NAT REP MPI ENG EP 3736860 Issue 4 Generic Technical Workscope - Design Installation of Electric Points Heating Equipment

NAT/REP/MPI/ENG/EP3736860
Issue: 04
Date: 1st June 2011
Revision History
Issue
01
Date
19.07.05
02
23.06.06
03
20.04.07
04
01.06.11
Reason for change

New Issue
Removal of orange pipe, HPSA reference, Removal of Remote Condition
Monitoring and associated update of drawings.
Document and drawings extensively revised following requirements
harmonisation between MP&I and Engineering Function led by Louis Nel.
New section 6.2
Update of sections 6.1, 6.3,6.4,6.6,7.1,7.2,7.3,7.57.7,7.10
Document Distribution
Copy
01
Recipient
Document Control Master.
Page 2 of 34
Issue: 04
Date: 1st June 2011
Contents
1.
Introduction................................................................................................................................. 4
2.
Scope ........................................................................................................................................... 4
3.
Definitions and Abbreviations................................................................................................... 5
4.
Standards and Relevant Documentation.................................................................................. 6
5.
Performance requirements ........................................................................................................ 7

5.1.
Service Life ..................................................................................................................... 7
5.2.
Product Acceptance........................................................................................................ 7
6.
General Design Requirements .................................................................................................. 7

6.1.
Equipment Layout........................................................................................................... 7
6.2.
Electrical Design ............................................................................................................. 8
6.3.
Earthing and Bonding ..................................................................................................... 9
6.4.
Track circuit Compatibility............................................................................................... 9
6.5.
Electromagnetic Compatibility (EMC) ........................................................................... 10
6.6.
DNO Supplies ............................................................................................................... 11
7.
Equipment Design .................................................................................................................... 11

7.1.
DNO Supply Cabinet .................................................................................................... 11
7.2.
Point Heating Control Cubicle....................................................................................... 12
7.3.
Point Heating Transformers.......................................................................................... 13
7.4.
Portable Tool Transformers. ......................................................................................... 14
7.5.
Trackside Connection Boxes ........................................................................................ 14
7.6.
Heaters ......................................................................................................................... 14
7.7.
Cabling.......................................................................................................................... 17
7.8.
Labels and Signs .......................................................................................................... 18
7.9.
Cubicle Construction..................................................................................................... 18
7.10.
Remote Condition Monitoring ....................................................................................... 19
7.11.
Rail Temperature Probes.............................................................................................. 20
8.
Removal of Redundant Materials ............................................................................................ 20
9.
Documents and Drawings........................................................................................................ 22
10.
Asset Recording ....................................................................................................................... 23
11.
Training...................................................................................................................................... 23
12.
Testing and Commissioning.................................................................................................... 23
Appendix A - Example Factory Commissioning and Testing Schedule for Points

Heating Control Cubicles .................................................................................................................. 24
Appendix B - Signage and Labels .................................................................................................... 28
Appendix C - Padlocks and keys: Network Rail Maintenance Areas ............................................ 30
3
Page 3 of 34
Issue: 04
Date: 1st June 2011
Appendix D - Drawings of Typical Arrangements for Points Heating Installations..................... 33
1.
Introduction
This document provides the generic Network Rail technical requirements for the design
and installation of electric points heating equipment and forms an integral part of the
design requirements for site specific detailed design. The Standard Detail Drawings of
points heating installations are included in Appendix D.
2.
Scope
This document applies to all new and replaced electric points heating equipment
installed by Network Rail. The scope includes electrical supply, distribution, control and
track mounted equipment.
This document mandates the requirements of NAT/TW/InfraInv/ENG/EP6248683
Design and Installation of New, Renewed or Refurbished Distribution Network
Operators (DNOs) Intakes and Consumer Facilities in respect of the DNO electrical
supplies.
The Standard Detail Drawings for points heating installations are included in Appendix D
and form part of these design requirements.
Page 4 of 34
Issue: 04
Date: 1st June 2011
3.
Definitions and Abbreviations

CPC
Circuit Protective Conductor
DNO
Distribution Network Operator
EMC
Electromagnetic Compatibility
MP&I, E&P
Major Projects and Investment, Electrification and Plant
RCD
Residual Current Device
RMU
Remote Monitoring Unit
SCADA
Supervisory Control and Data Acquisition
WMCU
Weather Monitoring Control Unit
PME
Protective Multiple Earth
PHCC
Points Heating Control Cubicle
MCB
Miniature Circuit Breaker
MCCB
Moulded Case Circuit Breaker
DC
Direct Current
AC
Alternating Current
TCB
Trackside Connection Box
UTX
Under Track Crossing
URX
Under Road Crossing
ELR
Engineers Line Reference
O&M
Operation and Maintenance
Page 5 of 34
Issue: 04
Date: 1st June 2011
4.
Standards and Relevant Documentation

This document shall be read in conjunction with:
1)
Relevant European and British Standards.
2)
Relevant Railway Group and Company Standards.
3)
NR/SP/ELP/40045 (Issue 5) Network Rail Business Process Document

Electric Points Heating.
4)
NR/GN/ELP/45002 : Network Rail Company Code of Practise The installation

of Electric Points Heating.
5)
NR/SP/ELP/21085 : Specification for the Design of Earthing and Bonding

Systems for 25kV AC Electrified Lines.
6)
BS 7671 : Requirements for Electrical Installations.
7)
BS EN 50122: Railway Applications Fixed Installations Part 1: Protective

provisions relating to electrical safety and earthing.
8)
BS 5395-3 : Stairs, ladders and walkways. Code of practice for the design of
industrial type stairs, permanent ladders and walkways.
9)
HSE Railway Safety Guidelines and Principles.
10) NR/SP/SIG/19812: Cross Track Cable Management

11) NR/SP/CIV/044 : Design and Construction of Undertrack Crossings.
12) NR/SP/ELP/27224 : Specification for the installation of cable routes forming
part of the traction distribution system.
13) NR/SP/ELP/27300 : Specification for Computer Aided Design Formats for
Electrification and Plant Documentation.
14) NR/GN/CIV/008: Model clauses for specifying Civil Engineering.
15) NAT/TW/InfraInv/ENG/EP6248683: Design and Installation of New, Renewed
or Refurbished Distribution Network Operators (DNOs) Intakes and Consumer
Facilities
16) PAN-E-EP-PRO-0035 Issue 3: Project Advice Note BS7671 17th Edition
Compliance
17) Network Rail Procedure for Arranging New Utility Supplies and Disconnections
18) The relevant site specific Technical Workscope.
Any requests for departures from the requirements of this document or relevant
standards shall be submitted in writing to the Employers Representative,
6
Page 6 of 34
Issue: 04
Date: 1st June 2011
together with justification for the request, including any efficiency benefits that
may be achieved.
In the event of any apparent conflict between the requirements of this
document and other relevant standards or Network Rail documents, the matter
shall be referred to the Employers Representative for clarification.
5.
Performance requirements
5.1.
Service Life
The service life shall be at least 20 years, except for strip heaters which shall
have a service life of at least 15 years.
Where existing equipment is considered to have a remaining service life of ten
years or more, the Employers Representative may chose to retain such
equipment as part of the new installation. Where existing equipment is to be
retained the Employers Representative will inform the Contractor and the
sponsor.
5.2.
Product Acceptance
Only product accepted equipment shall be used. If novel equipment is
proposed, prior agreement from the Employers Representative must be sought
and an application made by the Contractor for trial acceptance before the
equipment is installed.
6.
General Design Requirements
6.1.
Equipment Layout
All points heating equipment is to be located adjacent to the running lines or on
the track apart from the DNO supply cubicle and associated cabling which is
generally to be located remotely dependant upon access constraints.
The location of cabinets for the incoming electrical supplies from Distribution
Network Operator shall be in accordance with the document
NAT/TW/InfraInv/ENG/EP6248683 Design and Installation of New, Renewed
Facilities.
Where DNO cubicles are located in areas of high vandalism, the Contractor
shall where required by the Employers representative make provision for the
installation of a fenced compound and access gate complete with dual lock
Page 7 of 34
Issue: 04
Date: 1st June 2011
arrangement. Provision of this facility shall be considered on a site by site basis

by the Employers Representative.
The design shall ensure that transformers and Point Heating Control Cubicles
are located at least 3.5m from the nearest rail with cubicle doors facing away
from the track. Excluding the DNO cubicle, equipment shall not normally be
located further than 5m from the nearest running rail. Where existing
equipment, e.g. transformers, is to be retained, and is presently located closer
than 3.5m to the nearest rail, the Contractor shall re-site the equipment
incorporating necessary alterations to the electrical design.
Where possible the transformer is to be placed in line with the Trackside
Connection Box keeping trackside cabling to a minimum.
Trackside connection boxes are to be located a minimum of 1.469m from the
running rail and shall be positioned such that heater tail lengths are kept to a
minimum. The connection boxes shall be positioned adjacent to sleeper ends
with the lid facing away from the track. Where no clearance exists for the
installation of trackside connection boxes in accordance with the above
specified requirements alternatives may be proposed to the Employers
Representative. In these cases the Contractor shall submit the necessary
design information and receive approval in writing from the Employers
Representative, on a site by site basis, prior to implementation.
Where it is not possible to locate equipment at least 3.5m to the running rail,
appropriate barrier protection is to be installed at a minimum of distance of
1.469m from the running rail. Where the line speed is greater than 100mph the
barrier shall be installed at a minimum of 2m from the nearest running rail.
Where space is limited due to constraints such as cuttings or embankments
and the specified clearances can not be achieved with the provision of barrier
protection, support platforms are to be used. These platforms shall comply with
BS 5395-3. Support platforms are to be sited in accordance with the HSE
Railway Safety Guidelines and Principles.
Civil Engineering design approval shall be obtained for all structural works. All
works shall comply with the requirements of NR/GN/CIV/008.
Where there is a risk of equipment being damaged by road vehicles a simple
collision resistant barrier or posts shall be provided to segregate equipment
from areas to which vehicles have access. When sighting any barriers,
appropriate consideration is to be given to equipment access ensuring no
barriers prevent full and normal access to the equipment.
6.2.
Electrical Design
The electrical design shall be compliant with BS7671 Requirements for
Electrical Installations (IEE 17th Edition Wiring Regulations) with an overriding
requirement that accessible touch voltages as a function of time are within the
8
Page 8 of 34
Issue: 04
Date: 1st June 2011
limits set out in BS EN 50122-1 Railway Applications - Fixed Installations - Part

1: Protective provisions relating to electrical safety & earthing. However, if
agreed with the Employers Representative, compliance with the conventional
BS 7671 Requirements for Electrical Installations accessible touch voltage
limits and disconnection times may be deemed to meet the above requirement.
The 110V IT circuit from the secondary of the transformer to the track mounted
heater strip is to be designed to be compliant with volt drop and current rating
requirements. In accordance with Group Standard GI/RT7007 there is to be no
earth reference connected to the running rails and therefore earth faults need
not be considered. An insulation monitor is not required; maintenance routines
are used to confirm insulation integrity.
The current edition of Network Rail document PAN-E-EP-PRO-0035 BS7671
17th Edition Compliance provides the definition of final circuits to be used in
the design with respect to the BS7671 Requirements for Electrical Installations
(IEE 17th Edition Wiring Regulations). The document is available from the
Employer Representative.
Low voltage electrical distribution systems shall be designed and operated as
240 or 400 Volt single phase or 400 Volt three phase earth referenced systems.
The design shall be based on a TN system, however, with the agreement of the
Employers Representative a TT incoming system may be used if a TN supply is
not available in accordance with NAT/TW/InfraInv/ENG/EP6248683 Design
and Installation of New, Renewed or Refurbished Distribution Network
Operators (DNOs) Intakes and Consumer Facilities.
Circuit protection shall be by overcurrent devices in the form of electronic
protection relays, fuses or moulded case circuit breakers.
6.3.
Earthing and Bonding

In areas of AC overhead electrification, or those identified by the Employers
Representative as a potential electrification area using the AC overhead
system, Distribution Cabinets and Points Heating Control Cabinets shall be
bonded to the traction system according to Network Rail standard
NR/SP/ELP/21085 Specification for the Earthing and Bonding Systems for
25KV AC Electrified Lines. The means of bonding shall be dependent upon
whether the bond is for equipotential reasons or as a potential traction fault
current carrying conductor. Incoming DNO supplies shall only be gapped if
necessary. Distribution Cabinets and Points Heating Control Cabinets shall,
where possible, be located outside the overhead line contact zone.
6.4.
Track circuit Compatibility
Page 9 of 34
Issue: 04
Date: 1st June 2011
The equipment design shall be compatible with the track circuits installed.
Written approval shall be obtained from the Employers Representative to
confirm the required type of electric points heating and that interdisciplinary
coordination checks have been satisfactorily carried out such that the proposed
design is compliant with regard to track circuit compatibility as specified in
section 7.1 of standard NR/SP/ELP/40045 prior to implementation works
commencing on site.
6.5.
Electromagnetic Compatibility (EMC)

Cubicles shall be designed in accordance with current best practice to minimise
the effects of electromagnetic interference.
Independent certification by a recognised EMC specialist shall be provided for
each particular cubicle design. Any subsequent changes shall be assessed recertified.
10
Page 10 of 34
Issue: 04
Date: 1st June 2011
6.6.
DNO Supplies
When replacing existing gas fired points heating systems with electrically
operated systems the proposed design shall address the requirement to obtain
a new DNO connection point and the location of the required electrical
distribution equipment.
A comprehensive supply assessment is to be carried out on all sites where the
equipment is to be renewed or modified to confirm the suitability of the existing
DNO supply. Where it is identified that an increase in supply capacity is
required or provision of a new supply is necessary, the Contractor shall at the
early design stage undertake negotiations with the relevant DNO to establish a
robust order of cost for the proposed changes.
Where new or upgraded supplies are to be provided, the DNO supply must be
installed or modified in accordance with NAT/TW/InfraInv/ENG/EP6248683
Design and Installation of New, Renewed or Refurbished Distribution Network
Operators (DNOs) Intakes and Consumer Facilities
Changes with regard to DNO supplies shall be carried out in accordance with
the Network Rail Procedure for Arranging New Utility Supplies and
Disconnections.
Where tenants electricity supplies are derived from the DNO cubicle, including
supplies to Train Operating Companies, a meter shall be provided to record the
tenants electricity consumption.
7.
Equipment Design
7.1.
DNO Supply Cabinet

Where new or upgraded supplies are to be provided, the DNO supply cabinet
must
be
installed
or
modified
in
accordance
with
NAT/TW/InfraInv/ENG/EP6248683 Design and Installation of New, Renewed
Facilities.
11
Page 11 of 34
Issue: 04
Date: 1st June 2011
7.2.
Point Heating Control Cubicle

Points heating control cubicles shall include in addition to the requirements of
NR/SP/ELP/40045, an hours run meter. Typical schematic and equipment
layout arrangements for points heating control cubicles are shown on drawings
GENERIC/000/6.7/ET/018 and GENERIC/000/6.7/ET/039.
Equipment shall not be fixed to any cover which is removable for maintenance
or access purposes. Items of equipment fixed to doors shall be kept to a
minimum with due regard to maintenance requirements.
Grouped terminal blocks of sufficient size and capacity shall be provided for the
termination of all relevant cables.
All final circuit protective devices shall be of the MCB or MCCB type. These
shall be vibration resistant and it shall be demonstrated that they are suitably
rated and installed such that full load current can be drawn for the operating
environment.
RCD devices are only to be used where it is demonstrated that the specified
level of protection can not be obtained by other means.
A bulkhead type light fitting and an anti-condensation heater with thermostatic
control shall be provided.
A manual/auto switch to bypass the control system is to be incorporated. This
shall be capable of bypassing the control system and contactors so that in the
event of a contactor or control system failure the points heating can be
manually energised to operate continuously. When the control system is in
bypass mode the temperature controller and the hours run meter shall remain
energised.
Specific attention is also to be given to the type of MCBs used on the outgoing
circuits to the points heating transformers. The proposed design shall take
account of the transformer inrush characteristics and the associated risk of
false tripping which shall be avoided.
The cubicle lighting switch is to be sited away from any control switches such
as the Summer / Winter Switch.
Where the bypass switch is incorporated within the control panel along with the
main isolator, the bypass switch is not to be interlocked with the control panel
door.
All temperature sensor and data cable terminals shall be housed in an
enclosure separate from and electrically screened from all the other terminal
chambers.
12
Page 12 of 34
Issue: 04
Date: 1st June 2011
7.3.
Point Heating Transformers

Point Heating Transformers shall be continuously rated at either 5kVA or
10kVA with dual wound 110V secondary windings. Proposals to use Point
Heating Transformers of other power ratings will be subject to the approval of
the Employers Representative. The voltage rating shall be single phase
230V/110V or single phase 400V/110 V as stated in the site specific Technical
Workscope.
The transformers shall be petroleum jelly filled and fitted with a protective cover
that can be secured by a padlock. Padlocks shall be provided in accordance
with the information listed in Appendix C.
The transformer tank, terminal box and cover shall be constructed using either
stainless steel sheet type 316L with a minimum thickness 2.5 mm or steel
sheet hot dip galvanised with all nuts bolts and washers being brass or zinc
coated. Where constructed of stainless steel, the stainless steel sheet shall be
mill finish to ensure sunlight glare is kept to a minimum. The construction shall
be in accordance with the relevant European and British standards.
A double pole isolator shall be provided on the primary side of the transformer
which is accessible at all times. As a result the transformer lid is to be lockable
separately to the isolator cover. The isolator cover shall have the necessary
lugs for fitting a pad lock.
The secondary of the transformer shall be dual wound providing two electrically
separated windings. Each winding will be terminated on a busbar to which the
independently fused outgoing circuits are to be connected. The transformers
shall be fitted with the correct number of fused outgoing circuits. This will vary
with the number of heater strips fed from any single transformer and whether or
not Clamp Lock heaters are fitted. Typical connections for heating transformers
are shown on drawing GENERIC/000/6.7/ET/039.
Where DC heating strips are required to achieve track circuit immunity the
associated transformers shall incorporate bridge rectification.
Identification labels shall be mechanically fixed to both the body and the cover
of all transformers.
Drawing EEPH63/000/6.7/ET/039 provides typical foundation and other
relevant civil construction details.
13
Page 13 of 34
Issue: 04
Date: 1st June 2011
7.4.
Portable Tool Transformers.

Portable Tool Transformers shall not be provided as part of new of renewed
installations.
7.5.
Trackside Connection Boxes

Trackside connection boxes shall be post mounted, weatherproof to IP65 and
suitable for the termination of point heating and rail temperature probe cables.
Connection boxes shall be provided complete with fixed termination blocks,
links to allow circuit disconnection for testing and the appropriate glands.
Trackside connection boxes shall be constructed from high quality, high impact
resistant material. The lid shall be hinged at the top of the box so that it can not
be left open. The box shall be of sufficient size with adequate space around the
terminals to facilitate easy cable termination. Separate trackside connection
boxes shall be provided for hot and cold rail probe connections
Typical arrangements of trackside connection boxes are shown on the following
drawings:
7.6.
GENERIC/000/6.7/ET/023
Heaters
Rail, in-bearer and supplementary detector heaters shall be either of the
constant wattage strip type rated at 200 watts per metre, or of the self
regulating strip type with equivalent heat output capability. Where Clamp Lock
systems are used, they shall be heated with additional cartridge type heater
elements individually rated at 200W.
Allowance shall be made for the fact that Mk Clamp Lock and in-bearer
detectors are padlocked to prevent unauthorised access to the Clamp Lock and
in-bearer detector heaters which can only be fitted by competent Signalling
personnel.
Strip heaters shall have a minimum sheath thickness of 0.8mm. In DC third
and fourth rail electrified areas strip heaters shall be of the insulated type. Rail
clips used for fixing heaters shall be product approved.
Heater leads are to be kept as short as possible and shall not exceed 20m.
Typical details for the installation of strip heating elements are shown on
drawing
GENERIC/000/6.7/ET/025.
Drawings
GENERIC/000/6.7/ET/026,
GENERIC/000/6.7/ET/027 and GENERIC/000/6.7/ET/028 provide details relating to
14
Page 14 of 34
Issue: 04
Date: 1st June 2011
heater locations, designations and connections. Requirements for heater

lengths and are ratings are detailed in Tables 1 to 4 below:
113 LB or Bullhead Rail and Mechanical Frame, HW or equivalent Point motor

Switch
Type
Stock Rail Heater

Strip
Switch Rail Heater

Strip
Clamp Lock
Cartridge
Heater
Bearer
Heater
Strip
Supplementary
Heater Strip
Transformer Size
AV
2 x 4m
2 x 4m
N/A
N/A
N/A
5kVA
BV/CV
2 x 5m
2 x 5m
N/A
N/A
N/A
5kVA
DV
2 x 6m
2 x 6m
N/A
N/A
N/A
5kVA
EV
4 x 4m
4 x 4m
N/A
N/A
N/A
10kVA
FV
4 x 5m
4 x 5m
N/A
N/A
N/A
10kVA
SGV
4 x 6m
4 x 6m
N/A
N/A
N/A
10kVA
GV
4 x 5m + 2 x 4m
4 x 5m + 2 x 4m
N/A
N/A
N/A
1 x 10kVA +1 x 5kVA
HV
6 x 6m
6 x 6m
N/A
N/A
N/A
1x10kVA +1x5kVA
Table 1 Requirements for 113lb Bullhead Rail and Mechanical Frame, HW or equivalent Operating
Mechanism
113LB or Bullhead Rail and Clamp Lock Operating Mechanism

Switch
Type
Stock Rail Heater

Strip
Switch Rail Heater

Strip
Clamp Lock
Cartridge
Heater
Bearer
Heater
Strip
Supplementary
Heater Strip
Transformer Size
AV
2 x 4m
2 x 4m
2 x 200W
N/A
N/A
5kVA
BV/CV
2 x 5m
2 x 5m
2 x200W
N/A
N/A
5kVA
DV
2 x 6m
2 x 6m
2x200W
N/A
N/A
10kVA
EV
4 x 4m
4 x 4m
2x200W
N/A
N/A
10kVA
FV
4 x 5m
4 x 5m
2x200W
N/A
N/A
10kVA
SGV
4 x 6m
4 x 6m
2x200W
N/A
N/A
10kVA
GV
4 x 5m +2 x 4m
4 x 5m +2 x 4m
2x200W
N/A
N/A
1x10kVA + 1x5kVA
HV
6 x 6m
6 x 6m
2x200W
N/A
N/A
1x10kVA + 1x5kVA
Table 2 Requirements for 113lb Bullhead Rail and HW or equivalent Operating Mechanism
15
Page 15 of 34
Issue: 04
Date: 1st June 2011
CEN 60 Rail and HY-drive Operating Mechanism

Switch
Type
Stock Rail Heater

Strip
Switch Rail Heater

Strip
Clamp Lock
Cartridge
Heater
Bearer
Heater
Strip
Supplementary
Heater Strip
Transformer Size
2 x 5m + 2 x 4m
2 x 5m + 2 x 4m
2 x 200W
N/A
N/A
10kVA
2 x 5m + 2 x 4m
2 x 5m + 2 x 4m
2 x 200W
N/A
N/A
10kVA
2 x 6m + 2 x 5m
2 x 6m + 2 x 5m
2 x 200W
N/A
N/A
10kVA
2 x 5m + 4 x 4m
2 x 5m + 4 x 4m
2 x 200W
N/A
N/A
1x10kVA + 1x5kVA
SG
2 x 6m + 2 x 5m +
2 x 4m
2 x 6m + 2 x 5m +
2 x 4m
2 x 200W
N/A
N/A
1x10kVA + 1x5kVA
2 x 6m + 6 x 5m
2 x 6m + 6 x 5m
2 x 200W
N/A
N/A
2x10kVA
4 x 6m + 4 x 5m +
2 x 4m
4 x 6m + 4 x 5m +
2 x 4m
2x200W
N/A
N/A
2x10kVA + 1x5kVA
Table 3 Requirements for CEN 60 Rail with HY-drive Operating Mechanism
CEN 60 Rail and HPSS Operating Mechanism

Switch
Type
Stock Rail Heater

Strip
Switch Rail Heater

Strip
Clamp Lock
Cartridge
Heater
Bearer
Heater
Strip
Supplementary
Heater Strip
Transformer Size
4x4m
4 x 4m
N/A
380W
104W
10kVA
2 x 5m + 2 x 4m
2 x 5m + 2 x 4m
N/A
380W
104W
10kVA
2 x 6m + 2 x 5m
2 x 6 m + 2 x 5m
N/A
380W
104W
10kVA
2 x 6m + 2 x 5m
2 x 6m + 2 x 5m
N/A
380W
104W
10kVA
SG
2 x 6m + 2 x 5m + 2
x 4m
2 x 6m + 2 x 5m +
2 x 4m
N/A
380W
104W
1 x 10kVA + 1 x 5kVA
Table 4 Requirements for CEN 60 Rail with HPSS Operating Mechanism
16
Page 16 of 34
Issue: 04
Date: 1st June 2011
7.7.
Cabling
All external cabling shall be of the steel wire armoured type with the exception
of the cabling from the trackside connection boxes to the heater strips and
temperature probes which shall be unarmoured. All cabling installed on the
track shall therefore be unarmoured and unscreened.
Unless specifically advised otherwise by the Employers Representative,
cabling shall be installed in concrete troughing where practically possible and
the use of buried cable routes shall be kept to a minimum. Where troughing is
installed the open end shall be sealed and made rodent proof using rigid setting
expanding aerosol foam. In accordance with NR/SP/SIG/19812, where a cable
carrying a voltage above 110 V is required to cross under running lines of track
category 1, 1A or 2, it shall be installed within a full depth Under Track Crossing
in compliance with NR/SP/CIV/044, Design and Construction of Under track
Crossings.
Where cables are required to cross under a road, vehicular access track or
hard standing, within Network Rail property, the cables shall be installed in
ducts at a minimum depth of 500mm from the wearing course to the top of the
duct. At each Under Road Crossing two spare ducts shall be provided complete
with a draw ropes. Following installation of cables, ducts shall be sealed with
rigid setting expanding foam. Draw pits or bell mouths shall be provided at each
end of the URX except where terminating directly into the concrete base of a
cubicle. All URX installations shall comply with the requirements of
NR/SP/ELP/27224.
All point heater connection cables between the trackside connection boxes and
heating elements shall be installed in concrete troughing terminating adjacent
to sleepers. Cables shall then cross the ballast to the sleeper where they shall
be clipped to the top of the sleeper towards the longitudinal edge. Where there
multiple cables are routed along a sleeper edge they shall be secured in flat
formation. Drawing GENERIC/000/6.7/ET/024 provides typical details with regard
to the appropriate fixing of cables to sleepers. Orange pipe traditionally used for
the protection of cables crossing tracks shall not be used.
110 Volt point heater connection cables are allowed to cross a maximum of 4
tracks with the heaters installed on the fourth track. Where longer runs are
required, a full depth UTX shall be used where available. Where this is not
possible cables shall be clipped to the sleepers with additional lengths of
concrete troughing installed where appropriate. After crossing to the 10ft
nearest to the point to be heated or the far cess if nearer to the point to be
heated, the cables shall terminate at a second trackside connection box.
Heater element cable tails shall then be routed back to the heater element
concerned.
Where cables are clipped to the sleeper and pass underneath the running rail,
an approved cable protector shall be installed to protect the cable against
damage from the running rail.
17
Page 17 of 34
Issue: 04
Date: 1st June 2011
7.8.
Labels and Signs

Labels shall be provided in accordance with the requirements as outlined in
Appendix B.
All labels shall be made from engraved 2 or 3 ply, laminated plastic, legible for
the entire life of the installation and be UV stable. All Identification labels shall
be mechanically fixed in a location that shall not affect the integrity of the
enclosure.
Electrical Hazard Warning Labels shall be fitted to all cubicles doors (inside and
outside) and the lids of all transformers. Where the voltage contained within the
enclosure is in excess of 230V the label must also state the voltages contained
within the enclosure in line with the requirements of BS7671. Warning labels
shall be a minimum of 50 mm high x 40 mm wide for transformers and 200 mm
High x 150 mm wide for cubicles.
Identification label lettering shall be legible and indelible with a minimum letter
height of 6mm for distribution board circuits and 10 mm for all other equipment.
Cubicle designations shall have the following information.
Local Name e.g. Station Name or area;
Cubicle Name prefixed with a letter e.g. B Cubicle;
ELR.
7.9.
Cubicle Construction
Cubicles shall be rigidly constructed from type 316L folded stainless steel sheet
to the relevant European and British standards with a minimum thickness 2.5
mm. The cubicle shall be constructed using stainless steel with a mill finish to
ensure sunlight glare is kept to a minimum. Panels or doors larger than
1800mm x 1200mm shall be suitably reinforced.
The cubicles shall be weatherproof to IP 54 and independent certification by a
testing authority shall be provided for each particular design of cubicle.
Sufficient ventilation shall be provided to allow for natural convection and to
prevent the internal temperature from rising above the operating temperature of
the equipment within the cubicle.
The welding of stainless steel shall be carried out by welders qualified to the
relevant European and British standards. Door sealing edges shall be suitably
prepared, butt welded, dressed flush and burnished. Appropriate seals shall be
fitted to the doors. The cubicle shall have sufficient ventilation to prevent
condensation without compromising the specified IP rating. Finished panels
shall be without sharp edges and all screws, bolts, washers and similar
fastenings shall be of a suitable grade of stainless steel or brass to prevent
corrosion for the design life of the equipment. During manufacture, due care
shall be taken to ensure that clean conditions apply to prevent cross
18
Page 18 of 34
Issue: 04
Date: 1st June 2011
contamination with mild steel processes and resultant appearance of corrosion

to the cubicle.
Where dual access to a cubicle is required a dual padlock locking bar shall be
fitted to the door opening onto the public highway and this must be fitted initially
with two approved railway padlocks as detailed in Appendix C. The locking bar
shall be 20mm in diameter and drilled to allow the designated padlocks to be
fitted to both ends. All cubicles are to be locked through a single lockable
handle. The locking mechanism is to be of the multipoint type, which
simultaneously locks the top and bottom of the door on operation of a single
handle. Once locked the cubicle doors must not be able to come ajar. When
cubicles have double doors the door with the locking handle is to overlap the
non-locking door so that only one locking mechanism is required to lock both
doors.
Wooden back boards shall be marine grade ply with a minimum thickness of 18
mm.
Where practicable, cables and wiring shall be accommodated in trucking.
Cables and wiring shall not obscure labels or prevent access for maintenance
including testing.
Each cubicle shall contain the facility to store a set of drawings. This shall take
the form of a black plastic drawing tube, which is to be fitted to the inside of the
cubicle door complete with a retaining clip to allow easy removal of the tube.
Typical cubicle foundation and other relevant civil construction details are
shown
on
drawings
in
appendix
D:
GENERIC/000/6.7/ET/034,
GENERIC/000/6.7/ET/035 and GENERIC/000/6.7/ET/036.
7.10.
Remote Condition Monitoring

Remote Condition Monitoring shall not be provided in new locations or if the
existing cubicle that is to be replaced is not already fitted with Remote
Condition Monitoring equipment.
Where an existing point heating cubicle is fitted with Remote Condition
Monitoring equipment that is fully functional and reporting to a working
monitoring station the monitoring equipment shall be replaced. The Remote
Condition Monitoring system type shall be agreed with the Employers
Representative and shall be compatible with the existing system. All associated
modifications to the master station to ensure compatibility as a result of
changes within the points heating control cubicle shall be carried out.
Where an existing point heating cubicle is to be replaced which is fitted with
Remote Condition Monitoring equipment that is not fully functional, replication
of the remote monitoring system is not to be provided.
19
Page 19 of 34
Issue: 04
Date: 1st June 2011
If the Employers Representative specifies that space is to be provided to allow

future installation of Remote Condition Monitoring equipment, the space
provision shall be no less than 450mm width x 500mm height x 350mm depth.
7.11.
Rail Temperature Probes

Hot and cold rail sensor probes shall be installed on the common rail in areas
where single rail track circuits are installed. Where track circuits are installed on
both rails then the sensor probes shall be installed in the same track circuit
section and not bridge an insulated rail joint. The positioning of the sensor
probes shall be in accordance with the requirements of NR/SP/ELP/40045 and
NR/GN/EP/45002.
8.
Removal of Redundant Materials

All redundant equipment and materials shall be removed from site upon
completion of works including:
cubicles;
power distribution equipment;
fencing and gates;
concrete troughs;
ground material;
concrete bases;
gas bottles and storage tanks;
gas manifolds and regulating apparatus;
gas pipe work;
rail mounted gas burners;
electric equipment;
scrap materials.
Redundant Electricity Supply Industry connections and associated equipment

shall be fully decommissioned and removed.
Arrangements shall be made for the removal of all gas storage tanks and bottles
from site in accordance with current Gas Safety Regulations and Acts, British
Standards and Codes of Practice to meet the requirements of the Health and
Safety at Work Act. All redundant pipe work and equipment above ground shall
be removed from site. Abandoned gas pipe work below ground shall be
accurately plotted on As-built drawings. Where the gas supply originates from a
local gas supply company via a piped system passing onto Network Rail
property, arrangements shall be included to remove the metering installation and
permanently cap the gas supply. Where the gas points heating system
incorporates a power supply connection derived from the signalling
infrastructure, the power supply shall be decommissioned in accordance with the
20
Page 20 of 34
Issue: 04
Date: 1st June 2011
method as specified by the relevant Signalling Engineer and the Employers

Representative.
Unless agreed otherwise with the Employers Representative, where oil filled
transformers are to be disposed of, these shall be tested prior to disposal to
ensure that there are no PCBs present.
21
Page 21 of 34
Issue: 04
Date: 1st June 2011
9.
Documents and Drawings

The Standard Detail Drawings forming part of this document shall be followed
unless alternative arrangements have been approved by the Employers
Representative.
A full set of as built drawings are to be provided in each Operation and
Maintenance (O&M) Manual.
Drawings shall be produced in accordance with the requirements of
NR/SP/ELP/27300 and shall include as a minimum:
Site Layouts;
DNO Cubicle Layout;
Sub-distribution Cubicle Layout;
Points Heating Control Cubicle Layout;
Schematics of all Cubicles;
Transformer Details;
Foundation Details;
Track Equipment Layout;
Termination Diagrams.
Unless otherwise specified, standard BSI symbols are to be used on all

drawings. Details of points heating specific symbols are provided in drawing
GENERIC/000/6.7/ET/041.
A set of as-built layout and schematic drawings are to be provided in each
cubicle. The site drawings shall be of the non-degradable type, both water and
tear resistant. The drawings are to be issued with the O&M manual to the Area
Maintenance Organisation for them to control and install at each site.
All drawings shall be of a minimum size providing the information can be easily
read.
A full O&M manual is to be produced using standard Microsoft Office
applications.
22
Page 22 of 34
Issue: 04
Date: 1st June 2011
The O&M package shall contain as a minimum the following information:
All manufacturers literature and details associated with equipment

installed;
Design Documents including calculations;
Layout Drawings of Cubicles, Transformers, Track Equipment;
Schematic Drawings;
Test Certificate;
Relevant track circuit information
Commissioning documentation;
Circuit charts;
Updated Circuit charts when part renewal is performed;
A full parts list with part numbers, which is to include a list of
suppliers, contact telephone numbers and business addresses.
One hard copy of the O&M documentation shall be provided.

Four CD-Rom copies of the O&M documentation shall be provided.
CDs are to be labelled with a unique reference number, date of issue, version
number and the locations to which they apply.
10.
Asset Recording
All Network Rails asset recording and maintenance systems including Ellipse are
to be updated by the project covering all asset changes.
11.
Training
Training shall be provided where equipment which is new or novel to an area is
provided.
This shall include 2 half day sessions for each maintenance area in which the
equipment is installed.
The training shall include as a minimum how to set up the equipment, how to
maintain the equipment, testing requirements and fault finding.
12.
Testing and Commissioning

A number of typical testing and commissioning check lists and test sheets are
included in Appendix A.
23
Page 23 of 34
Issue: 04
Date: 1st June 2011
Appendix A - Example Factory Commissioning and Testing

Schedule for Points Heating Control Cubicles
PART 1 - VISUAL CHECKS
No. Description
Expected
Results
Cabinet, constructed as cubicle layout Refer

to
drawing
Site
Drawing =
1
Income Isolator Correct Size
1
Fuses Correct Size & Type
Terminals Correct Size & Type
Labelling Internal
Labelling External
Door Mechanism 90 & 180 Securing
Visual
Quality of Panel Construction
Visual
External Probes/Aerials
Visual
10
Lifting Eyes and Mounting Holes
Visual
11
Doors open and close correctly
Visual
12
Presence of panel schematic
Visual
13
Magnetic Door Switch Operational
Visual
14
Earth Bonding
Visual
15
Cable Identification
Visual
16
Terminal Identification
Visual
17
Protection Against Direct Contact
Visual
18
Single/Three Phase
Refer to 1
19
Protective Devices Correct
Refer to 1
Phase Supply
Test Engineer
Test Date
Location of Test
................................................
................................................
................................................
................................................
................................................
................................................
................................................
24
Result
Comments / Remedial
Pass
/ Action
Fail
Test Actual Voltage

Cubicle
Serial
Customer
No.
Approval
Page 24 of 34
Issue: 04
Date: 1st June 2011
Note:
Test Schedules will only be signed following remedial corrective actions
and successful retest.
25
Page 25 of 34
Issue: 04
Date: 1st June 2011
PART 2 -
Live Tests
No. DESCRIPTION
EXPECTED
RESULT
RESULTS
Pass / Fail
COMMENTS
Supply Voltage 1ph- Check Phase Lamps On

3ph
ACTION
Lamps
Monitoring
Voltage Check
Voltage
110 v A.C
Voltmeter
Correct
Bulkhead Light
Switch on
Correct
operation
Panel Heater
Switch On
Correct
operation
Override Button
Operate
Correct
operation
Timed light
Short control Circuit energises

terminals
and timers off
Control circuits
Energise
Connected
connected to correct
individual
correctly
MCB
MCBs
Sensor
Moisten
Icelert
probe
Phase Supply
Test Engineer
Test Date
Test Instrument
Location of Test
................................................
................................................
................................................
................................................
................................................
................................................
................................................
................................................
................................................
Test Actual Voltage

Cubicle
Serial
Customer
No.
Approval
Calibration Certificate
Note: Test Schedules will only be signed following remedial corrective actions and
successful retest
26
Page 26 of 34
Issue: 04
Date: 1st June 2011
PART 3 Temperature Sensing Tests

For these tests set Icelert cold (wet+2) cold (dry-0) hot (wet +15) hot (dry + 7) delay 0
No.
Circuit
Under Action
Expected
Results
Comments
Test
Result
Pass
/
Fail
Icelert shows wet
1
Precipitation
Spray with
condition
Sensor
water to
activate
Check Icelert
2
Rail temperature
Compare with
displayed values
sensor
ambient then
show ambient then
heat sensors
rises as sensors are
one at a time
heated
NOTE:- When
Energise and de3
DRY CONDITION Lower hot and
heating is ON
energise at correct
Icelert operation
cold probes
change
temperatures
below settings
summer/ winter
to energise.
switch to
Raise again to
summer.
de-energise
Heating off
(return to
Winter)
Energise and deLower hot and
4
WET
energise at correct
cold probes
CONDITION:
temperatures delay
below settings
Icelert operation
will be 30 sec.
to energise.
Raise again to
de-energise
with delay
5
Reset Icelert to
specification
Phase Supply
................................................
Test Actual Voltage
................................................
Test Engineer
................................................
Cubicle Serial No.
................................................
Test Date
................................................
Customer
Approval
................................................
Test Instrument ................................................
Calibration Certificate
................................................
................................................
................................................
Location of Test ................................................
Note: Test Schedules will only be signed following remedial corrective actions and
successful retest.
27
Page 27 of 34
Issue: 04
Date: 1st June 2011
Type
Designation & Location
External
Engraved
Designation Point No
External
Engraved
Designation
Circuit
Engraved
Fuse Ratings
Circuit
Engraved
Project Name, Number & Installed Date
Internal
Engraved
Danger Safety Electrical Connection - Do Not Disconnect.
Internal
Engraved
GPS Reference
External
Engraved
Supply Fed From
Internal
Engraved
RED Reference RTE Number (Where DNO Supply)
Internal
Engraved
Supply Fed From
External
Engraved
Supply Fed From
Internal
Engraved
Supply Feeds To
Circuit
Engraved
Heater Connection (i.e. H1, H2, H3, H4 , CHL 1, CHL2 , BH1, BH2 )
Internal
Engraved
Due To Signalling Immunity Wiring Must Not Be Altered
Internal
Engraved
This Installation Is Earth Free And Must Not Be Connected Directly To

Any Earthing System
External
Engraved
Electrical Warning & Voltage
External
Printed
28
3
3
3
3
3
3
3
Page 28 of 34
Point End
Trackside
Connection
Box
Transformer
Distribution
Board
Circuit
Designation
Other
Distribution
Board
Circuit
Designation
Points
Switch Gear
Fitted
Control
Cubicle
Label
Supply &
Sub
Distribution
Appendix B - Signage and Labels
Issue: 04
External
Engraved
29
Point End
Remove Hot And Cold Rail Probes Prior To Tamping
Trackside
Connection
Box
Engraved
Transformer
External
Distribution
Board
Circuit
Designation
Other
Heaters On (Fit Under Lamp)
Distribution
Board
Circuit
Designation
Points
Type
Switch Gear
Fitted
Control
Cubicle
Label
Supply &
Sub
Distribution
Date: 1st June 2011
3
3
Page 29 of 34
NAT/REP/MP&I/ENG/EP3736860
Issue: 04
Date: 1st June 2011
Appendix C - Padlocks and keys: Network Rail Maintenance Areas

Thames Valley, West Country, Wales & Marches
Application
Locking arrangement
Electrical Power
20mm dia dual locking bar
Supply single sided cubicle
Electrical Power Supply double 20mm dia locking bar.
sided cubicle
Locking handle Network
Rail side
Control cubicles
Locked handle
Locked cover plate
Transformers
Great Northern
Application
Pass Key No/ Padlock details

BR(W) EZZ326 bronze pin
tumbler 3102
tumbler 3102
tumbler 3102
RKB 222
tumbler 3102
Pass Key No/ Padlock

details
LT 205
20mm dia locking bar.
LT 205
Control cubicles
Transformers
Locking handle Network Rail

side
Locked handle
Locked cover plate
JW 442
JW 442
North Eastern
Application
Locking arrangement
Electrical Power
Electrical Power Supply double sided
cubicle
Electrical Power
cubicle
Control cubicles
Transformers
NAT REP MPI ENG EP 3736860

revision Draft rev 12.0ORG.doc
Locking arrangement

details
JW 442
JW 442

side
Locked handle
Locked cover plate
JW 442
JW 442
Page 30 of 34
Issue: 04
Date: 1st June 2011
Application
Locking arrangement

details
RC 27
Electrical Power
RC 27
Electrical Power Supply double sided 20mm dia locking bar.
cubicle
side
Control cubicles
Locked handle
RC 27
Locked cover plate
JC 27
Transformers
East Anglia
Application

details
LT 205
LT 205
Control cubicles
Transformers

side
Locked handle
Locked cover plate
LT 205
RKB 222
Kent, Sussex, Wessex

Application
Locking arrangement
Electrical Power
cubicle
Locking arrangement

details
CCC 2
CCC 2
Control cubicles
Transformers

side
Locked handle
Locked cover plate
CCC 2
RKB 222
London, North West

Application
Locking arrangement
Electrical Power
cubicle
Electrical Power
cubicle
Control cubicles
Transformers


details
RC 27
RC 27

side
Locked handle
Locked cover plate
BPH
BPH
31
Page of 34
Issue: 04
Date: 1st June 2011
Scotland
Application
Electrical Power
cubicle
Control cubicles
Transformers

Locking arrangement

details
PS 1
PS 1

side
Locked handle
Locked cover plate
PS 1
PS 1
32
Page of 34
Issue: 04
Date: 1st June 2011
Appendix D - Drawings of Typical Arrangements for Points Heating

Installations
Drawing Number
Title
Points Heating Control Cubicle Typical General Layout
Typical Trackside Connection Box Arrangement
Typical Cable Route Crossing Track
Typical Positioning of Heating Strips
Typical Arrangement for Points Requiring 4 Heater Strips
Single Sided DNO Supply Cubicle Typical General Layout
Points Heating Control Cubicle Typical Plinth Arrangements
Typical Civil Details at Cuttings & Embankments
Typical Details of Points Heating Control Cubicle & Barriers
Typical Points Heating Transformer Barrier Detail
Typical Points Heating Control Cubicle Schematic
GENERIC/000/6-7/ET/041
Points Heating Specific Symbols
NR-EP/4002
Arrangement Of Point Heater Strips for HY - Drive C Switch NR60
NR-EP/4003
Arrangement Of Point Heater Strips for HY - Drive D Switch NR60
NR-EP/4004
Arrangement Of Point Heater Strips for HY - Drive E Switch NR60
NR-EP/4005
Arrangement Of Point Heater Strips for HY - Drive F Switch NR60
NR-EP/4006
Arrangement Of Point Heater Strips for HY - Drive SG Switch NR60
NR-EP/4007
Arrangement Of Point Heater Strips for HY - Drive G Switch NR60
NR-EP/4008
Arrangement Of Point Heater Strips for HY - Drive H Switch NR60
NR-EP/4102
Arrangement Of Point Heater Strips for HPSS C Switch NR60
NR-EP/4103
Arrangement Of Point Heater Strips for HPSS D Switch NR60
NR-EP/4104
Arrangement Of Point Heater Strips for HPSS E Switch NR60
NR-EP/4105
Arrangement Of Point Heater Strips for HPSS F Switch NR60
NR-EP/4106
Arrangement Of Point Heater Strips for HPSS SG Switch NR60

33
Page of 34
Issue: 04
Date: 1st June 2011
Left Blank for CEN 54/56 and CEN 56/56 drawings

34
Page of 34

NAT REP MPI ENG EP 3736860 Issue 4 Generic Technical Workscope - Design Installation of Electric Points Heating Equipment

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

NAT REP MPI ENG EP 3736860 Issue 4 Generic Technical Workscope - Design Installation of Electric Points Heating Equipment

Uploaded by

Copyright:

Available Formats

NAT/REP/MPI/ENG/EP3736860

Reason for change

Definitions and Abbreviations................................................................................................... 5

Standards and Relevant Documentation.................................................................................. 6

Performance requirements ........................................................................................................ 7

General Design Requirements .................................................................................................. 7

Equipment Design .................................................................................................................... 11

Removal of Redundant Materials ............................................................................................ 20

Documents and Drawings........................................................................................................ 22

Asset Recording ....................................................................................................................... 23

Testing and Commissioning.................................................................................................... 23

Appendix A - Example Factory Commissioning and Testing Schedule for Points

Appendix D - Drawings of Typical Arrangements for Points Heating Installations..................... 33

Definitions and Abbreviations

Circuit Protective Conductor

Distribution Network Operator

Major Projects and Investment, Electrification and Plant

Residual Current Device

Remote Monitoring Unit

Supervisory Control and Data Acquisition

Weather Monitoring Control Unit

Protective Multiple Earth

Points Heating Control Cubicle

Miniature Circuit Breaker

Moulded Case Circuit Breaker

Trackside Connection Box

Under Track Crossing

Under Road Crossing

Engineers Line Reference

Operation and Maintenance

Standards and Relevant Documentation

Relevant European and British Standards.

Relevant Railway Group and Company Standards.

NR/SP/ELP/40045 (Issue 5) Network Rail Business Process Document

NR/GN/ELP/45002 : Network Rail Company Code of Practise The installation

NR/SP/ELP/21085 : Specification for the Design of Earthing and Bonding

BS 7671 : Requirements for Electrical Installations.

BS EN 50122: Railway Applications Fixed Installations Part 1: Protective

HSE Railway Safety Guidelines and Principles.

10) NR/SP/SIG/19812: Cross Track Cable Management

General Design Requirements

arrangement. Provision of this facility shall be considered on a site by site basis

limits set out in BS EN 50122-1 Railway Applications - Fixed Installations - Part

Earthing and Bonding

Track circuit Compatibility

Electromagnetic Compatibility (EMC)

DNO Supply Cabinet

Point Heating Control Cubicle

Point Heating Transformers

Portable Tool Transformers.

Trackside Connection Boxes

heater locations, designations and connections. Requirements for heater

113 LB or Bullhead Rail and Mechanical Frame, HW or equivalent Point motor

Stock Rail Heater

Switch Rail Heater

113LB or Bullhead Rail and Clamp Lock Operating Mechanism

Stock Rail Heater

Switch Rail Heater

CEN 60 Rail and HY-drive Operating Mechanism

Stock Rail Heater

Switch Rail Heater

Table 3 Requirements for CEN 60 Rail with HY-drive Operating Mechanism

CEN 60 Rail and HPSS Operating Mechanism

Stock Rail Heater