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SPG 0714 Compressed Air Systems

1. 62 5 90MM NUT MIIS2IC L0 MM TAILPIECE MALE MIIS2IL 90 MM NUT TAIL amp WASHER COMPLETE MIIS2ID 22 5 3 t7 50 MM DOUBLE ENDED TAILPIECE MIIS2IF 40mm TAIL MIISZIH LOMM NUT MIIS2IJ 40 MM NUT TAIL amp WASHER COMPLETE MIIS2IK DETAIL B _ 70 8 50 BSP AIR HOSE a eT A A SSENPE DEREN eT EN Dame EEE FITTINGS DETAILS MELLE UTE cepe a Pars 7 m RUNES you mey have to pay damages io Met N S W Or you may be prosecuted RailCorp Page 34 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 2 3 h 5 6 DISCONNECTION POINT x 3 SET 1050kPa A A EMERGENCY COMPRESSOR ROOM WALL NOTE FOR PIPING DETAILS E SEE M11 702 amp M11 703 Zzzzyzzzz3zzzzzzzz1zzzz zz s PRESSURE REDUCING PSV 1 TO DISTRIBUTION REGULATOR 1 SET 50kPa BACK PRESSURE _ H Y SET 510kP2 DN50 REGULATOR1 fa AEN 3 Te SET 520kPa L m FTICOMP RUN TE DATA c e M dal 9 Ll b gt tu e 1 COMPRESSOR 1 T DRYER 3 2 E DN50 04 5j By D E Hm 1 B n DN50 ME e g gt ia DN50 j M DN50 3 lt
2. 7 1 3 SYSTEM EE MU 19 7 2 miissen SIOMING mTrL 19 7 9 OMI ONIN A E 19 Appendix Typical System Documentation J Q J J 21 Appendix B Di Ji MEET o o omm 23 Appendix 8 7 CS Em 36 RailCorp Page 5 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 1 Scope 1 1 Introduction 1 2 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 Rooms 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 Reference Documents Standards and Codes The following reference documents form part of this specification M11 349 1 amp 2 Standard Air System Drawing Symbols for Air Systems M11 351 1 amp 2 Compressed Air Piping Arrangement M11 350 Connection Single Trainstop to Main M11 352 Anc
3. M11 349 1 amp 2 Standard Drawing Symbols for Air System M11 351 1 amp 2 Compressed Air Piping Details M11 350 Connection Single Trainstop to Main M11 352 Anchor Points M11 353 Steel Air Main Brackets M11 355 Label Holder Installation Part Carrington Tang Clamp 1 2 and 3 4 M11 354 Label Holder Installation Example on General Manifold Arrangement M11 307 Air Hose P V C Detail of Fittings 13 amp 20 BSP M11 321 40 amp 50 BSP Air Hose Fittings Details M11 701 General Arrangement Compressor Room Main Manifold RailCorp Page 23 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction SOLENOID VALVE SOLENOID VALVE NC TRAIN STOPS gt PRESSURE GAUGE WITH LOW PRESSURE ALARM FLOW TRANSMITTER i HEAT EXCHANGER Compressed Air Systems SPG 0714 1 3 6 gt lt VALVE GENERAL MANIFOLD ID MANIFOLD LEGEND PIT ws _No OF BRANCHES TYPE Mi FILTERS OR TRAN STOP CONTROLLER p lt 4 VALVE NC ON MANIFOLD LUBRICATORS TYPE 2 FILTER ONLY DERAILER A A TYPE LUBRICATOR ONLY N Dex BALL VALVE TYPE M amp FILTER AND LUBRICATOR D gt FILTER TYPE 5 FILTER AND AUTO DRAIN PLS TYPE M AUTO DRAIN ONLY PLUNGER LOCK SOLENOID MO BALL VALVE NC EXPANSION JOINT PLUNGER LOCK LO FILTER DRAIN TYPE 1 100mm TRAVEL Z A DIAPHRAGM VALVE TYPE 2 200mm TRAVEL ETC gt ANCHOR POINT pg DIAPHRAGM V
4. 4 5 6 8 9 0 Location of Services Connections Piping Schematic 5 6 8 9 Performance Test Certificates amp Data 0 2nd 3rd Party Accreditation 3 4 Hydrostatic Test Certificates amp Data 4 NDT Test Certificates amp Data 42 Material Test Certificates 43 0 Mechanical Flow Diagrams 7 1 RailCorp Page 21 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 0 2 oc a lt n DATA zo O a DESCRIPTION O gt NO ue o 5 tc i m lt Welders Qualification Certificates Welding Maps Record DL REVIEW CODE LEGEND F REVIEW REQUIRED PRIOR TO FABRICATION S REVIEW REQUIRED PRIOR TO SHIPMENT REQUIRED FOR INFORMATION ONLY REVIEW COPIES TO BE PROVIDED WITHIN THE TIME SHOWN EXPRESSED AS TIME AFTER AWARD AS BUILT COPIES SHALL BE PROVIDED BEFORE EQUIPMENT DELIVERY AS BUILT DRAWINGS SHALL INCLUDE ONE FULL SIZE WITH THE REMAINDER COPIES UNO CERTIFICATES AND PERFORMANCE DATA SHALL BE PROVIDED ON COMPLETION OF TESTS Table 2 Installer Supplied Data RailCorp Page 22 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 Appendix B Drawings The attached technical drawing sheets form part of this document
5. 5 5 6 Manifolds Manifolds shall be constructed from stainless steel pipe or stainless steel RHS tube and comply with the requirements of the drawings listed in Appendix B 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 Take offs from the main air lines shall preferably be vertically upwards Where the manifolds are to be located below the main air line a low point amp drain shall be provided below the take off points Flexible Hose All polymeric hoses not in tunnels shall be fabricated in accordance with AS NZS 2554 Class B All polymeric hoses in tunnels shall generally be in accordance with AS 2660 Class A and must be low smoke halogen free as required by cable specification RHG 3 of AS 4507 All hoses are to be subject to approval Stainless steel hoses shall be fabricated in accordance with relevant ISO standards and to be an approved type Flexible hose shall always be used for the connection between manifold and pneumatic equipment All flexible air hoses shall be protected from sunlight by conduit Hose connections to equipment within five metres of a manifold shall be run on the surface within a flexible orange coloured PVC conduit If the equipment is more than five metres from the manifold the hose and conduit shall be buried as per
6. B PVC excluding tunnels AS 2660 Class B PVC tunnels Accessories supports guides Saddle or U bolt Supports anchors Vents Double saddle to rigid surface DN 20 ball valve at high point Drains DN 25 ball valve at low point with auto drain 1 Items marked to be determined during design phase 2 Welded pipe spools to be hot dipped galvanised after fabrication RailCorp Issued March 2013 Page 37 of 39 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 E RailCorp DA TA SH EET Dala Sheel Number Gona i x gt _ Description Below ground carbon steel piping air service Design code AS 4041 class Design pressure kPa 800 Design temperature at maxpress 50 Test pressure kPa 1000 Fluids Compressed Air Size mn DN 15 to DN 150 _ Design life years 50 Corrosion allowance imm 1 5 Fluid Description Air at pressure to ISO 8573 class 4 Maximum 1000 particles per m of size 1 to 5 micron Moisture Dewpoint 3 C Oil Maximum 5 mg m AS 1074 medium polyethylene coated plain ends Fipe DN 65 to DN 150 AS 1074 medium polyethylene coated plain ends Welded with shrink wrap overlay or flanged note 2 Welded with shrink wrap overlay or flanged note 2 Flanges AS 2129 Table E slip on
7. 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 WH amp S Act 2010 All equipment proposed for the air system shall require type approval RailCorp Page 7 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 2 2 3 1 3 2 3 3 3 3 1 Design Documentation The following design documentation shall be generated as a minimum during the design process Process flow diagram mass balance and or network hydraulic model to document the capacity of the extended new system Equipment piping and instrument data sheets in sufficient de
8. Compressed Air Systems ONLY IF REQUIRED FOR RIGIDITY 5000 MAXIMUM q GROUND 40 X 10 BRACING BOLTED ON THE SIDE OF THE GST N Fl CSW MUFFLER CLAMP ff A RS OR EQUIVALENT TO SUIT 50MM NB PIPE LEVEL 10 GALVANISED STEEL CHANNEL h hb supporto on me BACK OF THE GST USING TWO 10 DIA 316 SS U BOLTS x 50 3000 MAXIMUM 40 X 10 BRACING BOLTED ON THE BACK OF THE GST GROUND LEVEL CHANNEL 100 N x 50 x 10 GALVANISED STEEL C ANCHOR POINTS Chief Engineer s Division REVIEWED VERIFIED APPROVED RLF RWA a ose aon Ponts ann SS 7777777 J J sata ES VERSIONS DESCRIPTION DATE DRAWN REVIEWED VERIFIED APPROVED DESIGNED LL Ra Te WI TRIN es _ E portlculor purpose ond cilent This Is protected by copyright You not reproduce DIMENSIONS DO 0 SCALE x TT ayo frm wat Iw writen parton of Rol Opel e Sun wont M L A97 OOC AMEND MANUALLY 74 wrs M11 352 r1 SUSERNAME 999955 YTIMET 111 11111511 0 GNE SPECIFICATIONSS 111 115114 SIGNALS DRAWN Page 29 of 39 Version 3 0 UNCONTROLLED WHEN PRINTED RailCorp Issued March 2013 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 ALL BRACKETS 50 WIDE t C Sa ee STANDARD BRACKET STEEL AIR MAIN BRA
9. Piping DS P 002 501 Piping DS P 003 5501 Piping RailCorp Page 36 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 Data Sheel Number DS P 001 General Description GMS01 Piping Above ground carbon steel piping air service and condensate Design code Design pressure kPa Test pressure kPa Fluids Size mm Design life years AS 4041 class 3 BOO 90 Design temperature C at max press 1000 Compressed Air DN 15 to DN 150 50 Corrosion allowance mm 1 5 Fluid Description Air at pressure to ISO 8573 class 4 Solids Maximum 1000 particles per m of size 1 to 5 micron Moisture Dewpoint 3 C Oil Maximum 5 mg m Pipe DN 15 to DN 50 AS 1074 medium galvanised threaded ends Pipe DN 65 to DN 150 AS 1074 medium black Joints DN 15 to DN 50 Screwed Welded or flanged Joints DN 65 to DN 150 Gaskets Compressed fibre non asbestos 1 5mm Thread sealant Bolting PTFE tape AS 2528 Valves DN 15 to DN 50 Ball valve 316 SS body and ball glass reinforced PTFE seat screwed BSP lever operated lockable Valves DN 65 to DN 150 Ball valve 316 SS body and ball glass reinforced PTFE seat flanged Table E lever operated lockable Flexible hose DN 20 to DN 80 AS 2554 Class
10. You nof reproduce OWENSIONS gt i C SATE a e ddp Ata AP dup M EE Np aS o mur itn as Ca DO NOT AMEND MANUALLY i4 06 2003 Ts DONO M11 354 DF 400 277 HER A S sa UC DC Sey ee E O RailCorp Page 32 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 f TY s 5 13mm ML i TEE 0 Eg el 13mm TAILPIECE MALE 32 K 56 L 2 20mm BSP 181 PITCH NYLON WASHER 32 K51 20mm TAIL 32 K 57 108444275 20mm NUT 32 K 58 20mm NUT TAIL amp WASHER COMPLETE 32 K 59 r 915 5 20mm TAILPIECE MALE 32 K 60 pw o Y al w T EI ju 2 i Pm _ 918 161 L 3 NYLON WASHER 32K 50 13mm TAIL 32 53 08 442242 13mm NUT 32 K 54 13mm NUT TAIL amp WASHER COMPLETE 32 K 55 20mm DOUBLE ENDED TAILPIECE 32 K 61 MI 08444713 MATERIAL ALL COMPONENTS EXCEPT WASHERS BRASS EDMS SG0145465 WARNING SCANNED IMAGE PREVIOUS DRG N D 06230 pom ew STATE RAIL AUTHORITY OF N S W 4 SIGNAL amp COMMUNICATIONS BRANCH 1 AIR HOSE PVC gt M 11 307 mo mew Merl s ser oF s ms RailCorp Issued March 2013 UNCONTROLLED WHEN PRINTED Page 33 of 39 Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714
11. gt Hit oP 9H te ss A Y E py w Bu sis x d COMPRESSOR 2 DRYER BACK PRESSURE PRESSURE REDUCING PSV 2 ER REGULATOR 2 s REGULATOR 2 SET 550kPa os FTICOUP RUN TME DATA I SET 520kPa La X r COMPRESSOR SET 510kPa WALL TO DISTRIBUTION 7 7272 zzzzzzzzzzzz2 7777777 l EMERGENCY x COMPRESSOR DISCONNECTION CONNECTION hi IN Timm RECEIVER 2PSV B qf 3 Ki U lt SET 1050kPa 1 MM s zzzzzz2ezzzezzzzezzezn ng v 5 DS QOlLY SLUDGE MANUAL z A UNIS as t DNt5 I m _ i OIL WATER T bo aca gt SEPERATOR CLEAN WATER TO L ON15 y NOT REQUIRED FOR SEWAGE SYSTEM DN15 OIL FREE COMPRESSORS DE GENERAL ARRANGEMENT D DESCRIPTION DATE DRAWN REVIEWED vesiriEO APPROVED lt DRAWN and the formation contained th wana have been created solely fora M MD H SINGH any act in any any foem without the written permission Aldere Ai New Wales if you IN ary ay om wou the writen parm C New South Wales or you may be prosecuted MILLIMETRES fsan cucu 3 i E b _ RailCorp Page 35 of 39 Version 3 0 Issued March 2013 UNCONTROLLED WHEN PRINTED RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 Appendix C Data Sheets The attached data sheets form part of this document DS P 001 GMS01
12. one manifold The local reservoir shall be of stainless steel construction with the air connection at the low point small diameter and vertically mounted They may require Workcover design registration but not require any other ongoing registration or maintenance other than inspection The units shall not exceed a PV of 100 MPaL based on a design pressure of 720 kpa approximately 135 L capacity maximum Hazard Level D to AS43438 If the design requires more than one unit may be installed to provide a greater capacity Usually they shall be installed at manifolds A point orifice plate shall be fitted at the manifold if connected via a PVC hose Pipework Piping Classes Piping classes are listed in the piping data sheets refer Appendix C 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 Pipework Arrangement Pipework design principles are shown in the reference drawings refer Appendix B These demonstrate preferred methods for manifolds branches drains etc and shall be adhered to in the design of the new work Underground cross ties shall be flexible hose within PVC pressure pipe conduit or galvanised steel pipe with 450g m coating No joints shall be allowed in flexible hose A cross tie using flexible hose may be installed in a single conduit with up to two large radius bends at each end to avoid the need f
13. raised face Fittings DN 15 to DN 50 ASTM A234 WFB std wt seamless butt welded Fittings DN 65 to DN 150 ASTM A234 WPB std wt seamless butt welded Gaskets Compressed fibre non asbestos 1 5 mm Bolting AS 2528 Valves DN 15 to DN 50 Ball valve 316 SS body and ball glass reinforced PTFE seat flanged Table E lever operated Ball valve 316 SS body and ball glass reinforced PTFE seat flanged Table E lever operated Valves DN 65 to DN 150 lockable Flexible hose DN 20 to DN 80 AS 2554 Class B PVC outer Accessories Supports guides Saddle or U bolt Supports anchors Double saddle to rigid surface Vents DN 20 ball valve at high point Drains DN 25 ball valve at low point with auto drain C Notes 1 Items marked to be determined during design phase RailCorp Page 38 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 General Description Design code Design pressure kPa Design temperature C at max press Test pressure kPa DATA SHEET Data Sheet Number DS P 003 5501 Piping Above ground stainless steel piping air service AS 4041 class 3 800 50 1000 Fluids Compressed Air Size m
14. shall be provided at an accessible position to permit work on the piping without the necessity to access the elevated portions 5 3 Steel Piping The compressed air lines shall generally be constructed from galvanised carbon steel pipe or stainless steel pipe For carbon steel lines joints shall generally be screwed or flanged as required Welding procedures to be used by the Installer shall be submitted for approval before commencing work These shall include weld repair procedures Welded pipe spools are to be hot dipped galvanised after fabrication For stainless steel lines joints shall generally be screwed welded or flanged Weld filler metal shall have corrosion resistant properties similar to or better than the base metal The welding procedure followed shall preserve corrosion resistance in the weld and heat affected zone to maintain optimum mechanical properties in the joint and minimise heat distortion Fabrication shall be carried out with equipment made from stainless steel free from contaminants and which has not previously been used on carbon steel or non ferrous material Joint cleaning shall not use chlorinated solvent All joints shall be aligned with mechanical devices and shall be free of depressions and bumps Heat shall not be used to obtain alignment Steel air mains must never be attached to overhead wiring structures or signal gantries Except for cross ties addressed in Section 5 4 A minimum clearance of 75mm mus
15. yanayay Z 222 stn eet atn cC of i f f Ithout the written mission of Roll Corporation New South Wales if you DRG No ec AA DUE ed De IET DO NOT AMEND MANUALLY M11 355 BEI I Ses Se fy RailCorp Page 31 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 In zm i MATERIAL LIST DESCRIPTION MATERIAL SUPPLIER PART No QTY 20mm NB BARRELL NIPPLE BSP 60mm LONG ST STEEL 316 CARRINGTON 4 20 NB TEE BSP ST STEEL 316 CARRINGTON ci 1 gt 20mm NB BARRELL NIPPLE BSP 100mm LONG ST STEEL 316 CARRINGTON py 4 20mmNB LABEL CLAMP ASSEMBLY ST STEEL 316 CARRINGTON JN REFER VANS EN DRAWING M11 355 LABEL CHANNEL LENGTH A R STSTEEL316 CARRINGTON N TRAFFOLYTE LABEL TO SUIT TRAFFOLYTE WHITE ON BLACK L TITLE St RailCorp LABEL HOLDER INSTALLATION EXAMPLE F puer SIGNALS ON GENERAL MANIFOLD ARRANGEMENT aps x Chief Engineer s Division vb tS epu IF HE This drawing and the Information contained thereon have been created solely for ALL AS SIM OES H E E Z RLE particular purpose and cilent This 15 protected by copyright
16. ALVE INC Al UNION STRAINER Q DRAIN AUTO MANUAL b r FLANGE RE PLUG VALVE as OIL WATER SEPARATOR BLANKED END WITH AUTO DRAIN PLUG VALVE INCI AF INSULATED JOINT HOSE COUPLING aa DKI GATE VALVE H FLOW METER m PRESSURE TRANSMITTER GATE VALVE NC 4l ORIFICE PLATE c5 LUBRICATOR 2 I CHECK VALVE PRESSURE RECORDER SPECTACLE BLIND CLOSED POSITION COMPRESSOR STATE RA PRESSURE RELIEF VALVE mE O POINTS CONTROLLER RECIPROCATING PRESSURE INDICATOR REGULATOR K un D PONT MACHINE m CONTROLLER FOR COMPRESSORS amp DRYERS j j j j j Jj M es C ee TB SYMBOLS UPDATED AND CHANGED pHOVIHSINGH frer jou 2 VERSION DESCRIPTION DATE DRAWN REVIEWED VERIFIED APPROVED This drowing ond Ite Information contained thereon hove been creoted solely for O portleutor purpose ond cilent Thfs Is protected by capyright You moy nor reproduce DIMENSIONS Of h In form without ite written permission of Raf Cor por otlon New South Woles f you do you Moy love Io damages to Corporation New South Wales you be prosecuted i Chief Engineer s Division sie DESIGNED DRAWN REVIEWED VERIFIED APPROVED ALL Sy C LIANG RLF RWA A DATE SCALE HT 1 gt DO NOT AMEND MANUALLY meno 11 349 0 RailCorp SIGNALS STANDARD DRAWING SYMBOLS FOR AIR SYSTEM DF 400
17. CKETS SIGNALS Chef Engineer s Division DESIGNEO ee or ee SUA DEOR d H E This drawing and the information contained thereon have been created solely for o em porticular purpose and cilent TNs 15 protected by copyright You not reproduce DATE of ni form without the written permission of Rali Corporation New South Woles if you or veo ta toss to hay di tojut fo BANOE ANANA Ny See Beleg s ya ip o arestented MILLIMETRES DO T AMEND MANUALLY 14 06 2003 DRAWN D RailCorp Page 30 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 CLAMP SADDLE 20NB PIPE CLAMP WITH MTG STRAP CLAMP ASSEMBLY Mbx16 HEX HEAD SCREW STAINLESS STEEL 316 C W HEX NUT amp PLAIN x WASHER 15 LABEL CHANNEL x TRAFFOLY TE LABEL Mbx20 HEX HEAD SCREW STAINLESS STEEL 316 2s 20NB PIPE NCWASHR ATERIAL STAINLESS 51 20NB CLAMP ASSEMBLY me LABEL HOLDER INSTALLATION PART CARRINGTON TANG CLAMP 1 2 AND 3 4 SIGNALS Chief e s Division a ee dal Cam ee Ht al o es es d DEO E Se Be T e FE s DESIGNED DRAWN This drawing ond the Information contalned thereon have been created solely for a HE HE ALL 5 Z7 ZE may A
18. Construction Compressed Air Systems SPG 0714 AS NZS 4792 Hot dip Galvanized Zinc Coatings on Ferrous Hollow Sections Applied by a Continuous or a Specialized Process NSW Work Health and Safety Act 2010 NSW Work Health and Safety Regulations 2011 Rail Safety Act 2002 1 3 Installer Supplied Data Refer to Appendix A for Installer supplied data 2 Design 2 1 Design Inputs 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 Heference 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
19. ESG 100 24 All sensors proposed shall be submitted for type approval including a proposed system configuration Where sensors are located remotely from the compressor room care is to be taken that surge protection is provided and galvanic isolation provided in cable troughs and air lines is not by passed Where fibre optic is available between locations it shall be used for the air monitoring in lieu of cables Copper cabling shall be kept short The electrical design of this system shall be documented in the signalling circuit books Where the equipment and wiring is installed in signalling locations it shall be physically separate from vital equipment All software code programming manuals maintenance and user manuals shall be provided including any necessary licences for the ongoing operation and modification of the system 7 Testing and Commissioning 7 1 Testing 7 1 1 Mechanical Equipment Testing No load testing of rotating equipment shall be carried out in coordination with other Installers Drives shall be checked for direction of rotation and then tested for no load running Testing shall comprise running the equipment to check for smoothness of operation vibration overheating and operation of safety switches instruments and appurtenances 7 1 2 Pipework Testing All pipework shall be pneumatically tested at the test pressures nominated in the pipe data sheets using dry air The Installer must ensure that line mount
20. Engineering Specification Signals Construction SPG 0714 COMPRESSED AIR SYSTEMS Version 3 0 Issued March 2013 Owner Chief Engineer Signals and Control Systems Approved by Warwick Allison Authorised David Nolan Chief Engineer by Principal Engineer Signals and Control Systems Signal Equipment and Interfaces Q Y Oo O TT n WW Transport NSW RailCorp UNCONTROLLED WHEN PRINTED Page 1 of 39 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 Document control Version Summary of change 26 February 2008 SPG 0714 replaced SC 09 20 00 00 SP v2 0 of November 2001 10 September 2008 1 0 0 2 2 1 2 2 2 3 2 4 2 9 2 6 in 5 4 Section 4 delete reference to Appendix C 6 1 add provision for adequate clean air intakes 2 9 hoses Appendix C delete reference to SPG 1837 M11 701 3 0 those having a M11 prefix flexible hoses 5 2 add note that pipework are to be accessible 5 5 added or RHS tube 5 6 added Where stainless steel hoses are used they shall be insulated at the connection to the manifold ball valve Summary of changes from previous version Summary of change Delete reference to drawings with SPGO0714 prefix and replace with M11 prefix drawings 4 1 Compressors add sentence concerning connection of compressors 5 2 Add p
21. ION NTS LUBRICATOR ONLY WHEN REQUIRED FILTER KS CONTROL MANIFOLD SEE M11 323 FOR INSULATING FLANGE SEE M11 703 FOR EQUIPMENT MANIFOLD CONNECTIONS TO PNEUMATIC EQUIPMENT ASSEMBLY DRAWING MAXIMUM 7 VALVES WHEN EQUIPMENT IN USE COMPRESSED AIR PIPING DETAILS Ths drawing aad the contained thereon have deen created solely for Cy A r i H jS H SINGH 1 RLF L purpose sed chert The protected by You may nor reproduce DALAENIONS 7 P zL J TL T Ly IE aan 1 L JPY laikun tr CAD DO NOT AMEND MANUALLY 34012012 N T S M11 351 575 RailCorp Page 26 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 AIR MAIN IN LINE DRAINAGE BRANCH P pu d MAIN HEH EX Lich OR SUB MAIN lex BRONZE STRAINER BRANCH OR SUB MAIN CONNECTION TO MAIN SEE M11 323 FOR INSULATING FLANGE SEE 11 703 FOR EQUIPMENT MANIFOLD AR 3 arua ASSEMBLY DRAWING Soi 24 ro AUTO DRAIN ee D DETAIL A FOR MANUAL MAINTENANCE CHECKING 7 TYP 300mm ARRANGEMENT WHERE MAIN PIPE HAS TO RISE 7 AIR MAIN DIPPING A LOW POINT N S zd SEE DETAIL A AUTO DRAIN x etude ir AT LOWEST POINT PIT pas ner TITLE COMPRESSED AIR B GRANGE IN CRO
22. SPG 0705 Construction of Cable Route and Associated Civil Works The flexible conduit is to be carried to within 100mm of the connection at each end of the hose whether buried or surface run Where stainless steel hoses are used they shall be insulated at the connection to the manifold ball valve Stainless steel hoses that run beneath the rails shall be enclosed in flexible orange coloured PVC conduit Where flexible air hose is used for the main air line it shall be installed in a properly constructed cable route in accordance with SPG 0705 Tails for flexible hoses shall be e For hoses less then 18 mm Nominal Bore NB a single non serrated bulb tail with one single stainless steel Bandit Clamp or approved equivalent e For hoses 18 mm NB or greater a double non serrated bulb tail with two stainless steel Bandit Clamp or approved equivalent Tails shall be of a type that does not damage the hose Tail size shall be specifically assessed as the correct size for the hose type Specifically the end of the tail shall be smooth and rounded to prevent damage to the pipe when flexed Bandit type clamps or approved equivalent shall only be applied using an approved tool which applies a pre set consistent application pressure Clamps shall apply an even pressure around the entire circumference of the hose The female union nut shall be capable of rotating without twisting the hose Where a main flexible air hose is to be bent through a
23. SSTIE lt e 282 Ar Z NL oli hief Engineer PIPING DETAILS mm wing and yh information con have been created solely for a Nm x a H SINGH CHIANG any Or ary Ya wana the wren erm Rat Copara ew Sou Wales you IN M11351 927 2 RailCorp Issued March 2013 UNCONTROLLED WHEN PRINTED Page 27 of 39 Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 BALL VALVE ALL STAINLESS STEEL PIPES ARE SCHEDULE 40 25 NB S STEEL 40 NB S STEEL OR FLEXIBLE PVC HOSE WHEN USED FOR MAIN yi m 1 INLET SUPPLY r lt dd Ln ad TO TRAINSTOP VALVE 40X25 REDUCING NIPPLE 49 NB INLET SUPPLY VALVE OUTLET SUPPLY VALVE DETAIL DETAIL B 7 OUTLET SUPPLY VIEW VIEW A MAIN LINE REDUCING NIPPLE 25X15 _ C 15 NB HOSE TAIL TRAINSTOP CONNECTION tallCorp 5 CONNECTION SINGLE N a TRAIN STOP TO MAIN Chie Engineer s SINGH 08 09 2012 N T S 7 11 350 RailCorp Issued March 2013 UNCONTROLLED WHEN PRINTED Page 28 of 39 Version 3 0 SPG 0714 RailCorp Engineering Specification Signals Construction E OF THE GST USING ONE 10 DIA 516 SS U BOLT SECURED WITH A NUT ON THE CHANNEL AND ONE U BOLT WITH 2000 A MUFFLER CLAMP ON THE PIPE SIDE
24. all hoses to be subject to approval delete reference to Alohagomma type Amended sections 6 6 7 1 1 and Appendix B added drawing 18 March 2013 Replace reference to drawings with a SPG0714 prefix with 4 1 add note that compressors are to be connected with 9 3 RailCorp Issued March 2013 UNCONTROLLED WHEN PRINTED Page 2 of 39 Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 drawings 5 5 Add text 5 6 Add paragraph Drawings M11 349 1 and M11 349 2 updated to revision B App B RailCorp Page 3 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 Contents 1 SCOPE u 6 1 1 EVEN e e L e PM 6 1 2 Reference Documents Standards and Codes 6 1 9 installer Supplied BIEN 7 2 L CS G ua 7 2 1 los II u Um 7 2 2 Design Documenialioii uU u u 8 3 Fluid Parameters Site Details and Equipment Parameters 8 3 1 Fluid el UCU CYS cect 8 3 2 Environmental and S
25. alves on sub main feeds Sub main 111 PTS 113 PTS 444 TS and otop valves on outlet of receivers compressors feeding certain areas Down Main West Manifold codes shall be determined during the design phase in consultation with the Asset Owner and Asset Maintainer All pipeline contents shall be identified by self adhesive labels in accordance with the methods given in AS 1345 The direction of flow shall be suitably indicated at each label When the pipe size is very small the strip is to be affixed by a suitable flag off the pipe in accordance with the standard The following method of colour coding is to be used An identifying strip is to be fixed to the pipe at the intervals recommended by the standard The identifying strip is to have coloured lettering on a white background The coloured lettering is to be in accordance with the pipeline colour as shown in Table 1 below The arrow indicating the direction of flow shall be the same colour as the lettering on the identifying strip and Where necessary warning flags are to be located at the ends of the identifying strip in accordance with the standard Pipe Contents Colour to AS 2700 u n o Compressed Air B25 Aqua Waste Water Table 1 Pipe Colours Letters shall be as follows e 25mm Letters up to DN 80 RailCorp Page 13 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Syste
26. aragraph re access to pipework Delete references of drawing numbers with SPGO714 prefix and replace with M11 prefix Minor updates from recent works Changed 1 1 1 2 2 2 4 1 4 5 5 4 5 6 6 1 6 3 6 5 6 6 added 7 1 3 Appendix 2 deleted SPGO714 added M11 321 amp Appendix deleted DS P 001 amend data sheet 21 November 2008 Update to sect 5 6 Flexible Hose New sect 5 8 Orifice Plates added 3 February 2009 Section 3 new text added New subsection 3 3 Equipment Parameters added at request of Chief Engineer Signals 19 January 2010 Air Compressor Data Sheet in Appendix 3 preferred added after Power Supply details 7 May 2010 Delete references to variable speed drives in Section 4 1 and Air Compressor data sheet and application of TMA 400 format 9 September 201 1 NSW Transport RailCorp logo applied Text added to sect 6 2 4 third paragraph except where the pipe run is Miscellaneous spelling and grammar corrections 6 December 2011 Amendments with respect to electrical insulation of pipework Section 6 2 4 amended formatting with respect to pipe anchoring Section 5 9 Valves New section 2 7 7 March 2012 New sections 4 6 Pressure Containment Valves amp 4 7 Local Reservoirs 2 8 3 April 2012 1 2 amp 4 1 add reference to SPG 1870 4 1 added where necessary after cooler at end of sentence 4 September 2012 5 6 add Class type to AS2554 amp 2660
27. ase RailCorp Issued March 2013 Page 39 of 39 UNCONTROLLED WHEN PRINTED Version 3 0
28. cordance with the manufacturers instructions Compressors shall be installed in their own room with sufficiently large entrances to permit the equipment to be removed amp maintained Adequate provision shall be provided for the supply of clean dry air for the compressor intakes in the quantity required to deliver the compressor outputs at their maximum demand In particular humid moist areas shall not be used for drawing air Ventilation shall consider noise levels and be arranged so that the building itself reduces any noise in the direction of adjacent houses 6 2 Pipework Installation 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 Installers res
29. ed items likely to be damaged by the pressure testing are removed The Installer shall supply install and remove any temporary closures required All flanged or threaded joints mechanical couplings field welds valves and fittings whether above ground or underground shall be left exposed with joints unpainted until testing has been completed to the satisfaction of the Asset Owner Drains vents safety valve discharges etc which are open to atmosphere do not require testing Such lines shall be checked to ensure all joints are properly made and are tight Test pressure shall be applied for at least 20 minutes If no leakage is observed and the pressure drop is not more than 5 of the test pressure then the section of pipe will be deemed to have passed the test Where leaks are observed or the pressure drops by more than 5 of test pressure the Installer shall locate and repair any defects and retest the repaired section The repair procedure is to be approved by Asset Owner prior to performing the repair The section shall then be retested as above When testing is completed all temporary blanking pieces shall be removed and the pipework drained Any items removed for testing shall be re installed and valves closed RailCorp Page 18 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 Written records of all tests sha
30. esaeseeesaaeeeeeas 13 5 8 Onee mm 14 5 9 V 7 c 14 6 juice me 14 6 1 Equipment Compressor ROOM cccccccssssssecceeeeeeaeeeeececeeeeeeeeeseceeeeeeesaseeseeeeeeeeessaaeeeeeeeesaaas 14 6 2 Pipework instalation Uu L U uu m 15 6 2 1 eru m 15 6 2 2 PACES 15 6 2 3 AS aes NE QUT 16 6 2 4 OSUDDOLS umay ee UTE 16 6 3 ONS MN aoe ae cae tac ca cated canes 17 6 4 s lO y CON uuu 17 6 5 Drainage amp Ventilatlioni uu o D o LTD 17 6 6 Control amp Maintainers System T naar 17 7 Testing and Commissioning U U J J J 18 RailCorp Page 4 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 7 1 TNO t 18 7 1 1 Mechanical Equipment Testing 18 7 1 2 IDC WOMK LO TE E T T TT 18
31. hor Points M11 353 Steel Air Main Bracket M11 355 Label Holder Installation Part Carrington Tang Clamp 1 2 and 32 M11 354 Label Holder Installation Example on General Manifold Arrangement SPG 1870 Air Compressors for Signalling Systems 11 307 Air Hose P V C detail of Fittings Drawings produced from design phase DS P 001 GMS01 Piping DS P 002 MS01 Piping DS P 003 SS01 Piping DS P 004 Halogen Free Flexible Piping DS EQ 001 Air Compressor DS EQ 002 Compressed Air Dryer DS EQ 003 Air Receiver SPG 0705 Construction of Cable Houte and Associated Civil works ESG 100 25 Compressed Air Systems SPG 0703 Signalling Documentation and Drawings The following Australian Standards and statutory codes form part of this specification AS 1074 Steel Tubes and Tubulars for Ordinary Service AS 1210 Pressure Vessels AS 1345 Identification of the Contents of Piping Conduits and Ducts AS NZS 1477 PVC Pipes and Fittings For Pressure Applications AS NZS 1518 External Extruded High density Polyethylene Coating System for Pipes AS 2129 Flanges for Pipes Valves and Fittings AS NZS 2554 Hose and Hose Assemblies for Air AS 2660 Hose and Hose Assemblies Air water For Underground Coal Mines AS 4041 Pressure Piping AS NZS 4680 Hot dip Galvanized Zinc Coatings on Fabricated Ferrous Articles RailCorp Page 6 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals
32. 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 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 Supports 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 except where the pipe run is a main run a
33. ite Factors cccccccccssscccceeeceseeseececeeeeeeeeeeeeeeeeeeesseeeseeeeeeeessaeaaseeeeeessaaaaeess 8 3 9 Equipment Paramelers mM ET 8 3 3 1 zl 8 3 3 2 9 4 Equipment Supply T J J JL 9 4 1 Com 0 uum 9 4 2 9 4 3 Bloc 9 4 4 elg RI EE EO T T ETT 9 4 5 Miscellaneous Equipment TTE 9 4 6 Pressure Containment Valves 9 4 7 OG aN c nel TETTE E T 10 5 PIDOWOTK uuu u uuu ul uui 10 5 1 I Ili C SO RN seme esses m mmm 10 5 2 Pipework ArranQeMen cccccccsseececeeeeeeeeeeeeeeeeeeeeeeseeseeeeseeeesseeeeesseaueeeseeeeessaueesesegseeesaeeeeeeas 10 9 9 11 5 4 MURON u u uu uuu uuu E 11 5 5 KI m 12 5 6 T rr M 12 8 7 Identification and Painting cccceeccccsseeceeeeeeeeecseeeeecseeseeeseaseeesseeeeeesaeeeeseaeeeeseees
34. l be fully tested and commissioned At completion of commissioning acceptance certificate as per SPG 0711 is to be completed RailCorp Page 20 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 Appendix A Typical System Documentation Insert tick in applicable boxes DESCRIPTION PRELIMINARY DESIGN COPIES AS BUILT COPIES GENERAL 3 General arrangement Outine Dimension e h 4 Routine Type TestCerificates a L _ S Manufacturing amp Delivery Schedule ooo 6 Technical Literature 8 Brochures 8 8 7 Priced Spare Pars fort yis Operation o 8 mwalton amp RgdngDagams L _ 9 Design Calculations amp Grtera p 8 o w Bits ormateras SS L j _ n Name Plate betas L j _ CepeePwstt L 2 _ instalation nstuctons e _ aa Operating Instuctions 0 2 s Maintenance instuctons L be bkabnshedies O j j 2 2 3 Foundation amp Support Plan amp Loads MECHANICAL Inlet Outlet Details Mechanical Completion Test Certificate i i 1 T 4 QUALITY MANAGEMENT 4 Materials Specification 1 Completed QA Compliance Matrix 1 4 4 Quality Manual 1 Inspection amp Test Plans 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3
35. ll be retained and these and any test certificates shall be forwarded to the Asset Owner and shall in addition be included in the operation and maintenance manuals 7 1 3 System Testing A System Testing Plan shall be provided to test that the design concepts have been achieved in the installed system The Test Plan shall itemise each design criteria and the method of testing for each criteria Examples of the testing to be conducted include Time to reach working pressure from empty Line flow restrictors perform as expected All monitoring points are functional All compressor on off controls are proved to function at the correct pressures All labelling is correct to design All electrical changeovers function as designed The test plan shall be independently verified and submitted for approval Testing shall be conducted in the presence of the asset owner The results of all testing shall be recorded and submitted to the asset owner Testing shall include all functions remotely monitored by the Maintainers VDU Where analogue monitoring is provided such as pressure the testing shall include calibration amp correct correspondence through the pressure range between system limits Any tests that failed to meet the design criteria shall have the design reviewed and appropriate corrective action agreed with the asset owner 7 2 Precommissioning The Installer shall precommission the equipment in all operation modes Precommissi
36. long the railway corridor where the maximum spacing shall be 3 0 m Where mounted on GST posts at 2 0 m spacing the pipe shall be supported at each post 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 5 m 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 mm x 50 mm x 10 mm channel galvanised to AS NZS 4680 with 450g m coating Air main brackets should be as per drawings M11 354 and M11 355 The pipe shall be anchored e Every 300 metres on straight runs e Where the main enters leaves a pit e Where a steel branch sub main or steel cross tie intersects with the main e 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 1 1 352 An air main shall be considered to be straight where e Its curved to a horizontal or vertical radius greater than 250 metres e here are minor offsets of 900 mm maximum around abutments or structures Use of structures for anchor points shall be subject to approval RailCorp Page 16 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Versi
37. m DN 15 to DN 150 Design life years 50 Corrosion allowance mm 05 Fluid Description Air at pressure to ISO 8573 class 4 Solids Maximum 1000 particles m of size 1 to 5 micron Moisture Dewpoint 3 C Pipe DN 15 to DN 50 ASTM 312 TP 304 sch 40s threaded ends Pipe DN 65 to DN 150 ASTM 312 TP 304 sch 40s plain ends Joints DN 15 to DN 50 Screwed Joints DN 65 to DN 150 Welded or flanged Flanges AS 2129 Table E slip on raised face ASTM A240 TP 304L Fittings DN 15 to DN 50 ISO 4144 screwed BSP 304L Fittings DN 65 to DN 150 ASTM A403 WP304 std wt seamless butt welded Gaskets Compressed fibre non asbestos 1 5 mm Thread sealant PTFE tape Bolting AS 2528 304 or 316 Valves DN 15 to DN 50 Ball valve 316 55 body and ball glass reinforced PTFE seat screwed BSP lever operated lockable Valves DN 65 to DN 150 Flexible hose DN 20 to DN 80 Ball valve 316 55 body and ball glass reinforced PTFE seat flanged Table E lever operated lockable AS 2554 Class B PVC outer Stainless Steel Braided Corrugated 15010380 1 annular corrugated metal hose ISO 304 single braided 316 stainless steel fittings Accessories Supports anchors Saddle or U bolt insulating material over Double saddle to rigid surface 304 or 316 Vents Drains DN 20 ball valve at high point DN 25 ball valve at low point with auto drain Items marked to be determined during design ph
38. m ballast during rail maintenance Equipment Parameters Points An EP points motor with 125 mm bore and 180 mm stroke has a volumetric capacity of 0 0022 cu M RailCorp Page 8 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 3 3 2 Train Stops An electro pneumatic trainstop having cylinder dimensions of 76 mm bore amp 70 mm stroke has a volumetric capacity of 0 0003175 cu M 4 Equipment Supply 4 1 Compressors Compressors shall be in accordance with SPG 1870 complete with integral oil separator and after cooler where necessary The minimum size shall be 10 Litres Second capacity Units shall be delivered handled and stored in a manner which maintains the new condition of the units Compressors shall be connected to the fixed pipework by flexible stainless steel hoses 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 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 Units shall be delivered handled and stored in a manner which maintains the new condition of the units 4 4 Expansion Joints Expansio
39. ms SPG 0714 e 50mm Letters above DN 80 The location of identification labels shall be at intervals of not more than 8 m 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 50 m 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 M11 355 and M11 354 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 m coating unless noted otherwise Damaged sections of galvanising shall be repaired in accordance with Galvanizers Association recommendations 5 8 Orifice Plates Orifice plates shall be of nylon not less than 3 0 mm thick and shall be provided to protect against failure of flexible hoses Orifice sizes shall be e 1 6 mm for trainstops e 3 2 mm for points Unless approved otherwise and shall be installed at manifolds Orifice plates sizes in flexible mains hoses shall be determined in the design Orifice plates shall be securely installed betwee
40. n joints shall be externally pressurised bellows type units complete with drain port Bellows shall be stainless steel and other components shall be carbon steel Flanges shall be AS 2129 Table E Joints shall be designed and manufactured in accordance with Expansion Joint Manufacturers Association recommendations An anchor point is to be provided mid point between expansion joints 4 5 Miscellaneous Equipment Miscellaneous equipment will be as follows All air filters shall be fitted with differential pressure dp valves Lifting devices for compressors shall be monorails or gantry cranes complete with wire rope hoist electric raise lower electric travel and pendant control 4 6 Pressure Containment Valves Each trainstop and manifold shall be fed through a non return valve located after the main shut off valve This valve is to prevent loss of air from the equipment in the event of an air main failure The pressure containment valve shall be of stainless steel construction with either metal metal or metal Teflon seats These valves shall be maintenance free RailCorp Page 9 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 4 7 5 1 5 2 Local Reservoirs Local reservoirs shall be provided when required to even out airflow demand and to backup the air supply pressure where a number of equipment items are fed from the
41. n the flat faces of the nipples where inserted into the ball valves 5 9 Valves Valves shall be full bore stainless steel Teflon seat ball valve type to AS4796 with the following characteristics e Full bore ball valve e Two piece body construction small valves threaded together and larger valves greater than 50mm bolted together which allows for the replacement of seals e Body made from stainless steel Grade 304 needs to be Grade 316 in areas where high levels of chlorine are present e Female threaded connections to AS1722 1 British Standard Whitworth parallel form e 90 degree operation between open and closed positions e Whilst handle is attached it can be locked in open or closed position 6 Installation 6 1 Equipment Compressor Room 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 RailCorp Page 14 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 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 ac
42. oily water and Compressor Room shall be provided with adequate ventilation to maintain recommended compressor operating temperatures and room air balance louvres ridge vents and other building openings shall utilise acoustic louvres Other noise attenuation devices shall also be supplied to comply with noise criteria EPA approvals shall be obtained for the proposed waste water arrangements 6 6 Control amp Maintainers System A system to permit the control and remote monitoring of the air system amp its performance shall be developed amp installed This system shall include e Analogue display of pressure e Visual and audible alarms e Schematic diagram VDU display showing all main elements of the system amp their Status e Power supply status e Compressor and dryer status and alarms e Logging of all events The indications shall be available in the compressor room and at least one remote site through a TCP IP interface The system shall be expandable to permit other remote sites to be added A non interruptible power supply shall ensure the continued functioning of the control and maintainers system when the power is interrupted or failed RailCorp Page 17 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 The design of the system shall fulfil the requirements of Air System Design Principle
43. on 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 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 Only dry air shall be used for cleaning 6 4 Safety Equipment The equipment and pipework shall be designed and installed to provide maximum protection and safety for operating and maintenance personnel Safety equipment shall include signage guards access covers inspection covers emergency stop equipment safety interlocks and other devices as specified or implied or as required by any Statutory Authority having jurisdiction 6 5 Drainage amp Ventilation Pits shall be provided with adequate drainage to a waste water system or other approved discharge points to continuously remove stormwater and other liquids and Compressor Room shall be provided with adequate drainage to a waste water system or other containment devices to control contaminants such as
44. oning 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 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 RailCorp Page 19 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 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 shal
45. or a pit Pipework shall be designed to ensure that there is sufficient flexibility to absorb any expansion or contraction without excessive stresses or loads on equipment or cause leakage at joints Expansion joints expansion loops anchor points pipe bends and other items as necessary shall be considered for this purpose Compressed air lines shall slope downward in direction of flow at 1 200 Condensate trap points shall be placed at the bottom of vertical risers Inline drainage trap points for compressed air shall consist of a tee drop leg ball valve and auto drain Waste water lines shall slope downward in direction of flow at 1 40 Notwithstanding this valves and equipment shall not be located in pits Valving arrangements shall facilitate the blowing out of water that may accumulate in low sections Except at anchor points the brackets supporting the main shall allow axial freedom for expansion and contraction but shall not permit vertical or lateral movement exceeding omm 2mm either side of expansion joints The bracket shall be manufactured from hot dip galvanised steel except in tunnels where it shall be manufactured from stainless steel RailCorp Page 10 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 All pipework shall be easily accessible Where pipe connections are unavoidably elevated a union
46. ponsibility 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 2 Access 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 RailCorp Page 15 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 6 2 3 6 2 4 items then the Installer shall report such
47. radius less than the manufacturers recommended minimum radius a stainless steel elbow shall be installed Flexible hoses shall not be bent within a distance of 5 x Hose Outside Diameter to the tail Additional hose supports clamps shall be provided where necessary to achieve this Flexible air hoses shall be buried in a separate conduit in buried cable routes RailCorp Page 12 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 In GST and GLT installations the air hose must be laid on top of all cables to avoid compression of the air line The ends of all flexible air hoses shall be sealed during installation to prevent the ingress of dirt or water 5 7 Identification and Painting Individual pipework items such as valves manifolds instruments and expansion joints shall be fitted with permanent labels The label shall be made of stainless steel and fixed to the equipment using split rings or screws Characters shall be a minimum of 4 mm high Identification label inscriptions shall include the following information Valve manifold instrument joint code up to 8 characters Manufacturer s model number and size and Design rating Valve codes shall be as follows Air user control valves SY 456S TS 333 PTS Stop valves on mains cross ties manifolds etc N O or N C Stop v
48. t be maintained between the air line and overhead wiring structure or signal gantry Wherever practical steel air main should be placed two metres from any overhead wiring structure or signal gantry 5 4 Insulation Joints Insulation joints shall be rated for 2500V AC for one second Insulation joints shall be installed in the following locations Between the main and the Compressor Room Where the main enters or leaves the ground or a pit Within 1 m of each end of any steel bridge Every 500 m in the steel mains and Coincident with steel troughing insulated joints where both pipe and troughing utilise the same support At least two insulated joints shall be provided between any two signalling locations Where the air line is within 2 m of an overhead wiring structure that is not fitted with a spark gap the line is to be covered with an insulating sleeve eg class 12 PVC pipe for a distance of 2 m either side of the structure Suitable clamps or clips are to be provided to prevent movement Where steel pipe is used for an overhead cross tie it must be separated from the steel main by at least 2 0 metres of flexible PVC air hose Insulated joints shall not be located where they could be bypassed by a metal structure e g a metal bridge RailCorp Page 11 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 5
49. tail to allow procurement of these items General arrangement layout and detail drawings of the Compressor Room equipment and instrument installation Electrical power and control details including protection scheme and interface list Schematic books similar to current books detailing the new pipework involved connections to existing pipework and corrections to existing schematics opecifications to cover fabrication installation and commissioning requirements and Functional description in sufficient detail to allow software coding to proceed Maintain VDU Compressor PLC system design user manual including all software amp licences Fluid Parameters Site Details and Equipment Parameters Fluid Parameters Fluid parameters are Fluid is compressed air to quality class 2 4 2 of ISO 8573 downstream of dryer post filter Temperature range 10 C to 50 C between compressors and receivers and Temperature range 10 C to 60 C downstream of receiver Environmental and Site Factors Environmental and site factors are e location is the Railcorp region within NSW e Ambient temperature range 10 to 60 C e Rainfall range 600 mm to 2000 mm per annum e Humidity range 40 RH to 100 RH e Ground conditions may include induced currents from rail power supply e Potential close proximity to noise sensitive areas and e Other environmental factors are vibration from rail traffic and mechanical damage impacts fro
50. x277 mess 6 RailCorp Issued March 2013 UNCONTROLLED WHEN PRINTED Page 24 of 39 Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 BRIDGE OVER THE AIR MAINS DN20 ABOVE GROUND PIPE A 0000 UNDERGROUND PIPE TRACK EQUIPMENT CONNECTED ed 5010 vee FLEXIBLE HOSES AIR MAIN OVER BRIDGE pg UNDERGROUND FLEXIBLE HOSES T lt S CHANGES IN PIPE SIZE 77 06 ECCENTRIC REDUCER PLATFORM 1 DN80 DNSO CONCENTRIC REDUCER CENTRAL 2 TYPICAL MANIFOLD UNDERLINE CROSSING VEHICLE ACCESS POINTS RailCorp STANDARD DRAWING SYMBOLS FOR AIR SYSTEM B SYMBOLS UPDATED AND CHANGED pseozijesm ar ow m E250 Chief Engineer s Division ES w DESIGNED DRAWN REVIEWED VERIFIED APPROVED This drawing ond tte Informorfon contained ihereon hove been created solely for o ALL AS 0 H E H E C L IANG RLF RWA usse C DATE SCALE SHT 2 REV N iat DU MIO hey MUNI D A QUA ID South Woles or you moy be prosecuted MILLIMETRES frey mor Ca DO NOT AMEND MANUALLY 14 06 2003 i M11 349 OF 2 400x277 0 j 3 uU 5 j 6 RailCorp Page 25 of 39 Issued March 2013 UNCONTROLLED WHEN PRINTED Version 3 0 RailCorp Engineering Specification Signals Construction Compressed Air Systems SPG 0714 TAKE OFF VERTICAL TO AVOID WATER CARRYOVER A SECT

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