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SPG 0714
This standard replaces Signalling Design Principle No SC 09 20 00 00 SP, Version 2.0 of November 2001.
Table of Contents
1. Scope ..........................................................................................................................................3 1.1. Introduction ....................................................................................................................... 3 1.2. Reference Documents, Standards and Codes ................................................................. 3 1.3. Installer Supplied Data...................................................................................................... 6 2. Design .........................................................................................................................................6 2.1. Design Inputs.................................................................................................................... 6 2.2. Design Documentation ..................................................................................................... 7 3. Fluid Parameters and Site Details...............................................................................................8 3.1. Fluid Parameters .............................................................................................................. 8 3.2. Environmental and Site Factors........................................................................................ 8 4. Equipment Supply .......................................................................................................................9 4.1. Compressors .................................................................................................................... 9 4.2. Receivers.......................................................................................................................... 9 4.3. Dryers ............................................................................................................................... 9 4.4. Expansion Joints............................................................................................................... 9 4.5. Miscellaneous Equipment................................................................................................. 9 5. Pipework ...................................................................................................................................10 5.1. Piping Classes ................................................................................................................ 10 5.2. Pipework Arrangement ................................................................................................... 10 5.3. Steel Piping..................................................................................................................... 10 5.4. Insulation Joints .............................................................................................................. 11 5.5. Manifolds ........................................................................................................................ 11 5.6. Flexible Hose .................................................................................................................. 11 5.7. Identification and Painting............................................................................................... 12 6. Installation .................................................................................................................................14 6.1. Equipment / Compressor House..................................................................................... 14 6.2. Pipework Installation....................................................................................................... 14 6.3. Cleaning.......................................................................................................................... 15 6.4. Safety Equipment ........................................................................................................... 16 7. Testing and Commissioning......................................................................................................17 7.1. Testing ............................................................................................................................ 17 7.2. Precommissioning .......................................................................................................... 17 7.3. Commissioning ............................................................................................................... 18 Appendix 1 Typical System Documentation ...................................................................................19 Appendix 2 Drawings .....................................................................................................................22 Appendix 3 Data Sheets.................................................................................................................32
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1.
Scope
This specification details the design, fabrication, installation, testing and commissioning of compressed air systems for railway signalling use, and is to be used for both new and altered systems. The compressed air system includes, but is not limited to, air compressor houses (consisting of air compressors, dryers, and controls), air receivers, pipe-work and associated piping components such as manifolds and valves. The compressed air systems will be used to operate track turnouts (points) and train stops, both of which are actuated by pneumatic cylinders.
1.1. Introduction
SPG 0714/01b
SPG 0714/02 SPG 0714/03 SPG 0714/04 SPG 0714/05 SPG 0714/06 SPG 0714/07a
SPG 0714/07b
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Data Sheet Number DS-P-001 DS-P-002 DS-P-003 DS-P-004 DS-EQ-001 DS-EQ-002 DS-EQ-003
Title GMS01 Piping MS01 Piping SS01 Piping Halogen Free Flexible Piping Air Compressor Compressed Air Dryer Air Receiver
Title Construction of Cable Route and Associated Civil works Compressed Air Systems Signalling Documentation and Drawings
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The following Australian Standards and statutory codes form part of this specification.
Standard Code AS 1074 Title Steel Tubes and Tubulars for Ordinary Service Pressure Vessels Identification of the Contents of Piping, Conduits and Ducts PVC Pipes and Fittings For Pressure Applications External Extruded High-density Polyethylene Coating System for Pipes Flanges for Pipes, Valves and Fittings Hose and Hose Assemblies for Air Hose and Hose Assemblies Air/water For Underground Coal Mines Pressure Piping Hot-dip Galvanized (Zinc) Coatings on Fabricated Ferrous Articles Hot-dip Galvanized (Zinc) Coatings on Ferrous Hollow Sections, Applied by a Continuous or a Specialized Process Occupational Health and Safety Act 2000 Rail Safety Act 2002
AS 1210 AS 1345
AS/NZS 1477
AS/NZS 1518
AS/NZS 4792
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2.
Design
The following data shall form part of the design inputs, along with other data listed in the Particular Specification (eg scope of work) and RailCorp Design Principles document: Reference documents, standards and codes (refer section 1.2); Available information on the existing air reticulation system and pneumatic signalling equipment in the project area to which the new work is to be connected; and/or plans showing the proposed location of the new pneumatic signalling equipment; Available information on the location of existing cable routes and any existing air reticulation system which is to be replaced by the new work; Available information on the current noise, air and waste emission approval limits, including any information on any new limits which may apply to the works; Fluid parameters (refer section 3.1); Environmental and site factors (refer section 3.2); Operating and control philosophy (refer to document ESG 100.25); Design life of 25 years for equipment, and 50 years for pipework and structures; Maximum thermal expansion of -10 C to 60 C, and maximum thermal movement of a manifold or cross tie branch to be +/- 25 mm; The equipment and pipe work shall be designed and installed to provide maximum protection and safety for operating and maintenance personnel. Safety equipment shall include guards, access covers, inspection covers, emergency stop equipment, safety interlocks, and other devices required by the statutory authorities; The pipework shall be designed to ensure all manually operated valves are in positions where the valve hand wheel can be comfortably reached and operated from an access platform, floor, walkway or stairway; and Permanent lifting devices to be provided for operation and maintenance personnel, such that maximum manual lift weight is 16 kg. This limit may be lowered further in specific instances, based on the outcomes of a risk assessment (refer OH&S Act 2000). All equipment proposed for the air system shall require type approval.
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3.
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4.
Equipment Supply
Compressors shall be oil injected screw type units complete with integral oil separator, after cooler and variable speed drive. Further details are contained in the data sheets (refer Appendix 3). Units shall be delivered, handled and stored in a manner which maintains the new condition of the units.
4.1. Compressors
4.2. Receivers
Receivers shall be horizontal or vertical cylindrical pressure vessels of carbon steel welded construction in accordance with AS 1210. Integration of the receiver into the compressor skid should be considered for smaller systems. Further details are contained in the data sheets (refer Appendix 3). Units shall be delivered, handled and stored in a manner which maintains the new condition of the units.
4.3. Dryers
Dryers shall be refrigerated type units. Further details are contained in the data sheets (refer Appendix 3). Units shall be delivered, handled and stored in a manner which maintains the new condition of the units.
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5.
Pipework
Piping classes are listed in the piping data sheets (refer Appendix 3), and contain details of design pressures, temperatures, materials etc. All pipework shall be selected from these piping classes only, and shall comply with AS 4041.
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5.5. Manifolds
Manifolds shall be constructed from stainless steel pipe, and comply with the requirements of the drawings listed in Appendix 2. Manifolds shall be placed adjacent to the equipment to which they are to be connected. Where it is physically impossible to place a manifold within 75 metres from the equipment it supplies the installer must seek additional approval.
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Letters shall be as follows: 25 mm Letters up to DN 80 50 mm Letters above DN 80 The location of identification labels shall be at intervals of not more than 8m, adjacent to changes in direction, branches, junctions, valves, wall penetrations and control points. Labels shall be placed so that they are easily seen. Uninterrupted lengths of external services, visible along their length, shall have labels at 50m maximum intervals. Manifold label holders shall be constructed from stainless steel, and incorporate traffolyte labels for manifold, valves, etc. The label holder installation shall be as shown in attached drawings SPG 0714/07a and SPG 0714/07b.
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Protective coatings are required for all ferrous pipework, pipe supports, and miscellaneous items. Equipment (compressors, dryers, receivers) will be supplied painted, in accordance with the manufacturers recommendations. Protective coatings shall be hot dipped galvanising to AS/NZS 4680 with 450g/m2 coating, unless noted otherwise. Damaged sections of galvanising shall be repaired in accordance with Galvanizers Association recommendations.
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6.
Installation
Equipment shall be installed on foundations or support structures. The Installer is responsible for supply of all materials needed (such as hold down bolts, grout, lubricants, etc) to complete the installation. The Installer shall follow all manufacturers instructions for the installation of the equipment and shall recheck all drive alignments prior to testing of the equipment. The Installer shall check the dimensions on site of all interface points. Where required, the Installer is to assemble equipment on site, in accordance with the manufacturers instructions.
6.2.1 General
All pipework installation and testing shall be in accordance with AS 4041, and shall include jointing, supporting, provision for flexibility, protection and anchoring. The Installer shall submit tie-in procedures for approval prior to any tie-in work. The procedure shall detail method/direction of system isolation, in situ work and weld procedure, branch isolation, and method of system repressurisation. Pipeline components must be fitted together in proper alignment and stress free before bolting or welding. Pipelines shall not be forced or sprung into line to be held with welding or bolting, unless cold pull is specified on the drawings. During erection, all pipes shall be supported and lined up. Gaskets are to be centrally located on flanges, to ensure the gasket does not protrude into the pipe bore. It shall be the Installer's responsibility to allow closing lengths of pipework to be cut to suit site measurements and to make sure flanges are site welded. The Installer shall ensure that the site run piping is sufficiently flexible to absorb any expansion or contraction without excessive stresses or loads on equipment or cause leakage at joints. The Installer shall install expansion joints, expansion loops, pipe bends and other items as necessary for this purpose. The Installer shall follow all manufacturers instructions for the installation of the instrumentation, and is responsible for supply of all materials needed to complete the installation. All joints shall be sealed with Loctite Master Pipe Sealant or approved equivalent, or taped with Teflon thread sealing tape. Underground air systems shall never be directly buried, but shall be installed as per the requirements of SPG 0705 Construction of Cable Route and Associated Civil Works.
6.2.2Access
The Installer shall arrange piping to allow removal of connected or other plant items and access to plant items for maintenance and operating purposes. Where drawings issued for construction show piping and/or fittings interfering with access to or removal of plant items, then the Installer shall report such interferences to the Asset Owner, who will decide on changes to the pipe routing. Where the positions are not specified on the drawings or pipelines are site run, the Installer shall locate all manually operated valves in positions where the valve hand wheel can be comfortably reached and operated from an access platform, floor, walkway or stairway. The location of the pipe, valve and valve operator shall not impede accessways.
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6.2.3 Storage
Pipe, fittings and valves are to be protected from damage during transport, storage and installation. Pipework spools shall have their ends temporarily plugged or covered after fabrication to prevent ingress of foreign matter during transport and storage. Pipework items shall be inspected and have all foreign matter removed prior to installation. Items such as valve stems shall be lubricated where necessary prior to installation.
6.2.4Supports
The Installer shall supply and install all necessary hangers, supports, brackets, anchors, and pipe support structural steelwork. Unless approved otherwise, supports shall be standard proprietary saddles. Where necessary during erection and testing, the Installer shall provide and install adequate temporary supports to prevent overstressing of pipework or the equipment to which piping is connected. Unless specified otherwise on the drawings, horizontal piping shall be supported at not more than the maximum spacings shown in AS 4041. Vertical pipes shall be supported at 2.0 m intervals unless noted otherwise. Where a valve, line fitting or other item is installed in a pipeline, a support or hanger shall be located as near as practicable and within 0.5 m. Piping shall be supported not more than 0.5m from any point where the piping changes direction, with the support or hanger located on the section having the longer span. Pipe support steel posts shall be typically 100 x 50 x 10 mm channel, galvanised to AS/NZS 4680 with 450g/m2 coating. Air main brackets should be as per drawing 714/07 a. Every 300 metres on straight runs b. Where the main enters/leaves a pit c. Where a steel branch, sub main, or steel cross tie intersects with the main d. To restrict the movement of any manifold to +/-25mm e. Where there are larger offsets or changes of direction the line shall be anchored in both directions as shown on drawing 714/05 An air main shall be considered to be straight where: a. Its curved to a horizontal or vertical radius greater than 250 metres. b. There are minor offsets of 900mm maximum around abutments or structures Use of structures for anchor points shall be subject to approval.
6.3. Cleaning
Prior to cleaning, all inlets to equipment that may get blocked during cleaning shall be protected using removable in-line strainers. These strainers shall be removed upon the completion of cleaning. The Installer must ensure that line mounted items likely to be damaged by the cleaning are removed. The Installer shall supply, install and remove any temporary closures required. Cleaning shall consist of air blowing the pipework at a sufficient velocity to remove the dirt in the pipe. Such flow shall continue at least 5 minutes and until the pipeline is clean.
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7.
7.1. Testing
7.2. Precommissioning
The Installer shall precommission the equipment in all operation modes. Precommissioning is the running of the plant and equipment and carrying out all necessary adjustments until it is ready and suitable for normal starting and running under service conditions. Precommissioning shall be conducted in a logical sequence in accordance with the programme prepared by the Installer and approved by the Asset Owner. The Installer shall prepare schedules and record the results of the tests on the appropriate log sheets.
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The Installer shall furnish the Asset Owner with a complete list of control instrument set points and alarm signal settings recommended by the Installer as a result of his precommissioning programme. These recommended settings may be supplied progressively during the precommissioning period but no later than at the end of the period.
7.3. Commissioning
Commissioning is the running of the plant and equipment and carrying out all necessary adjustments until it runs under service condition from part to full load. Commissioning shall include the tuning of interacting components of control loops to achieve the required control response. Where equipment items or systems are duplicated in the design to provide Running and Stand-by facilities, all items of equipment and/or systems of both the Running and Stand-by facilities shall be fully tested and commissioned. At completion of commissioning, acceptance certificate as per SPG 0711 is to be completed.
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GENERAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 MECHANICAL CIVIL Foundation & Support Plan & Loads 1 2 2 Completed Specification Data Sheets Performance Curves Data General Arrangement Outline Dimension Routine/Type Test Certificates Manufacturing & Delivery Schedule Technical Literature & Brochures Priced Spare Parts for 1 yrs Operation Installation & Rigging Diagrams Design Calculations & Criteria Bills of Materials Name Plate Details Complete Parts List Installation Instructions Operating Instructions Maintenance Instructions Lubrication Schedules Certified Dimensions 2 2 2 2 2 2 2 2 2 1 1 1 2 2 1 1 1 2 2 2 2 2 2
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23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 1
General Assembly & Cross Section Drawings Shop Fabrication Details Drive Assembly Details Equipment Assembly Details Mechanical Flow Diagrams Inlet / Outlet Details Mechanical Completion/Test Certificate4 Location of Services Connections Piping Schematic
QUALITY MANAGEMENT Materials Specification Completed QA Compliance Matrix Quality Manual 2nd/3rd Party Accreditation Inspection & Test Plans Performance Test Certificates & Data Hydrostatic Test Certificates & Data NDT Test Certificates & Data4 Material Test Certificates4 Statutory Code Certificates Welding Procedures Welders Qualification Certificates Welding Maps/Records
4 4 4
2 2 2 2
2 2 2
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F: S: I: 2
REVIEW REQUIRED PRIOR TO FABRICATION. REVIEW REQUIRED PRIOR TO SHIPMENT. REQUIRED FOR INFORMATION ONLY.
TIME AFTER AWARD). 3 AS-BUILT COPIES SHALL BE PROVIDED BEFORE EQUIPMENT DELIVERY. AS-BUILT DRAWINGS SHALL INCLUDE ONE FULL SIZE WITH THE REMAINDER A3 COPIES UNO. 4 CERTIFICATES AND PERFORMANCE DATA SHALL BE PROVIDED ON
COMPLETION OF TESTS.
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Appendix 2 Drawings
The attached data sheets form part of this document.
SPG 0714/01a SPG 0714/01b SPG 0714/02 SPG 0714/03 SPG 0714/04 SPG 0714/05 SPG 0714/06 SPG 0714/07a SPG 0714/07b Standard Air System Drawing Symbols (A) Standard Air System Drawing Symbols (B) Pit Drainage Arrangements Compressed Air Piping Arrangements Connection Single Trainstop to Main Anchor Points Steel Air Main Bracket Label Holder Installation, Part: Carrington Tang Clamp, 1/2 and Label Holder Installation Example on General Manifold Arrangement
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