TECHNICAL REQUIREMENTS (ERT)
5) OVERHEAD CONTACT SYSTEM (OCS)
Table of Contents
5.1 SCOPE OF WORK ...... 1 5.1.1 General ...... 1 5.1.2 System Requirements ...... 1 5.1.3 System Overview ...... 2
5.2 DEFINITIONS AND ABBREVIATIONS ...... 4 5.2.1 Definitions ...... 4 5.2.2 Abbreviations ...... 6
5.3 DESIGN CRITERIA AND STANDARDS ...... 7 5.3.1 Design Criteria ...... 7 5.3.2 Standards ...... 12
5.4 ENGINEERING CONDITIONS ...... 13 5.4.1 Engineering Philosophy ...... 13 5.4.2 Technical Design ...... 14
5.5 TECHNICAL REQUIREMENTS ...... 16 5.5.1 Steel Materials ...... 16 5.5.2 Steel Mast and cantilevers ...... 16 5.5.3 Pre-stressed Concrete Poles ...... 16 5.5.4 Hard-drawn Copper Stranded Conductors ...... 16 5.5.5 High-voltage Cross-linked Polyethylene Insulated Cables ...... 16 5.5.6 Galvanized Steel Wire Strands ...... 17 5.5.7 Insulator for Electric Overhead Line ...... 17 5.5.8 Pole Bands ...... 17 5.5.9 Contact Wires ...... 18 5.5.10 Messenger Wires ...... 18 5.5.11 Automatic Tensioning Devices ...... 18 5.5.12 Fixed Termination Devices ...... 18 5.5.13 Steady Equipment ...... 18 5.5.14 Pull-off Equipment ...... 18 5.5.15 Insulated Overlaps ...... 19 5.5.16 Section Insulators ...... 19 5.5.17 Jumper wires ...... 19 5.5.18 Crossover Equipment ...... 19 5.5.19 Guy Assemblies ...... 19 5.5.20 OCS Section Signs ...... 20 5.5.21 Lightning Arresters...... 20 5.5.22 Earthing & Bonding Devices ...... 20 5.5.23 Equalisation wire connections ...... 20 5.5.24 Feeder and Return Cables ...... 21 5.5.25 Cantilevers and Drop Tubes ...... 22 5.5.26 Isolators ...... 22 5.5.27 Supporting Structure for RISS ...... 22 5.5.28 Expansion Joint ...... 23 5.5.29 Insulated Overlap for RISS ...... 24 5.5.30 Jumper Wires for RISS...... 24 5.5.31 Anchoring ...... 24 5.5.32 T-section Aluminum-alloy Bar Affixed Contact Wire ...... 24
5.5.33 Stray Current Suppressing Devices (SCSD) ...... 26
5.6 DEPOT ...... 27 5.6.1 Moveable Conductor Rails in Workshop ...... 27 5.6.2 Retractable Power Conductors ...... 27 5.6.3 Train Roof Access ...... 27 5.6.4 Workshop Operation ...... 28 5.6.5 Controls Management ...... 29 5.6.6 Train Movement into Workshop ...... 29 5.6.7 Conductor Rails ...... 29 5.6.8 Rotating Suspension Arms ...... 29 5.6.9 Overhead Crane ...... 30 5.6.10 Half-gates at Platform ...... 30 5.6.11 Retractable Conductor Rail Installations...... 30 5.6.12 Permission to Access Train Roof ...... 30
5.7 INTERFACE REQUIRMENTS ...... 30 5.7.1 General ...... 30 5.7.2 Contractor’s Responsibilities ...... 30 5.7.3 Interfacing Items ...... 31
5.8 TESTING AND COMMISSIONING ...... 31 5.8.1 Measurement for Insulation Resistance ...... 31 5.8.2 Insulation Testing ...... 32 5.8.3 Stray Current Tests ...... 32 5.8.4 Trial Operation ...... 32 5.8.5 Contact Conditions ...... 33 5.8.6 Trial Runs ...... 33
5.9 TRAINING...... 34 5.9.1 Scope of Training ...... 34 5.9.2 General Requirements ...... 34 5.9.3 Training Plan ...... 35 5.9.4 Training Courses ...... 35
5.10 SYSTEM ASSURANCE AND RAMS ...... 37
5.11 SPARE PARTS, TOOLS AND MEASURING DEVICES ...... 37 5.11.1 Spare Parts ...... 37 5.11.2 Special Tools and Test Equipment ...... 38
List of Tables
Table 5.3.1 Safety Factors ...... 9
Table 5.6.3.1 Interlocking Conditions (X) ...... 28
Table 5.8.1 Insulation Resistance ...... 31 METRO MANILA SUBWAY PROJECT PHASE 1 Part 2 – Employer’s Requirements Package: CP106: E&M Systems and Track Works Section IV
CHAPTER 5 OVERHEAD CONTACT SYSTEM (OCS) 5.1 SCOPE OF WORK
5.1.1 General
The works covers the Overhead Contact System (OCS) is for the Metro Manila Subway Project from Quirino Highway to Bicutan, Terminal 3 and the depot yard.
This Specification covers the complete design, supply, installation, testing, commissioning, maintenance, training, and knowledge transfer of 1500V DC providing traction power to electric train- sets along the main line and the depot yard tracks.
The principal components shall include but not be limited to the following:
1. Complete OCS facilities, devices and equipment that are related to supporting structures, overhead contact lines, feeder wire assembly and associated facilities.
2. Positive and negative power feeder connections at traction substations.
3. Lightning arrester, earthing devices.
4. All works are closely related to civil, architecture, and track works, the Contractor shall coordinate with Interfacing Contractors for installation works including but not limited to:
a) Fixing bolts on segments in shield tunnel, anchor bolts on the ceiling of box and tunnels for the supporting structure of the Rigid Suspension System;
b) Supporting structure and cable troughs for feeder and return cable in the vicinity of traction substations;
c) Under track crossing for feeder and return cable under the track alignment;
d) Cantilevers bolted to drop tubes which is attached to platform ceiling structure at elevated section at Bicutan Station;
e) Cable wiring for earthing devices of grounding wire and lightning arrester; and
f) Excavation, backfilling, compacting, and finishing of troughs, hand-holes, and pipe conduits for feeder and return cables in the depot yard.
5.1.2 System Requirements
The Contractor shall be in responsible for the technical design, manufacturing, furnishing, erection and installation of a complete OCS, including but not limited to the following major requirements:
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1. The Contractor’s shall design a simple and secure OCS which meets train operation schedules under both normal operating and emergency conditions.
2. The Contractor shall design the OCS facilities based on easy maintainability, aesthetics, and economical efficiency.
3. The OCS shall provide excellent pantograph current collection under all train operation conditions.
4. The Contractor shall coordinate the design interfacing parties by exchanging information between relevant sections, e.g. Civil, Track and Architecture, regarding shield tunnel clearance to the RISS supporting structure and ceiling height in the station platform areas by establishing critical interfacing requirement on each section.
The Contractor shall be accountable for defects due to the absence of coordination with relevant contractors.
5. The Contractor shall supply all OCS facilities wherever installed in 15(fifteen) underground stations, 1 (one) elevated station, 13 (thirteen) DC traction substations located inside station premises, and the depot yard (e.g. storage track, light repair track, wheel re-profiling track, car washing track, etc.).
The Contractor shall be responsible for the coordinating of the final OCS design and installation with Interfacing Contractors.
5.1.3 System Overview
The OCS consists of sub-systems, devices, equipment which shall include but not be limited to:
Main Line
• OCS 15 (fifteen) underground stations, 1 (one) elevated station, and 13 (thirteen) DC traction substations; and
• 34.5 kV electric power is supplied to the traction substations from the Manila Electric Company (MERALCO) and rectified to DC 1500V for traction power for the electric cars.
1. U-shape retaining-wall section between the tunnel portal and the depot area.
Mountings for OCS facilities in the U-shaped retaining wall section shall be designed in consideration of civil and architectural structure conditions, maintainability, and future extension. Major facilities shall include but not be limited to:
a) Supporting structure for the steel tube beam integrated with the roof provided by
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Interfacing Contractors;
b) Overhead Contact Line (Feeder Messenger System); and
c) Earthing Devices.
2. Underground section
Material and mechanical components of the Rigid Suspension System in the underground sections shall be outline in regards of ease of construction, durability and maintainability. Major facilities shall include but not be limited to:
a) Rigid Suspension Components;
b) Supporting Structure for the Rigid Suspension System;
c) Expansion Joint;
d) Anchoring;
e) Feeding and Return Cables;
f) Isolators; and
g) Earthing Devices.
3. Elevated section at Bicutan Station.
Mountings for supporting structure in elevated sections shall be designed in consideration of climate conditions, aesthetics, durability, maintainability and economic efficiency. Major facilities shall include but not be limited to:
a) Steel Tube Masts;
b) Cantilevers;
c) Overhead Contact Lines;
d) Automatic Tensioning Devices;
e) Feeding Wire Assembly;
f) Feeding and Returning Cables;
g) Isolators;
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h) Earthing Devices;
i) Lightning Arresters; and
j) Overhead Grounding Wire Assemblies.
Depot Yard The OCS in the depot yard shall be designed in regards of ease of construction, proven facilities, uniformity of facilities, maintainability, etc. Major facilities shall include but not be limited to: a) Concrete Pole, Steel Tube Mast, Anchor Steel Mast; b) V-Truss Beam, Warren-Truss Beam, Cross-Beam and Tensioning Beam; c) Overhead Contact Lines; d) Automatic Tensioning Devices; e) Feeding Wire Assemblies; f) Feeding and Return Cables; g) Isolators; h) Earthing Devices; i) Lightning Arresters; j) Overhead Grounding Wire Assembly; and k) Rail Stray Current Suppressing Device.
The Contractor shall build up a combination of sub-systems, devices and equipment’s that best suits the OCS and the system as a whole.
5.2 DEFINITIONS AND ABBREVIATIONS
In this Specification, the following defined terms shall have the meanings described below:
5.2.1 Definitions
Anchor Ring Mechanical fixing device located at the center of successive Rigid Conductors which prevents movement to one side. Automatic Tensioning Device OCS equipment provided with counterweight or spring tensioning devices to maintain constant tension within a specified temperature range by
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compensating for conductor thermal elongation or contraction. Connector Conductor which provides a current path for traction current between the messenger wire and the contact wire of the OCL equipment to equalize voltage. Contact Wire Electric conductor of an overhead contact line with which the pantographs make contact. Disconnecting Switch Mechanical switching device which ensures specified clearance for safety reasons in the open position in order to maintain OCS facilities, to disconnect from a charged circuit under abnormal conditions such as a short circuit. Earthing Same as ‘grounding’. The connection of equipment introduces non-current carrying through metal parts to the earth, to provide safety to personnel, the public and equipment. End Approach Sloping end portion of Rigid Conductor which ensures smooth passage of the pantograph. Expansion Joint Mechanical joint for absorbing expansion of the rigid contact wire due to temperature changes. Feeder Messenger System Type of overhead catenary system which uses a large cross-section to more easily pass the current for the messenger wire. Also has the function of feeder wires. Dropper Fitting used to suspend the contact wire from the messenger wire. Headway Time interval between successive trains. Messenger Wire Longitudinal wire directly supporting the contact wire. Pull-off Device used on curves or at track turnouts to keep the conductors in their correct position. Rail Stray Current Suppressing Device installed in front of the light repair shop. Device Shall be provided to prevent electrolytic corrosion caused by the leakage current entering from the outside of the shed and also to prevent electrical shock for workers in the work-shop. Return Cable Cable which carries return current from the rail track to the substation. Rigid Conductor Main device in the form of a T-section aluminum- alloy bar which makes up the Rigid Suspension System.
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Rigid Suspension System Most common OCS used in the underground sections. A contact wire is flexed by ears at the lower part of a supporting T-section aluminum- alloy bar. Section Insulator Sectioning point formed by insulators inserted in a continuous run of contact line, with devices made of FRP or wood to maintain continuous current collection. Simple Catenary System Most common OCS used on elevated and at- grade sections. Consists of a support structure with a contact wire suspended from hangers beneath a messenger wire. Stagger Horizontal displacement of the contact wire from the projected centre line of the track. Steady Arm Hinge arm used to hold the contact wire in its correct position across the track and normally fixed to the registration arm so that the steady arm is always loaded in tension. System Height Vertical distance between the contact wire and the messenger wire in a Simple Catenary System. Tension Length Continuous interval between termination points of the Overhead Contact Line in a Simple Catenary System. Traction Substation Railway substation located inside station premises which receives incoming supply from the 34.5 kV power grid of the Manila Electric Company (MERALCO) and rectified to DC 1500 V for feeding traction power.
5.2.2 Abbreviations
DC Direct Current FMS Feeder Messenger System MERALCO Manila Electric Company
JIS Japanese Industrial Standard OCL Overhead Contact Line OCS Overhead Contact System RSCSD Rail Stray Current Suppressing Device RISS Rigid Suspension System
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SCS Simple Catenary System VVR Vinyl-insulated Vinyl-sheathed Round-type cable
5.3 DESIGN CRITERIA AND STANDARDS
5.3.1 Design Criteria
1. The OCS shall comprise two main elements: OCL facilities and Feeder Wire facilities.
The OCL facilities shall comprise: RISS, SCS and FMS. The Feeder Wire facilities include the feeding and returning cables from the rail side to the traction substation.
2. The Contractor shall fully coordinate with Interfacing Contractors and design suitable facilities to ensure compliance as stipulated by the Engineer.
3. The Contractor shall design the complete train operation pattern of the main line, e.g. the interval between continue trains dispatched and the total number of trains to be dispatched during morning / evening rush hours.
4. The Contractor shall verify the sizes and structure of the contact wires, messenger wire, feeder messenger wire, feeder wire, and feeder and return power cables under peak operation conditions.
5. The transition from FMS in the U-type retaining wall section to RISS in the underground sections shall be constructed so that the pantograph movement and characteristics of current collection between the different contact systems is as smooth as possible and do not result in any traction jerks, sparking or undue wear of contact surfaces.
The Contractor shall comply with the following criteria:
1. Electrification system as per EN 50163
All OCS to be applied shall be suitable for:
a) Direct Current (DC);
b) Nominal voltage: 1500 V;
c) Minimum voltage: 1000 V; and
d) Maximum voltage: 1950 V.
2. Construction gauge
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The upper limit of the construction gauge shall be 4700 mm above the top of rail in the underground sections and 5700 mm in other section.
3. Rust prevention
Fittings shall be of corrosion-resistant material and maintenance-free as required. The Contractor shall submit documentation to support his selection of corrosion-resisting materials to the Engineer for review including method statements for any proposed hot-dip galvanizing.
All steel supporting structures for the RISS in the underground sections shall be galvanized in conformance with JIS H 8641-2007: Hot dip galvanized coatings (Class 2-55), after completion of manufacturing or trial fabrication.
4. Insulation coordination and insulation level
The OCS shall be equipped with lightning arresters to safeguard the insulation between the OCS facilities and substation facilities shall be maintained in normal operation. Impulse withstand voltage for the OCS shall not be less than 50 kV.
5. Composition of feeding system
The composition of the feeding system shall ensure rapid and certain interruption of short circuit current in any situation. Disconnecting switches installed in main stations shall ensure confinement of the electrical outage range.
6. Climate condition
The design of OCS supporting structures shall be equipped to work efficiently and meet the requirements of the Contract under briefly stated below, however, the Contractor should refer to General Specification (ERG) for the details of Climate Condition in Manila. a) Ambient temperature:
At grade section
i) Standard: 30 deg. C;
ii) Maximum: 40 deg. C; and
iii) Minimum: 15 deg. C.
Tunnel section
i) Maximum: 40 deg. C.
OCS-5-8 METRO MANILA SUBWAY PROJECT PHASE 1 Part 2 – Employer’s Requirements Package: CP106: E&M Systems and Track Works Section IV b) Wind velocity
The design wind velocity for computation shall be:
i) Up to tunnel section: 10 m/s in emergency ventilation mode; and
ii) Maximum on at-grade section: 45 m/s. c) Earthquake resistance design
The earthquake resistance design of the OCS supporting structures shall adhere to the Guideline of a seismic design for overhead contact system issued by the Japanese Railway Technical Research Institute (RTRI) in March, 2013 and Design guidelines of supporting systems for overhead contact systems, issued by the Japan Railway Electrical Engineering Association (JREEA) in October 2010.
7. Safety factors
The safety factors of materials to be used for the OCS shall be as shown in Table 5.3.1. These safety factors are based on normal working loads and shall be considered by the Contractor before ordering materials.
Table 5.3.1 Safety Factors Type Item Conditions Safety Factor Wire Hard-drawn copper wires Tensile withstand load More than 2.2
Other wires Tensile withstand load More than 2.5
Supporting Steel materials Yield point withstand More than 1.5 Material strength Concrete poles Destructive withstand load More than 2.0 Guys Tensile withstand load More than 2.5
Insulator Stem insulators Bending destructive More than 2.5 withstand load Tensile withstand load More than 2.5
Suspension insulators Detective withstand load More than 3.0
Other Destructive withstand load More than 2.0
8. Contact wire design standards
a) Contact wire height
The contact wire height from the top of rail shall be as follows:
1) Standard:
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Tunnel section: 4450 mm
At-grade section: 5100 mm
Depot yard: 5100 mm
2) Maximum:
Tunnel section: 4500 mm
At-grade section: 5400 mm
Depot yard: 5400 mm
3) Minimum:
Tunnel section: 4400 mm
At-grade section: 4400 mm
Depot yard: 4900 mm
The normal height of the contact wire at supports shall be engineered to ensure that the lowest point shall never be lower than the minimum height even under the worst train operation conditions. The effects of temperature variation, pre-sagging, and installation tolerance shall also be taken into consideration for determining the contact wire height at supports.
b) Deviation at supports
1) Feeder Messenger System (At-grade section)
At straight section:
For main track, shall be 200 mm or less at any supporting point under zig-zag formation of one cycle of 2 spans.
For side track, shall be 200 mm or less at any supporting point under zig-zag formation of one cycle of 4 spans.
At curved section:
For main and side track, shall be 300 mm or less at any supporting point.
2) Rigid Suspension System (Tunnel section)
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For main track, shall be 200 mm at each anchoring point, and minimum deviation shall be configured at each expansion joint point.
3) Simple Catenary System (Depot yard)
At straight section:
For main track, shall be 200 mm or less at any supporting point under zigzag formation of one cycle of 2 spans.
For side track, shall be 200 mm or less at any supporting point under zigzag formation of one cycle of 4 spans.
At curved section:
For main and side track, shall be 300 mm or less at any supporting point.
c) System height
The normal system height of the SCS shall be up to approximately 1.0 m. In order to increase the span length or secure suitable clearance, the system height shall be adjusted to give the maximum clearance specified. The minimum dropper length at mid-span shall not be less than 150 mm.
d) Gradient
The maximum gradient of the contact wire with respect to the track shall be as follows:
1) Feeder Messenger System (At-grade section)
At-grade section
Main track: Not to exceed 5/1000
Side track: Not to exceed 15/1000
2) Rigid Suspension System
Main track: Not to exceed 1/1000
Side track: Not to exceed 2/1000
3) Simple Catenary System
Depot yard
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All track: Not to exceed 15/1000
9. Clearance
a) Electrical clearance
The following minimum clearances between live conductors and any grounded fixed structures shall be ensured:
Not less than 250 mm in general
Limit where contact not possible: 70 mm
b) Mechanical clearance
Mechanical clearance from the pantograph to any fixed structures, excluding registration assemblies and steady arm or registration fittings, shall not be less than 75 mm. Clearance to steady arm and registration assemblies used for registration purposes shall not be less than 35 mm under the worst train operation conditions including dynamic train displacement, as well as pantograph, track and maintenance tolerances.
10. Span length
a) Maximum span length
The design of maximum span length shall consider the effects of climate conditions, the alignment of tunnel segments, track geometry, vehicle and pantograph dynamic excursion including sway, as well as installation and maintenance tolerances.
b) Limitation of lateral load by contact wire
The angle of deviation of the contact wire at supports shall be limited in order to avoid large horizontal loads which cause excessive uplift of the steady arm or overloading of any part of the supports.
5.3.2 Standards
The following standards or other equivalent standards in compliance with the Contract shall apply:
JIS A 5373-2010 (Clause 5.3)
JIS C 3105-1994 (Clause 5.4)
JIS C 3606-2003 (Clause 5.5, Clause 5.22)
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JIS C 3810-1999 (Clause 5.7)
JIS C 3818-1999 (Clause 5.24)
JIS E 2101-1990 (Clause 5.9)
JIS E 2201-2013 (Clause 5.8)
JIS E 2301-1992 (Clause 5.7)
JIS G 3101-2015 (Clause 5.1, Clause 5.8, Clause 5.24)
JIS G 3106-1999 (Clause 5.1)
JIS G 3537-2011 (Clause 5.6)
JIS G 4303-2012 (Clause 5.24)
JIS H 3100-2012 (Clause 5.24)
JIS H 3140-2012 (Clause 5.24)
JIS H 8641-2007 (Clause 3.1, Clause 5.8)
JIS Z 3211-2008 (Clause 5.8)
JIS Z 3312-2009 (Clause 5.8)
EN50122, part 1
EN50122, part 2
5.4 ENGINEERING CONDITIONS
5.4.1 Engineering Philosophy
1. Ease of maintenance of the OCS.
For ease of maintenance of the OCS facilities, all steel components shall be hot-dip galvanized for corrosion resistivity and rust-resisting metal fittings shall be used.
2. Unification of OCS facilities.
Proven OCS facilities complying with the requirements of the Contract shall be adopted in reference to the existing Philippines railway system and modern Japanese practices.
3. Design co-ordination and interfaces.
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The Contractor shall be responsible for coordinating the OCS design and installation with the requirements in co-ordination with Interfacing Contractors.
4. To guarantee a stable traction supply for the OCS, the Contractor shall identify the type of feeding wire and cable with due regards of the consistency between the feeding and substation systems. The Contractor shall carry out the dynamic studies on the interaction between trains pantograph and OCS. This study shall take into account of the headway, interval between successive trains, number of trains dispatched at the same time in each OCS section.
5. Build-up of stable OCS supporting structures.
The Contractor’s design evaluation for the supporting structures shall include considerations of climate conditions, appropriate loading conditions and determination of the shape and member components for the OCS supporting structures and give due consideration to the harmonization of the design with the surrounding environment.
5.4.2 Technical Design
Design considerations shall include but not be limited to:
1. The design of the OCS facilities shall guarantee adequate safety and stability based on essential train operation conditions.
2. The Contractor shall perform a technical evaluation to determine conductor section sizes, and the capacity of the traction power system based on peak time train operation requirements in consideration of the maximum number forecast for future demand.
3. The Contractor shall design the most appropriate OCS supporting structures for this project while sharing information with Interfacing Contractors.
4. The Contractor shall submit the test review document for the main components of each facility to meet the electrical and mechanical performance requirements of the Contract.
5. The Contractor shall finalize a suitable electrical sectioning arrangement indicating the location of insulators and prepare feeding network drawings for review by the Engineer.
6. The Contractor shall fully examine the “OCS Plan in Main Line” and “Alignment of Layout of Supporting Point in Depot” as attached tender drawings, in order to understand the characteristics and shape of the civil structures.
7. The Contractor shall determine the location of air sections in consideration of actual train operation, and finalize the feeding network
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8. In determining the tension length and location of tensioning devices, the following principles shall be adopted:
a) For main line at-grade sections, the maximum tension length shall be regulated so that tension loss along half a tension length (i.e. from the fixed point to the automatic tensioning device at the termination point) due to steady equipment drag or movement in the track direction, shall not reduce the current collecting performance of the contact system.
b) The half tension length on at-grade sections shall not exceed 800 m in length.
c) In U-type retaining wall section, spring-type devices with mechanical, aesthetic and harmonizing advantages shall be supply as automatic tensioning devices for the main line.
d) In the depot yard, pulley–type automatic tensioning devices shall be equipped on one side of the OCL if the tension length does not exceed 800 m, or on both sides if it is more than 800 m. Spring-type devices shall be equipped on one side of the OCL if the tension length does not exceed 300 m, or on both sides if it is more than 300 m but less than 800 m.
9. The transition of the main line from FMS in at-grade section to RISS in tunnel sections shall be designed so that the pantograph movement and current collection between the different contact system sections is as smooth as possible without resulting in any traction jerks, sparking or undue wear of the contact wire surface.
10. Traction power for the depot yard shall be Supplied from the depot substation located in premises isolated from the underground substations. Feeding traction power shall be zoned with individual supplies to facilitate shunting, inspection, cleaning, stabling and wheel turning of cars. In addition, the cable route from the depot yard traction substation shall be reviewed by taking the shortest, most economical route.
11. Disconnecting switches and related earthing devices shall be provided for the maintenance of OCS facilities, prevention against electrical shocks for maintenance staff and minimizing sections affected by power outages.
12. The Contractor shall furnish the design assumptions, details, and technical computing results based on the design criteria.
13. The Contractor shall select the contact wire made of heat-resistant material for the underground sections.
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5.5 TECHNICAL REQUIREMENTS
The major materials and methods for the OCS to be provided shall confirm to the following requirements:
5.5.1 Steel Materials
All steel products shall conform to:
JIS G 3101-2015: Rolled steel for general structure (Class SS 400), or
JIS G 3106-1999: Rolled steel for welded structure (Class SM 400 A).
5.5.2 Steel Mast and cantilevers
1. Standard structural types shall be adopted based on rationalized design evaluation. Design evaluation for structural soundness shall be issued to the Engineer in typical cases for his review.
2. All structures shall be listed in accordance with the numbering given in the finalized OCS layout diagram. Enameled number plates at eye level from the base of mast (approx. 3 m above rail level) shall be provided on each mast or structure. Details to be submitted for review by the Engineer.
5.5.3 Pre-stressed Concrete Poles
1. Pre-stressed concrete pole manufacturing shall comply to Class 2 of JIS A 5373-2010; Precast prestressed concrete products. Concrete used for the poles shall be Class A.
2. Numbering of structures.
All structures shall be listed in accordance with the numbering given in “Alignment of Layout of Supporting Point in Depot” as attached to the tender drawings. The number plates shall be set at a height of approx. 2.5 m above rail level in the depot yard. Final details to be submitted for review by the Engineer.
5.5.4 Hard-drawn Copper Stranded Conductors
1. The materials to be used shall comply to the requirements of JIS C 3105-1994: Hard-Drawn Copper Stranded Conductors.
2. The size, composition, and mechanical and electrical characteristics shall conform to JIS C 3105-1994: Hard-Drawn Copper Stranded Conductors.
5.5.5 High-voltage Cross-linked Polyethylene Insulated Cables
1. The materials to be used shall comply to JIS C 3606-2003: High Voltage Cross Linked Polyethylene Insulated Cables.
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2. The size, composition, mechanical and electrical characteristics shall conform to JIS C 3606- 2003: High Voltage Cross Linked Polyethylene Insulated Cables.
5.5.6 Galvanized Steel Wire Strands
1. The materials to be used shall comply to JIS G 3537-2011: Zinc-coated steel wire strands.
2. The size, composition, mechanical and electrical characteristics shall conform to JIS G 3537- 2011: Zinc-coated steel wire strands.
5.5.7 Insulator for Electric Overhead Line
1. The materials to be used shall comply to JIS E 2301-1992: Insulator for electric overhead line and JIS C 3810-1999: Normal type and anti-pollution type suspension insulators.
2. Mainly 100mm, 150mm, and 250mm type insulators shall be adopted.
3. The mechanical and electrical characteristics shall comply to JIS E 2301-1992: Insulator for electric overhead line and JIS C 3810-1999: Normal type and anti-pollution type suspension insulators.
5.5.8 Pole Bands
1. Material
a) Steel materials to be used for pole bands shall comply to JIS G 3101-2015: Rolled steel for general structure, Class SS 400, and/or equivalent.
b) Welding material shall comply to JIS Z 3211-2008: Covered electrodes for mild steel, high tensile strength steel and low temperature service steel, and JIS Z 3312-2009: Solid wires for MAG and MIG welding of mild steel, high strength steel and low temperature service steel.
c) Pole bands shall be galvanized, comply to JIS H 8641-2007: Hot dip galvanized coatings, Class 2-55.
2. Method of processing
Processing, welding and zinc plating shall be executed to confirm to JIS E 2201-2013: Electric traction overhead lines – Fittings.
3. Mechanical characteristics
Pole bands shall be installed and fastened with bolts and nuts tightened to the torque confirming to JIS E 2201-2013: Electric traction overhead lines – Fittings.
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5.5.9 Contact Wires
1. Contact wires shall be of hard-drawn copper grooved trolley wires, conforming to JIS E 2101- 1990 for 110 sq. mm and 170 sq. mm.
2. The size, structure, mechanical and electrical characteristics of contact wires shall conform to JIS E 2101-1990: Hard-Drawn Grooved Trolley Wires.
5.5.10 Messenger Wires
Messenger Wires shall be of 150sqmm hard drawn copper stranded conductors complying with the requirements of JIS C103-1994: Hard Drawn Copper Stranded Conductors.
5.5.11 Automatic Tensioning Devices
1. The type of automatic tensioning devices shall be of spring-type or pulley-type to anchor the messenger wires and contact wires.
2. Automatic tensioning devices shall be installed to ensure compliance with the designs reviewed without objection by the Engineer.
3. Automatic tensioning devices shall comply to the requirements specified in Clause 4.2 “Technical design” (8).
5.5.12 Fixed Termination Devices
Fixed termination devices shall be constructed to anchor the contact wires and messenger wires securely with turnbuckles. Pulley-type or spring-type devices shall not be used.
5.5.13 Steady Equipment
1. Steady equipment shall be installed at straight track sections or curved track sections having a radius of curvature of more than 1600 m.
2. Components incorporated in steady equipment shall consist of stem insulators, steel tubes and fitting assemblies.
5.5.14 Pull-off Equipment
1. Pull-off equipment shall comply with the design requirements for supporting contact wires at curved sections and overlap sections.
2. Components incorporated in pull-off equipment shall consist of suspension insulators, hard- drawn copper stranded conductors and other fitting assemblies.
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5.5.15 Insulated Overlaps
1. Insulated Overlaps shall comply with the design requirements for terminating both contact wire lines to separate the power source provided by different traction substations. It also shall be compatible with the maximum distance of rolling stocks pantographs of different cars.
2. Insulated overlaps shall be designed to maintain the continuity of the passage of the pantograph without the loss of performance, under all temperature and operating conditions. The separation between conductors shall be such that, in the event of an isolation at one of the sections, there shall be no possibility of the two sections coming into contact with each other except when bridged by a pantograph. In normal operating conditions there should be no arc drawn by the pantograph when the two sections are bridged.
3. Insulated Overlaps shall be equipped in span lengths of 50 m or longer, and the horizontal distance between contact wires at overlap section shall be 300 mm.
5.5.16 Section Insulators
Section insulators shall be used to divide the contact wire into discrete electrical sections. The insulators shall be capable of bidirectional operation and shall permit the passage of the pantographs at full operational speed while drawing current without damage and without interruption of the flow of current.
Precautions shall be taken to ensure that any torque existing in the contact wires shall not affect the satisfactory operation of the complete assembly.
Section insulators shall not be positioned in areas of high traction current, such as near train stops and the pantograph shall not run on the insulators.
5.5.17 Jumper wires
1. Jumper wires shall comply with the design requirements for terminating both contact wire lines to keep continuity of traction power.
2. Jumper wires shall be provided in span lengths of 40 m or longer, and the horizontal distance between contact wires at overlap sections shall be 150 mm.
5.5.18 Crossover Equipment
Crossover equipment shall comply with the design requirements for supporting contact wires on crossover sections at turnouts, which shall be constructed with clamps, feeder ears, connectors, line guards, protectors and other fitting assemblies.
5.5.19 Guy Assemblies
1. Guy assemblies shall be installed at terminated supporting poles which anchor contact wires
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and messenger wires and categorized as single type and V-type. The installation method shall be based on the tension of both the contact and messenger wires.
2. Guy assemblies shall consist of suspension insulators, connecting rods, guy anchors, guy rods, pole bands, wire clips, and other fittings.
5.5.20 OCS Section Signs
1. OCL section signs shall be fitted at the approach points to each different electrical section of OCL.
2. Supporting point number plates shall be provided at the fixed points of OCL, the numbering scheme to be adopted shall be determined based on the approval of the Engineer.
3. OCL terminal signs shall be equipped at terminal points to termination of contact wires.
5.5.21 Lightning Arresters
1. Lightning arresters shall be of a type that can be easily maintained and durable with sufficient mechanical strength and electrical capacity.
2. Lightning arresters shall be installed at intervals of not more than 250 m.
3. The primary terminal of lightning arresters shall be connected through a hard-drawn copper stranded conductor of 25 sq. mm to feeder wires or feeder messenger wires and the secondary terminal to grounding wires.
5.5.22 Earthing & Bonding Devices
1. In elevated section at Bicutan, grounding wires of 600 V VVR 22 sq. mm shall be connected to power cables embedded into the piers and girders by the Civil Contractor. Wires, earthing-rods, and attached components shall be provided by the Contractor.
2. The earthing resistance value shall be less than 30 ohms.
3. The electrical sectionalisation length of grounding wires shall be around 250 m.
4. The earthing interval of sections shall be around 250 m at the middle of the sectionalized length.
5. In the depot yard, the upper wire shall have conduits for wire protection up to 3 m above the pole foundation. Underground wires shall be embedded at a depth of not less than 0.75 m measured from the finished ground level.
5.5.23 Equalisation wire connections
1. The maximum interval for feeding branch devices shall be 250 m with the specified hard-drawn
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copper stranded wire.
2. The distance from the feeding branch at a feeder end to the end of a live contact wire shall be a maximum of 125 m.
3. At equalisation wire connection locations, contact wires and messenger wires shall be securely connected to ensure equivalent voltage so as to avoid circulate current arising between the wires.
5.5.24 Feeder and Return Cables
1. Feeder and return cables shall be cross-linked polyethylene insulated polyvinyl chloride sheathed cables (eco-material cables used in tunnel sections) of 325 sq. mm in nominal cross- section, conforming to JIS C 3606-2003: High Voltage Cross Linked Polyethylene Insulated Cables.
2. Termination materials shall be of types reviewed without objection by the Engineer.
3. Feeder and return cable assemblies shall be installed in accordance with the following requirements:
a) The bending radius of feeder and return cables shall not be less than 10 times the diameter of the cable;
b) Feeder and return cables shall be laid so as not to cause any defects to cable sheaths;
c) In principle, no joints shall be made in continuous feeder and return cables;
d) Cable termination work shall be executed by experienced workmen with the required techniques and know-how, who shall be reviewed without objection by the Engineer.
e) Cable ends shall be shielded so as to prevent ingress of moisture or rain water and shall only be exposed immediately before starting termination work;
f) Underground feeder and return cables parallel to track shall be protected by concrete troughs, the top of which shall be placed at least 800 mm below ground level in ground sections. Troughs crossing under rail tracks or roads shall be placed at least 1500 mm below ground level;
g) Exposed rising feeder and return cables shall be protected by conduits up to 3 m above ground level;
h) Concrete markers shall be installed at a standard interval of 50 m at each bending location and/or crossing location; and
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i) Manholes and handholes shall be installed as required at crossings under rail tracks and roads.
5.5.25 Cantilevers and Drop Tubes
1. Cantilever shall be made of steel angles and fixed to poles with pole bands.
2. Drop Tubes shall be steel members, and fixed on tunnel ceilings, station sheds, and beams in the ground sections.
5.5.26 Isolators
1. In underground sections, cased-type devices shall be delivered and in the depot yard, lever-type or hook-type devices shall be provided.
2. Isolators for the OCS shall be controlled for opening and closing energized circuits with a rated voltage and shall not be designed for opening and closing load circuits.
3. Isolators shall be securely locked to ensure that they cannot be detached by vibration and shock while the blade condition is “ON”.
4. Isolators and their structures, including conductors, shall be constructed with materials conforming to JIS H 3140-2012: Copper bus bars, JIS H 3100-2012: Copper and copper alloy sheets, plates and strips, JIS G 3101-2015: Rolled steel for general structure, JIS C 3818-1999: Station post insulators and JIS G 4303-2012: Stainless steel bars.
5. The structure of the isolators installed in front of the Light Repair Shop shall be such that both positive and negative electrodes can be operated simultaneously with single manipulation.
5.5.27 Supporting Structure for RISS
1. Anchor plug for anchor bolt
a) The Contractor shall select the shape of supporting structure for RISS after confirming the section changing locations with the Civil Contractor.
b) The Contractor shall embed anchor bolts on the tunnel ceilings, except for segment structures in tunnel boring machine sections, after confirming the internal bar arrangement with the Civil Contractor. Anchor bolts shall be provided by the Contractor.
c) Supporting structure composed of steel angles, suspension insulators and fittings for RISS shall be installed after the approval of Design and Manufacture Drawings by the Engineer.
2. Supporting structures for RISS shall installed at suitable intervals based on the design
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requirements. The interval between successive fixtures shall not permit undue sag and vibrations.
The steel members shall be hot-dip galvanized and the materials of nuts, bolts and washers shall be corrosion-resistant, e.g. stainless steel of suitable grade for the moist and polluted tunnel conditions.
3. Support insulators and accessories
The electrical and mechanical characteristics of support insulators for the 1500V DC RISS shall be in accordance with the minimum requirements and shall be not be less than the following:
a) Water splash voltage at commercial frequency: 22 kV;
b) Impulse withstand voltage: 80 kV;
c) Energized destructive load: not less than 9800 N;
d) Bending destructive load: not less than 4900 N;
e) Oil immersed destructive voltage at commercial frequency: not less than 40 kV;
f) Withstand voltage at commercial frequency: 55 kV;
g) Tensile withstand load: 3234 N; and
h) Minimum surface creepage length: 300 mm.
Supporting insulator fixtures shall allow free sliding of rigid conductors to allow for expansion on account of temperature changes. Supporting insulators and accessories for rigid conductors shall be mounted on supporting structures to enable adjustment of the conductors to the required stagger as per the construction/installation design drawings.
4. Preventing loosening of bolts and nuts
Adequate measures shall be taken for preventing all bolts and nuts from becoming loose through the use of lock nuts/spring washers.
5. Numbering of structures
Number plates shall be set near the supporting structures for RISS.
5.5.28 Expansion Joint
1. Interval between expansion joints
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The standard interval between expansion joints shall be 250 m.
2. Parallel contact wires at expansion joint
a) The standard separation distance between two contact wires at expansion joint shall be 250 mm.
b) Parallel contact wires shall be jointed with an adequate number of flexible continuity jumpers.
c) The height of two rigid conductors which overlap at expansion joint shall be the same over a section of more than 500 mm.
5.5.29 Insulated Overlap for RISS
The main structure for insulated overlap shall be the same as those for expansion joint. The separation distance between two contact wires shall not be less than 250 mm. No insulated overlap shall be provided in station platform areas. Insulated overlap shall be provided at crossovers also to segregate two sections.
5.5.30 Jumper Wires for RISS
Jumper wires for rigid conductors shall be of stranded annealed copper with adequate current carrying capacity. Connections of jumper wires to rigid conductor rails shall be through suitable bimetallic terminals, each having at least two fixing bolts. Bolts shall not conduct any current. Jumper wires shall be flexible to allow creeping of rigid conductors.
5.5.31 Anchoring
1. Anchoring shall Supplied for the prevention of unidirectional creeping of rigid conductors.
2. Anchoring shall be supplied in the middle of one conductor run length between two expansion joints.
3. Anchoring insulators and fittings
The design insulator and fittings used at anchoring locations shall be least affected by-passing pantographs. Materials for anchors shall be corrosion resistant such as hot-dip galvanized or of stainless steel. Suitable bimetallic fitments shall be integral with the fittings to prevent electrolytic corrosion of aluminum.
5.5.32 T-section Aluminum-alloy Bar Affixed Contact Wire
1. Rigid conductors shall be of aluminum alloy section with wearing copper contact wire.
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2. Rigid conductors shall have an anti-corrosion treated surface. Sections of transportable lengths shall be joined together to form lengths of up to 250 m between expansion joints.
3. Stagger of contact wire for RISS
The stagger of contact wire for RISS shall be limited to 200 mm nominal from the rail centre on tangent track and on curves. However, the value of stagger shall be finalized based on the pantograph profile obtained from the Interfacing Contractors. Stagger of contact wire at supporting points shall be achieved over a suitable value to avoid grooving on the pantograph current collection strips. The design of RISS shall permit 50 mm track displacement in the horizontal direction without need for changing any components.
4. Crossover equipment
The horizontal separation distance between two contact wires at the center of scissors crossing turnouts shall not be less than 250 mm. The main track contact wires shall be installed 10 mm lower (vertical) than those of the turnout track.
5. Transition section from RISS to FMS
The transition from RISS in tunnel sections to FMS in ground section and vice versa shall be designed so that passage of trains is as smooth as possible without resulting in any pantograph jerking, sparking or component wear.
6. Temperature indicator stickers
Temperature indicator stickers shall be provided to detect the permissible operating temperatures at envisaged points rising in heat to fault conditions. The permissible operating temperature, changing color of stickers, shall be limited to 10°C or 20°C below the maximum allowable temperature. The permissible operating temperatures adopted for warning indications shall be finalized with the approval of the Engineer. The main envisaged points with rising heat are compressed sleeves of feeder wires and contact wires, blade and terminal of disconnection switches and jumper terminals of expansion joints for RISS.
RISS at one end and to feeder cables, disconnecting switch terminals at the other end and at knife edge contacts of disconnecting switches. Similarly, these shall be provided at return cable terminal connections so as to ensure that hot spots are detected well in time to take up remedial measures. The warning indication temperatures adopted for various terminal connections shall be finalized based on safe working temperature limits.
7. Transporting material and products
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Due care shall be taken that no breakage, dents, cracks or bending of any component take place during transportation. Due care shall be taken to prevent any damage from rust by applying antirust treatment. Materials delivered at work sites shall be laid up neatly at nominated locations and as agreed with the Interfacing Contractors so that interference does not occur with other nearby works.
8. Installation of RISS
a) Due care shall be taken while handling rigid conductors so that no twisting or bending or development of any cracks takes place. Temporarily supporting the rigid conductors with one end cantilevering shall be prohibited.
b) While installing rigid conductors at high locations, safe practices shall be adopted.
c) The erection of rigid conductors shall commence from the anchoring structure and continue on to the expansion joint.
d) Before installation of the end approach of expansion joints, adjustment of the final length shall be in accordance with the measured temperature in the tunnel.
e) On curved track, rigid conductor lengths shall be appropriately bent to the requisite curvature.
f) On turnouts the level of the crossover contact wire shall be raised so that it does not come in contact with train pantographs running on the main track, and for trains negotiating turnouts, the passage and current collection by the pantograph shall be smooth.
g) The tensile force in contact wires shall be maintained consistent with the design requirements.
h) The jointing of rigid conductors shall be carried out with a high quality and economical method in conformity with relevant worldwide working procedures. The Contractor shall select the most appropriate joint processing method in consideration of methods to ensure short working periods which do not require highly skilled workers without objection by the Engineer.
5.5.33 Stray Current Suppressing Devices (SCSD)
1. SCSD shall be equipped for the purpose of preventing electrolytic corrosion caused by leakage current entering from the outside to the Light Repair Shop and electric shock prevention to workers.
2. SCSD shall be installed in front of the Light Repair Shop and in other likely areas as necessary.
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The Contractor shall decide the final locations in consultation with the signaling section.
5.6 DEPOT
5.6.1 Moveable Conductor Rails in Workshop
Rigid power conductors, movable type, shall be supplied and installed at overhaul workshop (WKS) tracks to permit safe and unhindered roof access for maintenance of pantographs, air-conditioners, and other equipment.
5.6.2 Retractable Power Conductors
Movable Conductor Rails shall be part of the 1,500 Vdc traction system and shall be installed in the overhaul workshop (WKS) on Track 3 ‘Final Adjustment Shop’ and Track 5 ‘Unscheduled Repair Track’ to permit safe and unhindered train roof access for maintenance of pantographs and air-conditioners when Conductor Rail is retracted.
For train movements the Conductor Rail shall be positioned at track center for pantographs to contact traction power supply.
For access to the train roof the Conductor Rail shall retract to one side of the train and rest near the line of building columns in the work shop and shall automatically be grounded.
The Conductor Rails shall be a continuous metal structures equipped for pantograph contact to draw traction power. Conductor Rails shall be suspended and held in position by rotating arms projected from building columns at 10 m spacing.
Conductor Rails shall be retracted from the center of the track through the rotation of the suspension arms nearly 900. In retracted position Conductor Rail shall be earthed automatically at the end of rotation movement.
5.6.3 Train Roof Access
Facilities to be installed for access to train roof include:
▪ Traction power control panel; ▪ Secure roof access stairs with interlocked door; ▪ Roof platforms with railings, installed at sides of train for stepping on roof; ▪ Half-gates (Gates) across train roof from platform to platform, and ▪ Overhead crane (3 t) for replacement of pantographs and air-conditioners.
Condition during train movement:
▪ Conductor rail is positioned at track center; ▪ Access doors on stairs to platform are locked (no access);
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▪ Overhead crane(s) cannot move, interlocked with conductor rail, and ▪ Half-gates across train (platform to platform) are open, interlocked with conductor rail.
Access to train roof:
▪ Traction power is isolated; ▪ Pantographs shall be down; ▪ Conductor rail is moved to side along columns; ▪ Conductor rail grounding is confirmed; ▪ Half-gates near end of train roof are closed, interlocked with conductor rail; ▪ Access door to roof platform is unlocked, interlock with conductor rail, and ▪ Overhead crane can be moved, interlock with conductor rail is off.
Leaving train roof
▪ Overhead crane is moved to ‘safe’ location and interlocked to ensure no contact with conductor rail, i.e. hoist is located opposite to conductor rail movement; ▪ Half-gates near across train roof opened and interlocked; ▪ Access door to roof platform is closed and interlocked; ▪ Conductor rail is moved to center of track and grounding is off; ▪ Traction power is on; ▪ Pantographs shall be raised.
Table 5.6.3.1 Interlocking Conditions (X)
Workshop Facility Train Roof Access Roof Reversion to Train Movement Initiation Access Traction Movement
Traction power on X X
Traction isolated X X X
Cond. rail moves X X
Cond. rail grounded X
Access door control X – Locked X – Locked X – Opened X – Locked X – Locked
Gates at platforms X – Opened X – Opened X – Closed X – Opened X – Opened
Overhead crane X – Blocked X – Blocked X – Active X – Blocked X – Blocked
5.6.4 Workshop Operation
The Movable Conductor Rail system shall be designed, manufactured, installed and tested to provide efficient train roof access for maintenance and safe conditions for technicians.
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5.6.5 Controls Management
Retractable Power Conductors shall be installed at the MMSP Workshop (WKS) building on Track 3 ‘Final Adjustment Track” and on Track 5 ‘Unscheduled Repair Shop. These tracks are not adjacent therefore, separate control cabinets shall be installed at permanent locations for each track.
The control system with various input signals, control sensors, supervision parameters and interlocks shall be performed by a Programmable Logic Controller (PLC). A display screen shall be included to clearly indicate system and control status of retractable power conductors to create safe access to train roofs, operation of overhead cranes and gates at platforms.
Operation parameters shall be organized at three levels:
Administrator – This level shall be for the Workshop Manager or O&M Contractor to modify access codes for the workshop organization.
Operator – This level shall be for the Catenary Maintenance Manager to act in manual and automatic mode for set-up of the system.
User – This level is for operation only in automatic mode and shall be for technicians performing maintenance.
The PLC screen shall display Retractable Power Conductor hardware settings graphically and interlock parameters.
5.6.6 Train Movement into Workshop
Trains shall be able to operate from outside into the workshop building and vice versa in continuous motion. At building entry there shall be a neutral overhead section at the separation of traction power supply outside and inside the building. The physical structure for tensioning of the overhead line outside of the building shall be integrated with the structure of the building wall.
5.6.7 Conductor Rails
The retractable conductor rails shall be a continuous rail made of aluminum held in position by rotating suspension arms. The pantograph contact surface shall be the same material as overhead contact wires outside the workshop.
5.6.8 Rotating Suspension Arms
The conductor rail shall be suspended by arms that will rotate and move the conductor rail away from the train nearly 900 in close proximity of building columns. Rotating suspension arms shall be mounted at column locations at 10 m intervals. All suspension arms shall rotate simultaneously. Discrepancies of rotation shall cause the system to stop for investigation and correction. The rotating suspension arms
OCS-5-29 METRO MANILA SUBWAY PROJECT PHASE 1 Part 2 – Employer’s Requirements Package: CP106: E&M Systems and Track Works Section IV shall consist of powered and non-powered units. It shall be noted that the column center line to center of track is approximately 5 m.
5.6.9 Overhead Crane
The hoist of the overhead crane shall be located at the extreme end opposite the retracted conductor rail while such movements take place. The crane may remain at any location longitudinally relative to the track length.
5.6.10 Half-gates at Platform
These gates shall be installed from platform to platform across trains for employees’ safety when working on train roofs. The gates shall be operated automatically and shall be open to permit pantographs to pass by when trains are moved.
5.6.11 Retractable Conductor Rail Installations
On Track 3 the workshop bay is 10 m between column grid lines ‘D/E’ with track in the center. The conductor rail length inside the building from GL ‘1’ shall be 220 m.
On Track 5 the workshop bay is 15 m between column grid lines and the track is approximately 5 m from the west grid line ‘G’. The conductor rail length inside the building from GL ‘1’ shall be 240 m.
5.6.12 Permission to Access Train Roof
The procedures for permission to access the train roof platform safely and return shall be formulated by the O&M Contractor.
5.7 INTERFACE REQUIRMENTS
5.7.1 General
The Contractor shall interface with relevant authorities and other interfacing parties to ensure effective and compatible coordination of all aspects of design, installation, testing and commissioning of the Works.
5.7.2 Contractor’s Responsibilities
1. The Contractor shall ensure that all interface items listed in, but not limited to, the Employer’s Requirements – General Requirements, Appendix 6, are considered.
2. Other items not mentioned in the interface items but which are relevant to the design, installation, testing and commissioning of the Permanent Works, shall also be coordinated with the Interfacing Contractors.
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5.7.3 Interfacing Items
Interfacing items are described in the Employer’s Requirements – General Requirements, Appendix 6.
5.8 TESTING AND COMMISSIONING
The Contractor shall develop a Testing and Commissioning Plan and test specifications for putting the system to work and submit these for review by the Engineer.
However, if the performance tests indicate any faults or irregularities in the installed system, or if the Engineer recognizes that such detailed tests are necessary to identify the cause of the fault, any materials, labor or equipment necessary for these additional tests shall be at the Contractor’s expense.
Testing shall also include the Non-Destructive Testing (NDT) such as regular temperature measurement to the critical point of OCS / RISS / FMS / SCS as part of the testing and commissioning and O&M Manual.
5.8.1 Measurement for Insulation Resistance
Insulation resistance shall be as showed in Table 5.8.1.
Table 5.8.1 Insulation Resistance Item Insulation Resistance Location to be Measured Insulator Not less than 2000 Mega-ohms Between upper and lower metal fittings Section Insulator Not less than 2000 Mega-ohms Between connecting metal fittings for contact wires
The Contractor shall measure the as-built dimensions and check compliance with design of the following items:
1. Height and stagger at each support location;
2. Height and stagger mid-span between support points;
3. Along track setting of all support locations and record the distance from the fixed point and ambient temperature at the time each measurement is made;
4. Tension of all auto-tensioned and fixed termination wires and ambient temperature at the time each measurement is made; and
5. The position of the balance weight in the vertical range, number of turns on wheels and extension of spring tensioning devices, and ambient temperature at which each measurement is made.
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5.8.2 Insulation Testing
Tests shall be carried out in accordance with JIS standards as follows:
1. Insulation resistance test
a) Connections of arresters shall be isolated.
b) Circuit breaker connections at substations shall be isolated.
c) Disconnecting switches in feeding circuits shall be released.
d) Measurement shall be by a 1000V Megger to check whether the circuit is contacting ground.
2. Conductivity test
Each line system shall be checked with a 1000 V Megger, with the overhead contact wire connected to a rail at the end of the line.
3. Insulation withstand test
a) The test voltage shall be AC and 1.5 times greater than the nominal voltage of the feeding circuit and shall be supplied for ten (10) minutes continuously.
b) The test current and voltage shall be measured at zero minute (immediately when the current is switched on), after which measurements shall be made every 0.5, 1.0, 2.0, 3.0, 4.0, 5.0, 7.0 and 10.0 minutes respectively.
c) Immediately after the tests have been finished, an insulation test shall be carried out.
5.8.3 Stray Current Tests
1. The test voltage shall be DC at the nominal voltage of the feeding circuit and shall be supplied for 30 minutes continuously.
2. The test current and voltage shall be measured at zero minute (immediately after the current is switched on), after which measurements shall be made every 0.5, 1.0, 2.0, 3.0, 4.0, 5.0, 10.0, 15.0, 20.0, 25.0 and 30.0 minutes.
3. Stray current shall be less than 10 mA per linear kilometer of the catenary line.
5.8.4 Trial Operation
Prior to commissioning tests, the Contractor shall confirm the following conditions through trial operation:
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1. Contact conditions between the contact wire and pantograph slide when a trial train is running touch pantographs at work.
2. Contact conditions at cross-over, air-joint and air section shall be checked.
5.8.5 Contact Conditions
1. After tensioning of the contact wire has been completed, droppers, steady arm and pull-off equipment shall be checked for installation and adjustment of their final positions.
2. The following measurements shall be followed and recorded in the presence of the Engineer for each wire run with the contact wire in its final position.
a) Verification between the pole number and supporting point shall be conducted at the site.
b) System height, the distance between the messenger wire and the contact wire, shall be measured at each support point.
c) Contact wire stagger shall be measured with reference to the track center line of each registration point and at mid-span, and then the values relative to both the design and actual measurements shall be checked.
d) Contact wire height above each rail level at each supporting point and at mid-span shall be measured.
e) Wire temperature and air temperature, and time of day and date.
f) The exact rail level and setting distance from the face of the structure to the center line of the tracks shall be measured.
3. As necessary, the Contractor shall rectify errors and shall re-measure the OCS in presence of the Engineer.
4. A complete set of the final height and stagger dimensions of contact wire shall be available at the final inspection and shall be incorporated into the final as-built documents.
5. The Contractor shall make a clearance check using a height and stagger gauge fitted with a contact lie testing car.
5.8.6 Trial Runs
The Contractor shall employ staff who can carry out on-site testing and commissioning during the trial run period, and quickly solve any problems arising from the tests.
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5.9 TRAINING
5.9.1 Scope of Training
1. The objective of the training is to enable the O&M Company experts to become competent and deliver future courses for other employees of the Employer/Operator.
2. The Contractor shall provide training to the O&M Company experts on the OCS. Aspects covered shall include, but not be limited to:
a) Features and functional principles of the relevant systems;
b) System engineering aspects including but not limited to design standards, design criteria and parameters, structural strength and other calculations, clearances from other facilities;
c) Details of major equipment and components used in the system; and
d) Training in the Philippines and abroad including training at manufacturing facilities shall be covered as appropriate.
5.9.2 General Requirements
1. This section of the Technical Specification covers the requirements for a Training Program to train the training personnel and the Employers technical staff. The Training Program shall enable the O&M Company experts to maintain and perform technical work, such that the systems and associated equipment will perform in accordance with the Technical Specification of this Contract.
2. The Contractor shall provide comprehensive training to the O&M Company experts.
3. The Contractor shall provide outdoor OCS facilities Training, competent instructors, training manuals, all necessary aids and materials in support of all training courses. The training manuals shall be submitted plus necessary circulation hard copies in electronic format. The training instructors shall be qualified competent with sufficient years of practical experience in their relevant fields and possess good communication skills. The training instructors shall be competent staff of the Contractor, or the subcontractors. Training in the Philippines or abroad shall be conducted for the O&M Company experts in English. The respective training manuals shall be provided in English languages.
4. The training materials such as manual, training plan shall be developed by the Contractor in the English language and train the O&M Company staff.
5. The training shall be carried out at a best suitable location. This may be in the Philippines,
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abroad, at a place of manufacture, assembly or testing, or at such other locations as may be necessary. All training locations shall be proposed by the Contractor.
6. The training courses and / or sessions shall include all major OCS facilities and works engineered by the Contractor.
7. The Contractor shall supply full-time on-site management, coordination, and supervision of the entire training program to ensure the continuity of classes, and proper distribution of training materials, and be responsible for interfacing with the instructors.
8. The Contractor shall be required to arrange knowledge transfer and training to the Employer’s staff in respect of design, manufacture, installation, testing and commissioning of the system.
9. The Contractor shall submit assessment reports on the performance of individual trainees to the Employer and / or O&M Contractor. Training evaluation shall be required at regular intervals to monitor the progress and suitability of the training program. Items that require further information or tasks that require additional training or practice shall be discussed between the Engineer, the Operator and the Contractor at the evaluation meetings. Such items or tasks must be appended to the training program as soon as possible.
10. In case training courses shall be held in countries other than the Philippines, the Contractor shall provide allowances, hotel and travel arrangements for the Employer’s and O&M trainees, as well as for the Employer or / and the Engineer monitoring staff.
11. Throughout the training program, the Employer and the Engineer shall have free access to all training sessions to monitor the progress of the trainees and the Contractor's training instructors.
12. The Contractor shall provide an O&M Manual for the OCS.
5.9.3 Training Plan
1. The Training Program shall be prepared by the Contractor and submitted to the Engineer for his approval not later than six (6) months after the award of the Contract.
2. The Training Program shall include the objectives, content, method, location, timing and duration of each course.
5.9.4 Training Courses
1. The Contractor shall provide Training Courses on all facilities, systems and equipment. Each course shall be specific and shall consist of classroom, hands-on, or field training as necessary to accomplish the course objectives specified in the Training Program Plan. The Contractor shall develop detailed training modules based on information in the Operating and Maintenance
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manuals.
2. The technical training courses for the Employer shall be programmed in phase with the progress of manufacturing and installation to ensure that trainees are present during all stages of the manufacturing, installation and commissioning of the equipment which is the subject of the training. The Contractor shall ensure that the courses fully encompass all aspects of the basic design, manufacturing, installation, commissioning and maintenance of the facilities with maximum effort being directed at instruction for the maintenance of the installations.
3. The Contractor shall provide training courses for each system on the outdoor OCS facilities for practice, including, but not be limited to:
a) At the time during construction of the outdoor OCS facilities for practice:
Method for installation of poles and their foundations;
Method for installation of cantilevers;
Method for mounting of guys;
Method for installation of termination devices;
Method for wiring of grounding wires and insertion of arcing horns;
Method for installation of feeding wires, feeding branches and lightning arresters;
Method and procedure for pre-stretch of messenger wires and contact wires;
Method for installation of steady equipment and pull-off fittings;
Method for adjusting overhead contact lines.
Method for adjusting the height of the contact wire at cross-section of overhead contact line; and
Method for inserting of sectioning devices.
b) Taking the outdoor OCS facilities for practice:
Method for replacing of contact wires and messenger wires;
Method for replacing of steady equipment and pull-off fittings;
Method for replacing of termination devices and guys;
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Method for adjusting overhead contact lines including overlap sections;
Method for replacing of insulators for FMS;
Method for inserting of insulators;
Method for replacing of sectioning devices;
Method for adjusting the height of the contact wire at cross-section of overhead contact line;
Training for going up and down using ladders;
Method for rebuilding and renovating poles and beams; and
Explanation of the names and functions of OCS facilities.
5.10 SYSTEM ASSURANCE AND RAMS
Refer to Appendix 21 of Employer’s Requirements, Section VI.
5.11 SPARE PARTS, TOOLS AND MEASURING DEVICES
The general requirements for spare parts, consumables and tools are described in the Employer’s Requirements - General Requirements. This chapter defines the Particular Requirements for the OCS.
5.11.1 Spare Parts
1. The Contractor shall provide his own spares during the installation and commissioning period as well as for support during the Defects Notification Period.
2. The Contractor shall submit lists of spares within six (6) months after the commencement date of the works to the Engineer for review. The lists shall include:
a) Detailed descriptions with references and correlation with the maintenance manuals; and
b) Contractor’s own spares.
3. The Contractor shall keep and maintain sufficient stock of his own Commissioning Spares and Defects Liability Spares. In addition, in determining the list of spare parts for the Commissioning Spares and Defects Liability Spares, the Contractor shall provide a list of the proposed types and quantities with the following taken into account:
a) Total sum of the parts by type;
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b) Durable years; and
c) Preservation place.
4. The Contractor shall submit the list of Commissioning Spares, with the types and quantities of spares the Contractor intends to hold, at least three (3) months before the commencement of installation activities to the Engineer for review.
5. The Contractor shall submit the list of Defects Liability Spares, with the types and quantities of spares the Contractor intends to hold, at least three (3) months before the commencement of the Defects Notification Period to the Engineer for review.
6. The Contractor shall include details of the stock of the Contractor’s own spares in the Monthly Progress Reports. The status of the spares, either in store or under workshop repair, shall also be included.
5.11.2 Special Tools and Test Equipment
1. The Contractor shall provide special tools and test equipment.
2. The Contractor shall submit a list of items with unit prices and quantities of each type of special tools and test equipment and those recommended by the Contractor.
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