L1-CHE-SPE-300 BATTERIES FOR RAILWAY SIGNALLING APPLICATIONS

Transcription

1 Engineering Specification Signalling L1-CHE-SPE-300 BATTERIES FOR RAILWAY SIGNALLING APPLICATIONS Version: 1

2 ENGINEERING SPECIFICATION BATTERIES FOR RAILWAY SIGNALLING APPLICATIONS L1-CHE-SPE-300 Version: 1 Effective from: 1 st July 2018 Approval Name Position Signature Document Endorser Louisa Waymouth Manager Standards Approving Manager Phil Ellingworth Chief Engineer Amendment Record Approval Date Version Description 20/06/ Rebadge VRIOGS Batteries for Railway Signalling Applications. No change to the technical content. Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 2 of 20

3 ENGINEERING SPECIFICATION BATTERIES FOR RAILWAY SIGNALLING APPLICATIONS L1-CHE-SPE-300 Version: 1 Effective from: 1 st July 2018 PREFACE This Specification replaces VRIOGS Batteries for Railway Signalling Applications. The contents of this Specification were prepared by the Victorian Rail Industry Operators Group (VRIOG). This VRIOG Standard has been rebadged as an MTM document due to the retirement of VRIOG Standards as of 30 th June This Specification will be managed under the Engineering Standards Development Procedure (L1-CHE-PRO-032). As documents are uncontrolled once printed, it is imperative to check the currency of the Document on The Depot or the MTM s Document Portal which is available externally at All MTM Standards and Specifications are periodically reviewed, and new editions are published which incorporate learnings and Technical Notes (formerly known as Design Practice Notes). Technical Notes are issued between editions which correct any errors or ambiguities contained in an MTM Standard/Specifications. Standards and Specifications may also be withdrawn and/ or replaced. In the event of conflicts or discrepancies between different types of technical documents, refer to the order of precedence as defined in Chief Engineer s Guideline Engineering Standards Listing (L1-CHE-GDL-005). Note: Any clarification described in a Technical Note or Design Practice Note shall take precedence over the impacted clause or clauses in the associated MTM Standard/Specification. In the event a clause within a Standard/Specification is not achievable a waiver will need to be raised, please refer to the Engineering Waiver Procedure - L1-CHE-PRO-001. Note: MTM does not have the authority to grant waivers on any Standards/Specifications or clauses within a Standard/Specification which relate to Government Regulations or Legislation, e.g. Disability Discrimination Act. Referencing this document Clauses and subclauses of this document should be referenced using the following format style L1-CHE-XXX-YYY Clause Z.Z.Z. Referencing the VRIOGS document number is not required. Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 3 of 20

4 ENGINEERING SPECIFICATION BATTERIES FOR RAILWAY SIGNALLING APPLICATIONS L1-CHE-SPE-300 Version: 1 Effective from: 1 st July 2018 THIS PAGE IS INTENDED TO BE BLANK Approving Manager: Chief Engineer Approval Date: 20/06/2018 Next Review Date: 20/06/2021 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 4 of 20

5 Victorian Rail Industry Operators Group Standards VRIOGS Batteries for Railway Signalling Applications Revision: A Issue Date: 06/11/2009

6 ii VRIOGS Revision A VRIOGS Batteries for Railway Signalling Applications Revision A Issue Date: 06/11/2009 APPROVAL STATUS APPROVER STATUS DATE QUALIFICATIONS Document Developer VRIOG Steering Committee Approved All Sections Accredited Rail Operator Metropolitan Train (Metro Trains Melbourne) Intrastate Train (V/Line) Interstate Train (ARTC) Tram (Yarra Trams) For any queries please contact vriogs@transport.vic.gov.au.

7 VRIOGS Revision A iii PURPOSE OF THE STANDARD The Standard has been created through the collaboration of members of the Victorian Rail Industry Operators Group (VRIOG) for the purpose of establishing standards which, if implemented throughout the Victorian Rail Network, will facilitate the interoperability of infrastructure. The use of the Standard is not prescribed by law but, if adopted, conformity with the provisions of the Standard is mandatory in order that the purpose of the Standard be achieved. DISCLAIMER The Standard is published by the Director of Public Transport for information purposes only and does not amount to any kind of advice. Each person is responsible for making his or her own assessment of all such information and for verifying such information. The content of this publication is not a substitute for professional advice. The Director of Public Transport and VRIOG accept no liability for any loss or damage to any person, howsoever caused, for information contained in this publication, or any purported reliance thereon. COPYRIGHT STATEMENT Director of Public Transport This publication is copyright. No part may be reproduced by any process except in accordance with the provisions of the Copyright Act. Where information or material is so used, it should be used accurately and the Standard should be acknowledged as the source of the information.

8 iv VRIOGS Revision A TABLE OF CONTENTS SECTION 1.0 CONVENTIONS... 1 SECTION 2.0 DEFINITIONS... 2 SECTION 3.0 SCOPE AND APPLICATION Scope Application Quality Assurance Quality Assurance Documentation Maintenance Manual Advisory Bulletins Occupational Health and Safety... 3 SECTION 4.0 OPERATING ENVIRONMENT Environmental Conditions Lightning and Surge Protection... 4 SECTION 5.0 TECHNICAL REQUIREMENTS General Load Capacity Battery Life Details Valve Seal Tests Labelling... 6 SECTION 6.0 DELIVERABLE REQUIREMENTS Inspections and Tests Certificates... 7 SECTION 7.0 WARRANTY... 8 SECTION 8.0 MAINTAINABILITY... 9 SECTION 9.0 PACKAGING AND DELIVERY SECTION 10.0 BATTERY DISPOSAL SECTION 11.0 REFERENCES... 12

9 VRIOGS Revision A 1 SECTION 1.0 CONVENTIONS 1) Words or phrases that appear capitalised out of context are defined within the Definitions section of this VRIOG Standard. 2) The word Shall is to be understood as mandatory. 3) The word Should is to be understood as non-mandatory i.e. advisory or recommended. 4) Uncontrolled Standards may not be referenced within the VRIOG Standards. These include former PTC Standards, Franchisee Standards, Franchisee Subcontractor Standards and Infrastructure Lessee Standards. 5) Controlled Standards, including Australian Standards and other VRIOG Standards, may be referenced but only if: The referenced item can not be adequately explained with an amount of text that could not reasonably be inserted into the body of the Standard. The reader is not referenced to another Controlled Standard necessary for the item to be adequately explained i.e. one document link only. The referenced document is a Figure or table and could not reasonably be included in the appendices of the Standard. 6) The format employed in the VRIOG Standards is compatible with Australian Standards, and will be used from this point on. 7) The numbering system for the VRIOG Standards is chronologically sequential from the point of introduction, and is not based on any form of interpretive system. 8) The VRIOG Standards contain engineering information necessary to operate a safe Railway. VRIOG Standards will not contain any information that can be construed as a work instruction, procedure, process or protocol. This information forms the basis of each individual entity s Safety Accreditation Certification, and, as such, is outside the scope of VRIOG Standards.

10 2 VRIOGS Revision A SECTION 2.0 DEFINITIONS Terminology used and/or applied in this Standard is defined as follows:- Terminology Accredited Rail Operator (ARO) Application for Variation of Accreditation AS Purchaser Type Approval VRIOG VRIOGS Definition An Accredited Rail Operator who controls Rail Infrastructure. An application to the Safety Director by an Accredited Rail Operator for variation of its accreditation due to the Accredited Rail Operator proposing to make change to or to the manner of carrying out, accredited rail operations that may reasonably be expected:- To change the nature, character and scope of the accredited rail operations; or To not be within the competence and capacity for which the Accredited Rail Operator is accredited. Australian Standard Person or organisation to which the batteries are supplied or being supplied. Note: They may not be a direct representative of the ARO. Consideration of form, fit and function under specified conditions to approve equipment suitability for me within VRIOG infrastructure. (Refer to VRIOG Standard for Signalling Design and Documentation VRIOGS 012.1, Clause 4.2) The Victorian Rail Industry Operators Group comprising the following members:- VicTrack V/Line Passenger Metro Trains Melbourne Yarra Trams Australian Rail Track Corporation (ARTC) Public Transport Division of the Department of Transport (PTD) Victorian Rail Industry Operators Group Standards. Table 1 - Terminology

11 VRIOGS Revision A 3 SECTION 3.0 SCOPE AND APPLICATION 3.1 Scope This Standard provides the minimum acceptance criteria for the design, manufacture and supply of batteries for use in signalling applications within the Victorian Railway Network. 3.2 Application Unless otherwise specified, all batteries for railway signalling application shall be Type Approved by the ARO and shall be designed, manufactured and supplied in accordance with this specification. The battery shall be of sufficient capacity to provide proper operation for the system under normal operating conditions for a period to cover identification and rectification of a problem with the main power supply. 3.3 Quality Assurance The manufacturer shall be accredited to the appropriate Australian Quality Standards or recognised international equivalent if the manufacturer is based overseas. It is considered that the following are appropriate Australian Quality Standards:- - AS/ISO Quality Management Systems Requirements - AS/ISO Quality Management Systems Guidelines for Performances 3.4 Quality Assurance Documentation Quality assurance documentation shall be in accordance with the requirements of Australian Quality Standard Quality Management and Quality Assurance Standards AS/ISO or recognised international equivalent if the manufacturer is based overseas. 3.5 Maintenance Manual The maintenance manual shall be in accordance with the requirements of VRIOG Standard Specification for Signalling Supply, Construction and Installation VRIOGS 012.2, Section Advisory Bulletins The Purchaser shall check and act upon any related manufacturer and ARO issued product bulletins in order to ensure that they are aware of and action any safety related concerns regarding batteries. 3.7 Occupational Health and Safety The manufacturer shall comply with the Victorian Rail Safety Act 2006, the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations The weight of the equipment shall be considered with regards to the current Occupational Health and Safety Regulations 2007 & Codes of Practice with regards to safe handling by persons and with respect to the installation and maintenance requirements. The manufacturer shall comply with a recognised international equivalent if the manufacturer is based overseas.

12 4 VRIOGS Revision A SECTION 4.0 OPERATING ENVIRONMENT 4.1 Environmental Conditions The battery shall comply with the category conditions specified in VRIOG Standard Environmental Conditions VRIOGS (i) (ii) The battery shall be subject to the condition specified for Category B4 equipment if housed in steel or aluminium box. The battery shall be subject to the condition specified for Category A3 equipment if housed in control room signal box. 4.2 Lightning and Surge Protection The application of the battery shall comply with the VRIOG Standard Lightning and Surge Protection General Requirements VRIOGS

13 VRIOGS Revision A 5 SECTION 5.0 TECHNICAL REQUIREMENTS This section of the specification details the minimum acceptance criteria to be considered for the design and manufacture for maintenance free batteries. 5.1 General a) All batteries shall be maintenance free during the whole service life. b) The batteries shall have the capacity to maintain the full level crossing protection installation under fault conditions for a minimum period of three hours in the metropolitan area and at least six hours for the country area. c) The manufacturer shall specify the batteries operational parameters in the battery data sheet. These shall include but not be limited to the following information:- i) Manufacturer Name and Contact number ii) Battery Details Voltage (V) Capacity (A/H) Size (mm) Weight (kg) Maximum load current capacity (A) Battery life Cyclic operations without affecting battery life Self discharge Gelled Electrolyte description iii) Valve Seal Information Body material Membrane material Cover material Operation pressure (mbar) Closing pressure (mbar) Valve testing conformances iv) Battery Construction Details Case material Electrolyte acid density (kg per litre) Positive plate material / thickness (mm) Negative plate material / thickness (mm) 5.2 Load Capacity a) The duty cycle must be performed within the first charge/discharge cycle of the battery. b) Any battery which fails this requirement will be deemed to be non-conforming and shall be replaced free of charge by the manufacturer. c) The capacity test of the battery shall be in accordance to AS Stationary Batteries Lead Acid Valve regulated type or approved equivalent international standard.

14 6 VRIOGS Revision A 5.3 Battery Life Details Cyclic Operation a) The battery shall be able to perform 10 years float life with 200 cycles at 100% of rated capacity Design Life a) The battery shall has a design life of up to 18 years, be completely rechargeable and can be stored up to 2 years at 20ºC without a recharge Electrolyte Stratification a) The battery shall use a Recombinant Gelled Electrolyte System to eliminate electrolyte stratification Deep Discharge a) The battery shall, after 30 days of being connected to a low resistance ( 1Ω) load be recharged within 48 hours at normal float voltage and recover a minimum of 75% of rated capacity. b) The 25% loss of capacity must be recovered within seven cycles in accordance with DIN ( ) Storage Cells and Batteries: Testing: General Information and General Test Methods. 5.4 Valve Seal a) Each cell of the battery shall be fitted with an automatically resetting one way valve to release gas in case of excess pressure. b) The valve shall be tested and approved to by a recognised authority to meet their flame arresting requirements. The manufacturer shall submit the test file recognition number or copy of the approval. 5.5 Tests a) All batteries shall be supplied Fully Charged and ready for service. The manufacturer shall have local facilities to charge batteries to their full state prior to delivery. b) Any batteries not performing to specification will be rejected. 5.6 Labelling a) An indelible label attached to the battery shall specify the following minimum details:- Manufacturer s name Manufacturer s unique serial number Battery voltage & A/H capacity b) The battery shall have the following (indelible, embossed or engraved) labelling detailing :- Positive and Negative terminal designations Date of manufacture c) Labelling shall be in accordance with VRIOG Standard General Requirements for Labelling of Signalling Equipment VRIOGS

15 VRIOGS Revision A 7 SECTION 6.0 DELIVERABLE REQUIREMENTS 6.1 Inspections and Tests a) Each battery shall be subjected to a series of inspections and tests to confirm that it conforms to the requirements stated in this specification. b) The manufacturer shall carry out all electrical and/or mechanical inspections and tests to verify that battery supplied conforms fully to the requirements stated in this specification prior to delivery. c) All these tests shall be carried out at the manufacturer s premises at their cost. The Purchaser reverses the right to witness these tests. d) All apparatus and instrumentation required for the tests shall be provided by the manufacturer. e) The inspection and test records shall be retained by the manufacturer for a period not less than the nominated storage life and warranty period of the equipment. 6.2 Certificates a) The results of the inspections and tests are to be submitted in the form of a signed certificate on the manufacturer s company letterhead. b) The manufacturer shall provide the completed Certificate of Compliance to the Purchaser with the delivery of the battery. c) The certificate shall include but not be limited to the following information:- Certificate number and Date of issue Customer s name and Contract number Purchase order number Date of manufacture Quantity of delivery Unique serial number for individual product or batch code assigned by the manufacturer Inspection and test results Date of the inspection and testing Statement of compliance to certificate that the product meets all the requirements of this specification Name and Signature of the manufacturer s management representative d) The Purchaser shall have the right to request supporting Quality Assurance documentation to accompany the manufacturer s Certificate of Compliance.

16 8 VRIOGS Revision A SECTION 7.0 WARRANTY a) The manufacturer shall provide warranty to the Purchaser on all items of equipment supplied. b) All goods supplied by the manufacturer shall be guaranteed against faulty workmanship and/or materials for a period of 12 months from the date of commissioning of the equipment or 24 months from the date of delivery, whichever is the later. c) The manufacturer shall replace without expense to the Purchaser any part (or parts) of the equipment found to be not in accordance with this specification throughout this warranty period. d) The manufacturer shall warrant components bought-in from external suppliers for a warranty period no less than that specified in Section 7(b) of this specification.

17 VRIOGS Revision A 9 SECTION 8.0 MAINTAINABILITY a) The manufacturer shall provide a recommended maintenance plan for routine preventative maintenance tasks, task frequencies and fault finding of the equipment to the Purchaser. b) These shall include but not be limited to the following information:- Installation and maintenance instructions Maintenance periodicities Test equipment and specialist tools required to install, adjust, fault find and maintain the equipment Detailed drawings showing complete assembly details Operational test plan A troubleshooting guide (fault indications, their likely cause and suggested solutions) Details on equipment repair and replacement procedures Spare parts list

18 10 VRIOGS Revision A SECTION 9.0 PACKAGING AND DELIVERY a) All battery shall be individually and securely packed to avoid mechanical damage. b) All batteries shall be handled in such a manner that the delivery and storage of these units will not materially influence their subsequent in-service performance. c) The packaging shall be labelled in accordance to VRIOG Standard General Requirements for Labelling of Signalling Equipment VRIOGS , Section 4.4.

19 VRIOGS Revision A 11 SECTION 10.0 BATTERY DISPOSAL a) All used lead acid batteries are hazardous waste and the disposal of used lead acid batteries shall comply with the Victoria Environment Protection Act 1970, Environmental Protection (Prescribed Waste) Regulation 1998 and Australia Hazardous Waste (Regulation of Exports and Imports) Act 1989.

20 12 VRIOGS Revision A SECTION 11.0 REFERENCES The following documents have been used and referenced for the preparation of this Standard:- No. Ref No. Title 1. AS/ISO 9001 Quality Management Systems Requirements 2. AS/ISO 9004 Quality Management Systems Guidelines for Performances 3. AS/ISO Quality Management and Quality Assurance Standards 4. AS Stationary Batteries Lead Acid Valve Regulated Type 5. DIN ( ) Storage Cells and Batteries : Testing : General Information and General Test Methods 6. VRIOGS Standard for Signalling Design and Documentation 7. VRIOGS Specification for Signalling Supply, Construction and Installation 8. VRIOGS Lightning and Surge Protection General Requirements 9. VRIOGS Environmental Conditions 10. VRIOGS General Requirement for Labelling of Signalling Equipment Rail Safety Act 2006 (Victoria) Occupational Health and Safety Act 2004 (Victoria) Occupational Health and Safety Regulation 2007 (Victoria) Environment Protection Act 1970 (Victoria) Environmental Protection (Prescribed Waste) Regulation 1998 (Victoria) Hazardous Waste (Regulation of Exports and Imports) Act 1989 (Australia) Table 2 References