review the information and provide comments to the Departmentas to the completeness and adequacy of the information prior to commencing theconstruction. The contractor shall advise the department regarding the following.1. Adequacy and completeness of the detailed design.All provided documentation shall be reviewed such that any information thatmaybe missing or is inaccurate is identified. This review is essential to ensurethat construction is not delayed or hindered in anyway after commencement.2. Safety related risks that may be encountered due to design features.Any safety related risks that maybe encountered during the construction shall beidentified along with any other potential risks due to any aspect of the design.3. Constructability and maintainability of the design.Any foreseeable construction difficulties or maintainability restrictions shall beidentified by the construction contractor.The drawings shall be reviewed to determine the requirements for maintainingand operating the equipment. In particular the clearances for the followingsituations shall be reviewed.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

14 VRIOGS 010.4 Revision A• Check the adequacy of access space around key items of electricalplant for operation and maintenance purposes.• For example adequate space is required to rack out the circuitbreakers (both AC and DC), to open panels and inspection doors.• Access is required to visually inspect earth and short circuitconnections and unambiguously determine the status. Also theconnection shall be possible to be viewed in dark conditions.• Switchgear is to be fully operational from ground level, without theneed to work off platforms.• Adequate space is provided for the removal of individual items ofequipment without the need to relocate other equipment items. Alllayouts, pathways, doorways etc shall be sufficiently dimensioned toprovide the required space and clearances.9.3 DESIGN ADJUSTMENTS REQUIRED DUE TO SPECIALDRAWINGSIt is also possible that certain drawings may not be available from equipmentManufacturers at the commencement of construction. These final drawings mayhave a bearing on certain aspects of the detailed design and may need adjusting.Discussion shall be carried out between the Department, the designer and theconstruction contractor regarding what to do in this situation.If the review concludes that a major design change is required, the design drawingsshall be updated and reissued.All design changes shall be in accordance with the VRIOG – Railway TractionSubstation Design Standard.The updated drawings shall also be issued to the maintenance contractor forapproval.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 15SECTION 10.0INSPECTION OF WORKS10.1 PRE COMMENCEMENT INSPECTIONPrior to commencement of any site works, a site inspection involving the Contractorand the Department or its representative shall be held to gain familiarisation with therailway environment, principles of the design and site specific considerations.10.2 CONTRACT PERFORMANCE INSPECTIONSThe contractor is responsible for the totality of all works on site. During theperformance of works of this contract inspections shall be carried out by theDepartment (or its representative) to ensure compliance with the ConstructionStandards.The Contractor shall give the Department (or its representative) at least two (2)working days’ notice of when inspections are required.The contractor shall ensure that each stage of the works is completed in a mannerand to a standard which will allow uninterrupted completion of the following stages ofwork.In particular, the inspections shall ascertain the following aspects of the design.a) Earth grid installation as per design. ( the earth grid resistance shall be as perthe design)b) Conduits, pipes, ducts, pits are located exactly to design.c) Insulated and close tolerance flooring meets design and equipmentmanufacturer requirements.d) External and internal doors will allow equipment entry without equipmentdisassembly or modification of entry.e) Walling will allow installation of all equipment to be so installed includingthrough cables without equipment disassembly.f) All electrical and ergonomic clearances are as per the design.g) All primary and secondary equipment installations are as per the design.h) All major cable joints and terminations have been carried out satisfactorily.i) Any design changes by the contractor has not altered the original intent of thedesign.In addition to the above, general inspections will be carried out by the Departmentprior to and after testing. The Department or its representative will also attend thecommissioning.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

16 VRIOGS 010.4 Revision AAdditional random safety inspections shall also be carried out by the Department atits discretion.10.3 ONSITE CONSTRUCTION DRAWINGSThe contractor shall maintain on an ongoing basis, a set of marked up constructiondrawings on site. The Departments or its representative shall have access to thesedrawings to monitor the progress of the construction. Particularly at Brownfield sitesthe constructions drawings shall be adequate enough to enable emergency operationand reactive maintenance of any in service equipment while the construction isoccurring.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 17SECTION 11.0PROGRAM OF WORKSThe program of works activities shall be sequenced as follows:a) Within two weeks of the contract date, the Contractor shall supply for theDepartment’s approval, a Gantt chart showing the proposed program ofworks. The Gantt chart shall identify all tasks, duration and resources fortasks, milestones, critical path etc.b) Within three weeks of the contract date, the Contractor shall supply to theDepartment the results of the design review carried out as discussed in 9.2.c) If the construction site is an existing site, the contractor shall be trained onany operations, technical, safety or environmental aspects of the site. Thisshall take place before commencement of any work.d) Negotiation and provision of all temporary builders supply required for thesubstation construction work.e) Preparation of the site prior to carrying out any construction.f) Laying the earth grid that will eventually be below the substation building.g) Laying out the conduits and trenches.h) Construction of the substation building.i) Fit out of the building which includes electrical works such as:i). Lighting and power equipment and circuits as required,ii). Power cabling as required, andiii). Conduits as required.j) Secondary equipment installation.k) Primary equipment installation.l) Testing and Commissioning.m) Handover of all required construction documentation as specified in sectionSECTION 21.0.The Approved Program of Works of the Contract is a control document for thepurpose of the Contract. Any variation to the sequence of works or other departurefrom the Program shall require prior approval by the Department.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

18 VRIOGS 010.4 Revision ASECTION 12.0SITE EARTH WORKS12.1 EXCAVATIONThe contractor has a duty of care to observe with regard to underground networkswhen digging or excavating. Underground network information should be sought wellin advance to construction activities. The contractor shall inform itself of the locationsof underground services through the “Dial Before You Dig Service”.In addition to the information provided by the “Dial Before You Dig Service” and theearthing layout provided as part of the detailed design, the contractor shall also carryout a visual check of the area around the site to see whether any cables or servicesare entering the site.If there are any underground services, the Department as well the appropriateauthority shall be informed prior to carrying out any excavations. All requirements ofthe authority that owns the underground service must be followed when carrying outwork.Suitable measures shall be taken to safeguard the existing underground services.12.2 SITE ENVIRONMENTAL REQUIREMENTSa) Trees, shrubs and ground vegetation outside the earthworks area shall not beremoved.b) Areas of ground disturbance shall be minimised.c) Any ground that has been disturbed shall be restored to its original conditionor better.d) Where possible excavated soil should be reused as Select Fill.e) Surplus Fill shall be used for landscaping.f) Contaminated waste shall be treated or disposed of off-site in accordancewith EPA 448 requirements.g) Erosion and sediment control shall be implemented during construction.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 19SECTION 13.0THE EARTH GRIDThe earth grid shall be laid in accordance with the design requirements.13.1 INSTALLATIONa) Before any preparation or form work is made for the reinforced concrete slab,the contractor shall install an Earth Grid System at a nominal depth specifiedon the design at a level below the finished floor level of the substation.b) Trenches will be cut in the sub soil to the required depth relative to thesurveyor’s marks approximately 200mm wide.13.2 INSTALLATION OF EARTHING ELECTRODESCopper earthing Electrode each 3 metres in length with a minimum diameter of16mm, shall be driven into the trenches at the design indicated points to a depth soas to leave approximately 100mm clear for cadwelding or brazing to the grid wire.13.3 BUILDING CONNECTIONS TO THE EARTH GRIDa) The switchroom main earth bar shall be connected the outside earth grid asper the design. Disconnection point for testing shall be at the main earth bar.There shall be some means to visually and electrically confirm the connectionof the switchroom earth bar to the external earth grid.b) Provision shall be made in accordance with design documentation forconnection of fences, slab reinforcement, transformers and all other metalcladequipment to the earth grid.13.4 TESTING OF THE WHOLE INSTALLATIONThe resistance of the earthing grid shall be tested in an approved manner afterinstallation together with the resistivity of the soil. This shall be carried out before theconcrete base is laid and the Department or its representative advised of the resultswithin 24 hours of the test being completed.Further construction work shall not proceed until the Department evaluates the earthgrid test results and confirms that the results are satisfactory.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

22 VRIOGS 010.4 Revision ASECTION 15.0ELECTRICAL INSTALLATIONThe general sequence of the electrical installation is:a) General lighting and power wiring and switchboards are fitted.b) Phone communications installed.c) Batteries and battery charger are installed.d) Secondary equipment is often installed prior to the running of cables toprevent damage to cables. Where the building provides access limits to thedrawing of cables through conduits, heavy cables are run prior to equipmentbeing installed.e) Primary equipment is installed.f) Cables which are terminated in accordance with the Terminal StripInterconnection drawings(s) and connected to equipment.g) Earthing cabling and negative cabling.The Remote Terminal Unit of the SCADA System will be installed by the Departmentrepresentative and wired by the Department's representative following the completionof Stage e above.If required the electrolysis mitigation equipment will be installed by the Departmentsrepresentative after the commissioning of the substation.This sequence of work shall be read together with the general sequence of works ofthe Contract, Clause 11 above, and shall be incorporated in the Program of Works.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 23SECTION 16.0SECONDARY EQUIPMENT INSTALLATION16.1 415/240V SWITCHBOARDThis switchboard shall be manufactured as specified in the design. The switchboardshall be mounted so that the top is 1800mm from floor level and held to the wallusing 12mm anchors.16.2 DC SWITCHBOARDThis switchboard shall be manufactured as specified in the design. The switchboardshall be mounted on the wall so that the top is 1800mm from floor level and heldusing 12mm anchors.Both switchboards (415/240 AC switchboard and DC switchboard) shall be locatedas shown on Equipment Layout Drawing and wired up as per Auxiliary SuppliesDrawing.16.3 DC BATTERY CHARGER AND BATTERY BANKThese shall be installed as per design instructions and details.16.4 SUBSTATION LIGHTING AND POWER CIRCUITSThe lighting and power installation for the location shall be installed in accordancewith the specifications and drawings.16.4.1 LayoutThe position of all fittings shall be as set out in the Light and Power Layout drawing.Note that the circuits are supplied from 415/240V switchboard and 110V DCswitchboard for emergency lighting.Note the location and details of the special heavy current three-phase outlet.16.4.2 StandardsThe cabling to fittings, power sockets and light fittings shall comply with AS 3000, theregulations and standards as appropriate.Cables shall be placed in accordance with the specifications and drawings.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

24 VRIOGS 010.4 Revision A16.5 COMMUNICATIONS EQUIPMENTAllowance shall be made in accordance with design specifications and drawings forsupervisory pilot cable(s) and P.A.B.X. phone which will be terminated in a pilot wireterminal box mounted on the outside substation wall. All installation requirements forconvertors / amplifiers / Power source shall be carried out as per the designspecifications and drawings.Connections between the outside wall terminal box and cable head box will becompleted by Department's representative.16.6 REMOTE TERMINAL UNIT (RTU)The RTU cubicle will be supplied as a principal item and shall be located andinstalled as per design specification and drawings. Cabling shall be run fromequipment to the RTU cubicle and cut with sufficient length to allow terminationinside RTU by the Department's staff.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 25SECTION 17.0PRIMARY EQUIPMENT INSTALLATION17.1 EQUIPMENT GROUPINGThe electrical equipment is grouped into six principal areas in a substation.a) AC switchgearb) Transformersc) Rectifier(s)d) DC switchgeare) Signal switchgearf) Remote terminal unit.Cable connection between areas is generally run in floor ducts and conduits passingthrough and below the concrete slab floor. Design instructions and drawings shall beadhered to. Any deviation from design must have prior approval of the Department.17.2 GENERAL REQUIREMENTSa) When transporting and moving the switchgear to its designated location allManufacturer recommendations shall be adhered tob) Before commissioning all connections shall be checked for tightness. Allbolts that need tightening shall be tightened only to the torque recommendedby the manufacturer.c) The contractor undertaking installation is responsible for the removal anddisposal of all packing, shipping fasteners and any other foreign materials.d) All AC switchgear enclosures shall be earthed as per the design. DCswitchgear enclosures shall not be earthed.17.3 PROHIBITED MATERIALThe following substances are not to be used in any part of the traction ElectricalNetwork installations:• Asbestos or Asbestos containing materials or equipment.• Polychlorinated biphenyls (PCBs)• Sulphur Hexafluoride (SF6)It is the responsibility of the contractor to ensure that the above mentioned prohibitedmaterials are not introduced during the construction works.In particular, the contractor shall be responsible for the taking of oil samples of allelectrical equipment containing oil, or taking of oil samples of bulk oil prior topumping into electrical equipment. The contractor shall then arrange for the testingof the oil samples for PCB level.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

26 VRIOGS 010.4 Revision AThe level of PCB present shall be determined by Gas Chromatography using an ECDdetector, and an official test report submitted to the Department.17.4 AC SWITCHGEAR (22KV AND SIGNAL SWITCHGEAR)a) Manufacturers of indoor metal clad switchgear specify a high tolerance floorflatness which must be observed. The floor area over which the switchgear isto be mounted shall be carefully checked to ensure that it meets themanufacturer's specified tolerance flatnessb) Where metal clad switchgear is specified, the cubicles shall be groupedtogether and earthed to the main substation earth bus.c) Cubicles shall be clearly marked with designation and purpose and installedin accordance with specification drawings and the manufacturer'srecommendations.d) Particular care is required in ensuring that the floor is flat and level prior to theinstallation of cubicles.e) The insulators and contacts shall be cleared and freed from obstruction andthe operating mechanism lubricated, in accordance with the manufacturer’srecommendations.17.5 TRANSFORMERSThe Transformer(s) shall be installed in accordance with the design. All manufacturerrecommendations and tests shall be carried out prior to commissioning of thetransformer including the following;a) Before and after mounting, the transformers shall be carefully inspected fordamage, particularly oil leaks and cracked or broken insulators.b) The transformer manufacturers’ specifications for cooling requirements shallbe met. The Department shall be informed if the design does not allow for thespecified cooling requirements.c) A sample of the transformer oil shall be tested in accordance with AS 1767and shall have a minimum dielectric strength of 50kV.d) The oil level shall be checked and the oil seen to be clean and clear. Thesilica gel breathers shall be clear and operational and the insulators clean.e) All valves, pipes and fittings shall be in its correct position and fitted firmly.f) Ensure that the LV/HV neutral earthing is as per the detailed design.g) Ensure that the tank earthing is as per the detailed design.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 27h) Any areas of corrosion shall be wire brushed and repainted with an approvedcompatible paint.17.6 RECTIFIER UNITSa) Each rectifier and control cubicle shall be mounted on separate woodenplinths.b) The two plinths shall be anchored to the concrete floor using 12mm anchors.The cubicle shall be installed on the plinths using wood screws in accordancewith the design instruction, such that the insulation resistance of cubicles toearth is greater than 1 MΩ using 2500V megger.17.7 1500V DC CIRCUIT BREAKER CUBICLESa) 1500V DC Circuit Breakers cubicles are grouped side by side on an area offloor which is insulated earth. The cubicles are connected to the negativebus.b) The switchgear requires high tolerance top floor flatness over the area onwhich that switchgear is to be mounted. This area must be checked toensure that it is within tolerance prior to mounting the switchgear.c) Before commissioning, all connections shall be checked for tightness.Insulators shall be clean and free from obstruction. Operating mechanismsshall be lubricated in accordance with the manufacturer's recommendation.d) Circuit breakers are required to be easily pulled out from their operatingpositions for servicing. When returned back into their cubicles they shall beable to lock in accurately when connecting with the bus. The manufacturer'sinstructions shall be followed for correct adjustments.17.8 1500V LINE ISOLATORSThe 1500V Line isolators shall be installed as per design instructions and details andlocated as per equipment layout.The bottom of the isolator base structure shall be mounted at a height of 4.5m abovethe finished operating level. The base of 1500V Line Isolators shall be connected tothe Negative Bus.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

28 VRIOGS 010.4 Revision ASECTION 18.0INSTALLATION OF CABLESAll cables shall be installed or arranged to be installed as specified in the design.a) All cables shall be multi-stranded.b) The control cabling shall be installed in accordance with the Cable Schedulewhich shall be read in conjunction with the Terminal Strip InterconnectionDrawing.c) Cables shall be installed so that they can be withdrawn for the purposes ofrelocation and /or rewiring.d) Cables shall not be forced into a radius less than that specified by themanufacturer.e) All cables shall be run in a neat and tradesman-like manner in full accordancewith the appropriate Standards, Regulations, Railways of Australia Code andto the satisfaction of the Department.f) In areas which could present possible future problems such as difficult accessareas, the Contractor shall provide spare cables, spare cores in multi-corecables and pull wires.g) Underground conduits and other forms of wiring enclosures shall be selectedas to AS3000 appendix C6.1 so that cables and circuits may be installedwithout damage.h) The contractor shall provide an allowance for a reasonable degree ofslackness, particularly for control cables.i) The preparation and installation of cables, lugs, busbar and termination pointsshall be completed in an approved manner to prevent hot spots, faultyconnections or stresses on busbars & insulators.j) In areas where cabling is likely to be disturbed or damaged by vandals orother causes, appropriate additional protection is to be provided over andabove traditional cabling practices. This protection can include (but not belimited to) means such as:• Undergrounding of cable within conduit, pipe, ducting, etc.• Covering of cable with metal cover's,• Use of galvanised steel conduit or galvanised steel water pipesupported by heavy duty saddles with approved fixings at approvedintervals,• Use of metal duct or where appropriate cableways such as cableladder appropriately supported.k) PVC conduit used externally shall be suitable for prolonged exposure tosunlight or suitably protected against the effects of UV radiation. Note thatNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 29HD (orange) electrical conduit to AS 2O53 does not comply and requiresprotection if exposed to sunlight.l) PVC conduit shall be adequately supported using galvanised steel saddleswhen used externally. Due regard must be paid to the expansioncharacteristics of this material when exposed to heat with expansion jointsbeing used as appropriate.m) Where cable ties are employed in areas exposed to sunlight, they shall be UVstabilised (black) or be of stainless steel construction.n) Cables shall be installed in such a manner that adequate space is providedfor fixing and for heat dissipation. Bending radii shall not be less than themanufacturer's recommendation. Cables with conductors in excess of 16mm 2shall be run straight for at least 300mm immediately prior to enteringswitchboards and other equipment.o) Control and indication cables and light and power cables shall be runseparately from H.V. cables.p) All cable ducts, conduits etc shall be clean and free of debris.18.1 HIGH VOLTAGE POWER CABLESThe general cable requirements listed above are also applicable to power cables, butthe following additional precautions shall be observed for HV and power cables.a) The cables shall be installed in continuous lengths between each of thepieces of apparatus. No joints will be permitted except with the express,written permission of the Department.b) All cables will be cut from drums in such a manner that off-cuts are aminimum and any surplus cable remaining is in a single length.c) Ends of H.V. cable which during the substation construction period will beexposed to the weather or be buried below ground are to be protected bypropriety end caps.d) All cables should be handled carefully and at no time should they be forcedinto a radius less than that specified by the supplier. During laying twists orkinks in the cable and snaking must be avoided.e) When drawing cables into conduits, care must be taken not to exceed themaximum pull specified by the manufacturer. If a winch is used this shouldhave automatic limitation of the pull exerted.f) Cables should be run on the rollers to ensure they do not contact the groundor get soiled. Vertical rollers should be used where there is a change ofdirection.g) Cables must not come in contact with petroleum based substances such asgrease, oil or petrol which will damage the insulation. Only approvedlubricants are to be used with cables.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

30 VRIOGS 010.4 Revision Ah) Damage occurring to any cable must be reported to the Department beforecable termination commences.i) The metallic screens of the 1500V DC positive cables shall be connected tothe negative strip on the 1500V DC switchgear bus only.j) The metallic screens on AC cables shall be earthed on the supply end only.The screen on the load side of the cable shall be pulled back and insulated.k) Termination of HV cables shall be done using an approved heat shrinkableplastic termination kit (22kV, 2.2kV) or, for 1500V cables, completed as perthe departments drawings.l) High Voltage and Heavy Power cables shall be run in accordance with designdetails, being adequately supported along route lengths by standard methods.m) Termination of HV cables shall be undertaken only by qualifiedtradespersons.n) Only compression tools approved by the cable lug manufacturer shall beused. Where hand operated tools are used they shall be of the type whichwill not release until full compression is achieved.o) A cable plan shall be provided for all underground cables showing exactlocation, depth and any obstructions over or under the cable route etc. Anyvariations to the proposed cable plan shall be approved by the Departmentand the amended drawings provided by the Contractor.18.2 JOINTINGThe contractor shall comply with the following requirements;a) In HV cable installations the number of cable joints must be kept to aminimum.b) All proposed HV joints must be shown on the design drawings and approvalshall be sought from the Department prior to installation. The HV cablesjoints are also subject to inspection by the Department.c) HV Joints are to be located in a pull through cable box for ease of accessshould a failure of a joint occur in the future.d) Jointing techniques for copper to copper, copper to aluminium or aluminium toaluminium are well documented, and such techniques shall be observed forthe electrical construction works. Only the cable jointing kit recommended bythe cable manufacturer shall be used. The cable manufacturer and joint kitmanufacturers instructions shall be followed when carrying out the jointing.e) In particular, whenever Aluminium for crimp lug or busbar is specified, hotdipped, galvanised, thick, flat washers and belleville washers and stainlesssteel bolts shall be used to compensate for different rates of thermalNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 31expansion and maintain correct contact pressure under all operatingtemperatures.f) In addition, the contact surface area, preparation of surface prior to jointingand selection, size and location of fasteners shall be such that contactresistance for the joint is maintained for rated current and voltage.g) For resin cable jointing systems the manufacturers recommendations withregard to temperature and humidity storage requirements shall be followed. Inaddition the resin shelf life shall be monitored.h) All jointing work shall be carried out in dry clean conditions.i) The cables shall be checked for moisture contamination prior to the jointing. Ifmoisture contamination is detected the affected cable shall be removed andnew cable installed.18.3 CABLE IDENTIFICATIONa) All cables shall be installed with identification labels. These should beinstalled as close to the termination point as practical and shall be positionedsuch that they are easily visible when all the cables are installed in their finalposition.b) The identification of each cable and in addition each core of multicore cableswill be labelled in accordance with the cable schedules.c) In addition, all AC cables shall be marked with phase identification colouredPVC electrical tape applied over the completed cable termination in a 12mmwide strip close to the cable lug. For AC busbars within switchgear cubicles,phase identification coloured paint shall be applied along the entire length ofthe busbard) Where pits are provided, cables should be marked by fixing trafolyte or similarlabels to the cable which show the cable identification number. Labels shallbe tied to the cable by PVC cable ties or approved equivalent.18.4 ELECTRICAL TESTINGBefore HV cables are connected to the equipment, each cable shall be insulationtested to ensure no damage has occurred during laying.A value in excess of 50M ohms should be obtained using a 2,500 volt megger range:• between single cable cores when in the same conduit• cable cores to an earth pointNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

32 VRIOGS 010.4 Revision ASECTION 19.0NEGATIVE BUSA special copper bus bar shall be manufactured in accordance with the specificationsand drawings.The negative bus bar will be located as per Equipment Layout Drawing to suit thenegative cable outlet requirements.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 33SECTION 20.0TESTING AND COMMISSIONINGThe Contractor shall supply all testing schedules for approval by the Department’srepresentative. The Traction Electrical Network Assets shall be commissioned by theContractor using the established procedures of the Department for the types ofequipment installed at other locations.a) Due notice shall be taken of any manufacturers requirements concerning, inparticular, high voltage testing, such that sensitive equipment is disconnectedas appropriate. The responsibility for ensuring these instructions are carriedout and that no damage occurs to equipment shall lie with the Contractor.b) The Department shall supply the Contractor with the necessary protectionsettings before the commissioning date.c) At least 4 weeks of notice is required for the SCADA database to be created.All SCADA equipment shall be operational prior to commissioning of theremaining secondary and primary equipment.d) The Contractor shall give at least 7 days notice to the Department prior to thecommencement of commissioning.The Department’s representative reserves the right to have these testswitnessed.e) Testing shall take place using the approved Test Schedules as appropriate.f) When appropriate, the Contractor shall inform the Department’srepresentative that the location is ready for connection to the Electricalnetwork (distribution).g) The Department’s representative will make arrangements with the ElectricalNetwork Operator (Electricity Distribution Company) to inspect the substationand to issue a H.V. clearance certificate after which the supply will beconnected and the substation will become energised.h) Testing shall continue to the Test Schedules.i) The final stage of testing concerning the SCADA System shall be a combinedtest between the Contractor and the Department’s representative.j) The Departments representative (includes the Electrical Infrastructuremaintenance contractor) shall be trained in all aspects of the new electricalinstallation. All operational, technical, safety and environmental aspects ofthe new installation shall be covered during the training. The technical trainingshall involve going through the as constructed drawings and operatorinstructions.k) Copies of all test sheets, completed schedules and certificates shall besupplied within 14 days of completion to the Department’s representative.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

34 VRIOGS 010.4 Revision ASECTION 21.0DOCUMENTATION OF ELECTRICAL WORK21.1 AS CONSTRUCTED DOCUMENTATIONAs part of the works, the contractor shall supply all “as constructed”documentation. It is expected that this documentation will involve the markingup of the design drawings which may only be modified with approval of theDepartment.Where, in the opinion of the Department, the changes are significant enough towarrant preparation of new drawings, the Contractor shall supply 3 copies ofeach new drawing. The contractor shall also provide copies of the aboveinformation on a CD in PDF and "Microsoft Office Word - Version 11.8" formatfor documents and in PDF and "Intergraph" microstation ‘dgn' format for alldrawings. The drawings shall also be submitted to the Victrack DrawingManagement System (DMS).21.2 ADDITIONAL DOCUMENTSIn addition, as constructed documentation shall be supplied for the following:• Details of additional equipment supplied and installed.• Maintenance instructions for equipment supplied and installed that werenot in the original design.• Schedule of changes to original design.• Operating instructions written in the format used by the electricalinfrastructure maintenance contractor.• A register of hazards and risks that maybe encountered during theongoing operation of the substation.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 35SECTION 22.0 REGULATIONS AND PUBLISHEDSTANDARDSSubstation Construction requirements will comply with the requirements of theDepartment’s Traction Substation Construction Standard 2007, unless notedotherwise.All construction shall comply with all relevant regulations of Government and SemiGovernment Authorities.In particular, the construction shall comply with the provisions of current editions of thefollowing acts, codes, regulations and standards. Where a conflict of requirementarises, the contractor shall immediately refer such conflicts to the Department forclarification.• Electricity Safety Act and all associated codes, regulations and guidelines.• Occupational Health & Safety Act.• HV Safety Rules• Building Code of Australia.• Victorian Building Regulations.• Historic Building Act.• ROA Code “For the installation of other party’s services and Pipelines withinRailway Boundaries”.• Code of Practice for the Defined Interstate Rail Network, January 2003.• Victorian Service & Installation Rules.• Electricity Distribution Code - Essential Services Commission - Victoria• Australian StandardsReferenceAS 4000AS 3008AS 2676AS 2987TitleGeneral Conditions of ContractElectrical Installations, Selection of CablesGuide to Installation etc. of Secondary BatteriesGeneral Conditions of Contract for the Supply ofEquipment with or Without Installation.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

36 VRIOGS 010.4 Revision AAS 1270AS 1337AS 1716AS 2210AS 3012AS 4292.2AS 4360AS 3000AS 2067AS 1767AS 3760AS 1725AS 2053Hearing Protection Devices.Eye Protectors for IndustrialApplications.Respiratory Protective Devices.Occupational Protective Footwear.Electrical Installations – Construction and DemolitionSites.Railway Safety Management. Part 2: Track, civil andelectrical infrastructure.Risk ManagementWiring RulesSwitchgear Assemblies etc. Above 1kVInsulating liquids - Specification for unused mineralinsulating oils for transformers and switchgearIn-service safety inspection and testing of electricalequipment.Chain link fabric security fences and gates.Conduits and fittings for electrical installations - GeneralrequirementsEnergy Safe VictoriaCodes of PracticeEPA 448C.C.I.T.T.EPAIndustry Standard for Electrical Installations onConstruction Sites.Manual HandlingEPA Publication 448 Classification of wastesDirectives Concerning the protection ofTelecommunications Lines Against Harmful Effects fromLinesNoise RegulationsWhere two standards refer to the same item, the more stringent standard shall beapplicable.• MAINCO SpecificationsMAINCO SpecificationsCD 012MESP 0005TitleSafety and Environmental Requirements forContractors Working on MAINCO premisesInspection and testing of electrical equipment andsystems (substations)NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.

VRIOGS 010.4 Revision A 37• VRIOG StandardsVRIOGSVRIOGS 010.3VRIOGS 010.4VRIOGS 010.5VRIOGS 010.7VRIOGS 010.8VRIOGS 012.1VRIOGS 012.2TitleRailway Traction Substation Design StandardRailway Traction Substation Construction StandardTrain Overhead Design Standards for the Electrification of NewRoutesTraction bonding, track circuit connections and tractioninterfacesRailway Traction Electrical Network Study Standard.Signalling Design and DocumentationSpecification for Signalling Supply, Construction and InstallationNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may not be current.