\lil'~ Business Process Document. Cross Track Cable Management. Kevin ~~~ad Electrification & Plant Engineering. Network Rail '!

Transcription

1 Ref NR/SP/SIG/19812 Issue 1 Date 2007 Business Process Document Cross Track Cable Management Endorsement & Authorisation ead of Signal Engineering... ~~~ Kevin ~~~ad Electrification & Plant Engineering Bob Cummings, ead of Track Engineering Accepted for issue by: \lil'~ M McManus, National Standards Manager This document is the property of Network Rail. It shall not be reproduced in whole or part nor disclosed to a third party without the written permission of the Standard Owner. Copyright 2007 Network Rail Uncontrolled copy once printed from its electronic source. Published & Issued by: Network Rail 40 Melton Street, London NW1 2EE Network Rail '!;"'~

2 Issue record Issue Date Comments 1 Feb First Issue Implementation This standard supersedes all details of cross track cable management within Network Rail which reference the use of orange pipe or detail other means for cross track cable management. It should be applied to all maintenance and projects on publication of this standard unless a non compliance has been agreed. This is an emergency standard issue. Compliance This Network Rail Specification is mandatory and shall be complied with by Network Rail & Contractors from the 1st April When this Specification is implemented, it is permissible for all projects, which have formally completed GRIP Level 4, to continue to comply with the Issue of any relevant Network Rail Standards current when GRIP Level 4 was reached and not to comply with requirements contained herein unless the Chief Engineer has stipulated otherwise in the accompanying Briefing Note. Where the Chief Engineer has specified that all projects shall comply with the requirements, specific authority not to comply can be sought in the usual manner using the appropriate non-compliance authority processes described in Network Rail Standard, NR/SP/STP/045 Managing the Process for Non-compliance Authority (formerly RT/LS/P/045). Disclaimer In issuing this document for its stated purpose, Network Rail makes no warranties, express or implied, that compliance with all or any documents it issues is sufficient on its own to ensure safe systems of work or operation. Users are reminded of their own duties under health and safety legislation. Supply Copies of documents are available electronically within Network Rail s organisation. Hard copies of this document shall be available to Network Rail employees on request to the Document Controller and to other organisations from IHS Technical Indexes ( ) Page 2 of 20

3 Contents 1 Purpose 4 2 Scope 4 3 Superseded documentation 4 4 Definitions 5 5 Background 6 6 Policy 6 7 Constraints 11 8 Typical Layouts 12 9 Technical Background 15 Appendix A Table Showing A Summary Of Key Features of Special Sleepers to Date. 16 Appendix B Reduced Specification under Track crossing 17 Appendix C Variety of Cable Management Applications. 18 Page 3 of 20

4 1 Purpose The purpose of this specification is to provide details of the requirements for cross track cable management. 2 Scope The contents of the specification apply to all work carried out on Network Rail infrastructure from date of issue of this standard. This specification sets out the asset policy for cross track cables. It is essential to manage these carefully to ensure track maintenance, in particular an absolute track geometry railway, can be maintained appropriately. This specification is mandatory for all renewals, enhancements and maintenance work. Renewals and enhancement work is classed as all work that requires the disconnection of a cross track cable within planned work. Maintenance work is defined as work carried out in a rapid response situation, most usually when rectifying a fault 3 Superseded documentation 3.1 NR/SP/ELP/27242 (Issue 1, December 2005) - Specification for electrical installations on rail premises. The requirements stated in section of NR/SP/ELP/27242 shall be superseded by the requirements in this specification. 3.2 NR/SP/ELP/40045 (Issue 5, December 2005)- Specification for electric point heating. The requirements stated in section 19 of NR/SP/ELP/40045 shall be superseded by the requirements in this specification. 3.3 NR/SP/ELP/21104 (Issue 2, April 2006)- Design & Installation of Electric Track Equipment for DC Electrified Lines. The requirements stated in section 10.7 of NR/SP/ELP/21104 shall be superseded by the requirements in this specification. 3.4 RT/CE/S/073 (Issue 1, December 2003) - Design, Assembly and Installation of RT60 Switches and Crossings. The requirements stated in section 11.2 of RT/CE/S/073 shall be covered by the requirements in this specification. Page 4 of 20

5 3.5 NR/GN/SIG/11600 (Issue 1, August 2000) - Signalling and Operational Telecommunications Design: Technical Guidance. The guidance stated in section of NR/GN/SIG/11600 shall be superseded by the requirements in this specification. 3.6 NR/GN/SIG/11210 (Issue 1, August 2000) - Signalling Installation Handbook. The guidance stated in appendix 2A15 of NR/GN/SIG/11210 regarding the use of orange pipes shall be superseded by the requirements in this specification. 3.7 NR/GN/SIG/11210 (Issue 1, August 2000) - Signalling Installation Handbook. The guidance stated in appendix 2R20 of NR/GN/SIG/11210 shall be superseded by the requirements in this specification. 3.8 NR/GN/SIG/11210 (Issue 1, August 2000) - Signalling Installation Handbook. The figures shown as guidance in appendix 2P05 of NR/GN/SIG/11210 shall be superseded by the requirements in this specification. 3.9 NR/SP/SIG/10173 (Issue 3, April 2004)- Train Protection and Warning System (TPWS) Track Sub System Installation Requirements. The requirements stated in sections and of NR/SPSIG/10173 shall be superseded by the requirements in this specification NR/SP/SIG/11752 (Issue 2, August 2001)- Train Detection. The requirements stated in sections 5 and 10 of NR/SP/SIG/11752 shall be superseded by the requirements in this specification NR/PS/SIG/11762 (Issue 1, December 2000)- Track Circuit Assister Interference Detectors. The requirements stated in section 9.2 of NR/PS/SIG/11762 shall be superseded by the requirements in this specification. 4 Definitions A cross track cable is defined as a cable that has been or is planned to be installed passing underneath a rail. Page 5 of 20

6 5 Background The use of orange piping passing underneath rails is no longer considered as being the preferred method for cable protection. The use of such piping shall therefore be discontinued where alternative methods of achieving protection against damage can be used. The policy is based upon the difficulties experienced by mechanised track maintenance plant in working around the numerous installations of orange pipe which can lead to poor track geometry. 6 Policy 6.1 General Policy The cross track cable management policy on Network Rail infrastructure is detailed below. The options are listed in order of preference, with the preferred option first Under Track Crossing (UTX) To be used for passing multiple cables across track. Power cables at the lowest level and telecoms cables to be segregated into separate pipe within the crossing. To be constructed with a number of pipes having a spare capacity Reduced Specification under Track Crossing Used for allowing for more economic construction methods. More details are shown in Appendix B Hollow Steel Sleepers and Bearers Sleepers are used for conveying and protecting multiple cables across track or tail cables close to point of termination. Bearers are used for housing Hy-Drive and HPSA point operating equipment Ducted / Asymmetric Concrete Sleeper Ducted sleepers are manufactured with a groove for cable management. Used where single or small numbers of cables are passing across the track. Cable guards shall be used to protect the cables when routed underneath the rail. Asymmetric sleepers are in development for signalling or traction power supply cables where an under track crossing is not practicable. Asymmetric sleepers can be installed adjacent to the existing cable, which is then cleated to the sleeper without the need for disconnection. Page 6 of 20

7 6.1.5 Ducted Steel Sleeper For use in steel sleeper track only. Multiple adjacent ducted sleepers may be used to accommodate greater numbers of cables Cleat Cables to Sleepers / Bearers Using approved cable cleats the cables shall be neatly secured to the sleeper(s). On concrete they shall be secured using the Excalibur or Hilti equivalent fastenings. On timber the cleats can either be nailed or screwed down. The cables shall be neatly installed with the cleats running down the centre of the sleepers / bearers. Cable guards shall be used to protect the cables when routed underneath the rail Orange Pipes This option can only be used if any of the above options are not possible. Orange pipes (or any other coloured pipe) laid in the four foot shall be kept to a minimum. If orange pipe is used it shall not be installed in a manner which significantly prevents track maintenance, for example: In a bay where there is a rail joint or weld, or in a bay adjacent to them; In a bay which is less than 0.37 meters (1 foot 3 inches) wide; In a bay which already has an orange pipe or other obstruction, or one adjacent to it. Always leave at least one clear bay between obstructed bays. Orange pipe shall not be used where new switch and crossing arrangements are being installed. The use of unprotected loose laid cable in the four foot is not permitted. 6.2 Guidance on Application of Policy Major Renewals and Enhancements This includes track relaying works, S&C renewals, junction remodelling, re-signalling work, level crossing renewal, point heating renewal etc Minor Renewals and Enhancements This includes replacing a short section of track, replacement of a half set of switches, renewal of individual pieces of equipment e.g. Point machine, signal head and renewal of tail cables etc. Page 7 of 20

8 6.2.3 Maintenance As this has been designated as rapid response work, it is agreed cables may be disconnected and reconnected using their existing method of cross track cable protection. However if there is an opportunity to improve the situation by implementing the general policy then the correct method shall be carried out. 6.3 Cable management between Sleeper(s), Bearer(s) and the cess. When leaving a sleeper / bearer care shall be taken to avoid track maintenance areas such as ballast regulating and tamping zones. If the cable(s) are going to a disconnection box or piece of line side equipment, they shall be neatly routed up to the point of termination. Cable ties should be used to improve the quality of the installation. Troughing runs shall be used for cable protection when routing cables parallel to the track. Protective plastic pipe should be used to route cables from ballast shoulder to troughing run. Cable shall enter the troughing via the ends or via a cut out notch. Cables shall not be buried while running along the ballast. The routes between sleepers / bearers and the cess shall be kept as short as possible. Page 8 of 20

9 Cross Track Cables Major Enhancements and Renewals Main Cables (Line side, Multicore, SSI Data link) (Equipment e.g. Point m/c, AWS, TPWS) (Track Circuits) *** Minor Enhancements and Renewals Main Cables (Line side, Multicore, SSI Data link) (Equipment e.g. Point m/c, AWS, TPWS) (Track Circuits) *** Maintenance Main Cables (Line side, Multicore, SSI Data link) (Equipment e.g. Point m/c, AWS, TPWS) (Track Circuits) *** Implementation of Policy in DC 3 RD Rail Areas. Ref: NR/SP/SIG/19812 Track Categories 1,1A&2 Track Categories 3,4,5& Table showing the preferred choice of options 1st 2nd n/a 3rd n/a n/a * * n/a 1st n/a n/a 1st 2nd n/a 3rd n/a n/a * * n/a 1st n/a **2nd n/a n/a n/a 1st n/a 2nd n/a n/a n/a 1st n/a **2nd 1st 2nd n/a 3rd n/a n/a * * n/a 1st n/a n/a 1st 2nd n/a 3rd n/a 4th * * n/a 1st n/a **2nd n/a n/a n/a 1st n/a 2nd n/a n/a n/a 1st n/a **2nd * n/a n/a 1st n/a n/a * * n/a 1st n/a n/a * n/a n/a 1st n/a **2nd * * n/a 1st n/a **2nd n/a n/a n/a 1st n/a **2nd n/a n/a n/a n/a n/a **1st Note* If the original cable route was via an UTX or Reduced Spec UTX, the new cable(s) shall go back via the original UTX. Note** Where three or more tail cables cross the track in one bed section, they shall be re-routed to allow the use of cleats. This shall be common when removing an orange pipe. Note*** For advice on the use of Audio Frequency Track Circuits see section Page 9 of 20

10 Cross Track Cables Major Enhancements and Renewals Main Cables (Line side, Multicore, SSI Data link) (Equipment e.g. Point m/c, AWS, TPWS) (Track Circuits) *** Minor Enhancements and Renewals Main Cables (Line side, Multicore, SSI Data link) (Equipment e.g. Point m/c, AWS, TPWS) (Track Circuits) *** Maintenance Main Cables (Line side, Multicore, SSI Data link) (Equipment e.g. Point m/c, AWS, TPWS) (Track Circuits) *** Implementation of Policy in 25kV Electrified & non Electrified Areas. Ref: NR/SP/SIG/19812 Track Categories 1,1A&2 Track Categories 3,4,5& Table showing the preferred choice of options 1 st 2nd 3rd n/a n/a * 1st n/a n/a 1 st 2nd 3rd n/a n/a * 1st n/a **2nd n/a n/a 1st 2nd 2nd n/a 1st 2nd **2nd 1 st 2nd 3rd n/a n/a * 1st n/a n/a 1 st 2nd 3rd n/a 4th * 1st n/a **2nd n/a n/a 1st 2nd 2nd n/a 1st 2nd **3rd * n/a 1st n/a n/a * 1st n/a n/a * n/a 1st n/a **2nd * 1st n/a **2nd n/a n/a 1st 2nd **2nd n/a n/a 1st **1st Note* If the original cable route was via an UTX or Reduced Spec UTX, the new cable(s) shall go back via the original UTX. Note** Where three or more tail cables cross the track in one bed section, they shall be re-routed to allow the use of cleats. This shall become common when removing an orange pipe. Note*** For advice on the use of Audio Frequency Track Circuits see section Page 10 of 20

11 7 Constraints 7.1 Signalling Specific Constraints Audio frequency track circuits suffer a change of impedance when the cables are taken through a complete metal surround. Connections to the track shall not be placed through hollow steel sleepers or ducted steel sleepers for the following track circuits; TI21 Audio Frequency SF 15/U Type Aster Reed Type RT FS2600 Aster 1 Watt Hollow steel sleepers shall not be used for the conveyance of earth bonds or traction power cables. 7.2 Constraints on Third Rail Areas Hollow steel sleepers / bearers shall not be used for cable management on DC third rail electrified track due to DC corrosion issues. 7.3 Track Specific Constraints Shallow depth designs of hollow steel sleeper may be used in softwood track where line speed is less than or equal to 60 mph There shall not be more than two hollow steel sleepers in succession There shall not be fewer than six standard sleepers between subsequent runs of hollow sleepers. Page 11 of 20

12 7.3.4 Hollow steel sleepers shall not be used in steel sleepered track Typical Layouts Figure 1: Hollow steel sleepers shall not be installed within two sleepers of an insulated or fish plated joint. A diagrammatic representation of the options identified in this specification is shown in figure 1. It is shown for Illustration purpose. Figure 2: An extract from the signalling installation standard (NR/GN/SIG/11210) Appendix 2A15 Use of sleeper clipped cable is shown in figure 2. Page 12 of 20

13 Page 13 of 20

14 Page 14 of 20

15 9 Technical Background 9.1 Key Features of sleepers The table shown in appendix A lists the key features of cross track cable management sleepers available. Below is an explanation of each feature. Manufacturer and model reference lists all the options available to date. Sleeper material. Sleeper depth shown for comparison and installation advice. A desirable option would be to install the new sleeper without the need for cable disconnection. Type of rail fastening and rail section compatibility with sleeper is listed. Sleeper weight is shown for comparison and installation advice. Using 12 core C2 cable as a size (29.3mm dia) example to illustrated the number of cables that can be accommodated safely. Compatibility with point machine plug couplers. (70mm dia). Product acceptance certificate numbers. PADS catalogue numbers. 9.2 Approved Cleats There are various styles of approved cleats available from Network Rail s product suppliers. Excalibur M6 X 40 mm or Hilti equivalent shall be used when securing cleats to concrete sleeper. 9.3 Approved Cable Guards Vortok cable guards are quick and easy to install and provide a neat and secure means of cable protection. The cables guards shall be used whenever a cable is routed underneath the rail. (As shown in Appendix C). PADS Number / Rail Section 057/ / Flat Bottom 057/ / CEN / / Bull Head 9.4 Future Products for Cable Management Current sleeper manufacturers are keen to improve cross track cable management. They have shown an interest in development of possible improved designs which are currently in the engineering process. Page 15 of 20

16 Appendix A Table Showing A Summary Of Key Features of cable management Sleepers to Date. Ref: NR/SP/SIG/19812 Manufacturer Type Sleeper Requires Fast clip (1432/1435) Pan V Vossloh Weight Nominal Plug PA PADS & of Depth Cable Dual Inclined Vertical kgs cable Coupling certificate Catalogue models Sleeper D/connect Cen60/113A 113A 113A Cen60/113A capacity*** suitable Number Schwihag steel 165mm no yes yes yes no yes PA05/01894 Full Depth hollow Tenconi Mk1 steel 160mm yes yes not yet not yet no 5 yes PA05/01608 Full Depth hollow available available Tenconi Mk1 steel 125mm yes yes not yet not yet no 5 yes PA05/01608 Shallow Depth hollow available available Tenconi Mk1 steel 160mm yes no no no yes HABD no PA05/0094 HABD hollow Cable Only Tenconi MkII steel 215mm no yes yes yes no 5 yes PA05/02490* Full Depth hollow Balfour Beatty steel 197mm yes yes no no no 5 yes PA05/ / hollow RMC G44D ** concrete 210mm no yes no no no yes PA05/ mm RMC G44 35mm concrete 210mm yes yes no no no no PA05/861 discontinued GMT 560 steel as yes yes no no no 2 no PA05/2066 UTX 560 H Stanton Bonna concrete 193mm no no no yes PA05/02701T n/a Asymmetric * Stanton Bonna concrete 180mm no no no yes PA05/02701T n/a Grooved * Edgar Allen * 75mm concrete 186mm yes 3 yes n/a Note * indicates feature in development or with trial acceptance only Note **indicates cable protection guard to be used. (PA05/596) Note ***indicates the amount of 12 core C2 cables that can be housed safely. (see table 7 of RT/E/PS/00005) Page 16 of 20

17 Appendix B Reduced Specification under Track crossing The minimum depth of under track crossings constructed by the open out method, measured from rail level to the top of the highest point of the duct shall be 800mm. The technical specification for the ducts shall be as per (NR/SP/CIV/044), unless otherwise approved. The ducts shall be brightly coloured (to reduce the risk of accidental damage). Concrete surround in not required. A marker warning tape (yellow and black legend) shall be laid over the top of the granular surrounds to the duct(s). Marking of the under track crossings and supply of records to the territory asset steward shall be strictly in accordance with sections 10 and 11 respectively of NR/SP/CIV/044 (apart from the depth of the marking tape that shall be reduced to accommodate the reduced depth of the crossing). The above application of (NR/SP/CIV/044) shall reduce the cost of installation of under track crossings for the project works and shall avoid the further proliferation of surface cables and orange pipes between sleepers, which are prone to damage (and subsequent train performance impact) and hinder good track maintenance. The reduced depth of cover to ducts has been endorsed by (Head of Track Engineering in 2005), in respect of track maintenance and renewal activities. Page 17 of 20

18 Appendix C Variety of Cable Management Applications. Vortok Cable Guard: PADS No (057/ Flat Bottom) (057/ CEN 60). Hollow Steel Sleeper used for the management of cables to a HW point machine. Page 18 of 20

19 Ducted sleepers manufactured with a grooved for cable management. Asymmetric sleepers used for DC Third Rail for traction cable management. Page 19 of 20

20 GMT 560 for use in steel sleepered track areas. Cables cleat to concrete sleeper. Page 20 of 20

21 Amended Standards Briefing Note Ref: NR/SP/SIG/19812 Publication 24/04/2007 Compliance 01/04/2007 Title: Cross Track Cable Management Standard Owner: Head Of Signal Engineering Compliance rep: Head Of Signal Engineering, Head Of Telecoms Engineering, Head Of Track, Head Of Civils And Head Of Electrification & Plant. Purpose: The purpose of this specification is to provide details of the requirements for cross track cable management. Scope: The contents of this specification apply to all work carried out on Network Rail infrastructure from date of issue. This specification sets out the requirements for cross track cable management. This specification is mandatory for renewals, enhancements and maintenance work. What s New/Changed: New standard - Refer to section 3 of this standard for a detailed description of superceded requirements. The following teams require awareness briefing: Group Finance Contracts and Procurement Finance Enhancement Contracts Group Insurance Internal Audit Funding Deputy Chief Executive Commercial Property Organisation Change CTRL Human Resources Information Management Maintenance Operations & Customer Serv Risk Safety and Compliance Director, Scotland Strategic Analysis Westwood Affected documents: Reference NONE Impact Implementation requirements: The following posts have specific responsibilities within this standard and shall receive technical briefing as part of the Implementation Programme: Territory Engineer (Signals, Telecomms, Track, Civils and E&P, Area Track Engineer, Area Signal Engineer, Area E&P Engineer and Project Engineering Manager (MPI) Engineers/Managers involved in renewals, enhancements and maintenance work. For further information contact: Name: Bleddyn-James Davies Contact number: Bleddyn.davies@networkrail.co.uk Projects and Engineering Engineering Business Engineering Civil Engineering E&P Engineering Enhancements Engineering Ergonomics Infrastructure & Development Ops principles & standards Rail Vehicle Engineering Railway Systems Telecoms Engineering Track Engineering Signal Engineering Projects Major Projects & Investment National Delivery Service Network Development Prog Dir FTN/GSM-R Prog Dir PSU & Thameslink Prog Dir West Coast Prog Dir Crossrail Govt and Corp Affairs Group Company Secretary Planning and Regulation