Technical Note: Issued Date 12 March 2015 Effective Date 12 March 2015

TN 013: 2015
For queries regarding this document

standards@asa.transport.nsw.gov.au
www.asa.transport.nsw.gov.au
Technical Note
TN 013: 2015
Issued date 12 March 2015

Effective date 12 March 2015
Subject: Withdrawal of EP 08 00 00 02 SP Overhead Wiring
Maintenance Standards
This technical note is issued by the Asset Standards Authority as a notification to remove from
use RailCorp document EP 08 00 00 02 SP Overhead Wiring Maintenance Standards, Version
4.0.
EP 08 00 00 02 SP is a legacy document and shall be used for reference purposes only. ASA
standard T HR EL 08011 ST Overhead Wiring Maintenance Standards, Version 1.0 supersedes
this document.
Authorisation
Technical content Checked and Interdisciplinary Authorised for
prepared by approved by coordination release
checked by
Signature
Name Wilfred Leung Neal Hook John Paff Graham Bradshaw
Position Principal Engineer Lead Electrical Acting Chief Principal Manager

Overhead Lines and Engineer Engineer Rail Network Standards &
Cables Services
Asset Standards Authority

A4118698
© State of NSW through Transport for NSW Page 1 of 1
Engineering Standard
Superseded by T HR EL 08011 ST
Electrical
Overhead wiring
Engineering Standard
EP 08 00 00 02 SP
OVERHEAD WIRING MAINTENANCE

STANDARDS
Version 4.0
Issued June 2013
Owner: Chief Engineer Electrical
Approved Neal Hook Authorised Neal Hook

by: Chief Engineer by: Chief Engineer
Electrical Electrical
Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.
UNCONTROLLED WHEN PRINTED Page 1 of 23

RailCorp Engineering Standard — Electrical — Overhead wiring
Superseded by T HR EL 08011 ST Overhead wiring maintenance standards EP 08 00 00 02 SP
Document control
Version Date Summary of change
July 2008 Last Technical Review
3.0 May 2010 Application of TMA 400 format
4.0 June 2013 See Table below
Summary of changes from previous version

Summary of change Section
Document re-formatted and re-organised All
Section on “Introduction” renamed “Scope and application” and expanded 1
References and definitions updated 2&3
Relevant provisions from EP08000006SP (now superseded) updated and included in
4
this document
Relevant provisions from SRA document EP08010001ST updated and included in this
6
document
Maintenance standards for conductor splices, dropper arrangements, section insulators,
7 - 12
insulated knuckles, surge arresters and wood pole support structures added
Corrective maintenance triggers and base safety or operating limits re-organised and
updated; maximum times to complete corrective actions added. Refer to supporting 13 & 14
document in file for details.
Relevant provisions from EP08000003SP (now superseded) updated and included in
14
this document
Base safety and operating limits added for
• Twist in polymeric insulator
14
• Vegetation clearance
• Weight tension regulator wire rope
Base safety and operating limits removed for:
Clearance from catenary to overline bridge – Covered by criteria in static and passing 14
clearances, signs of arcing and damage to conductors
Requirements for data set associated with overhead wiring maintenance added 15
© RailCorp Page 2 of 23
Issued June 2013 UNCONTROLLED WHEN PRINTED Version 4.0
Contents
1 Scope and application ............................................................................................................4

2 References...............................................................................................................................5
2.1 Australian and international standards......................................................................................5
2.2 RailCorp documents..................................................................................................................5
3 Definitions................................................................................................................................5
4 Vegetation clearances ............................................................................................................6
5 Maintenance of overhead wiring to design ..........................................................................6
6 Contact wire.............................................................................................................................7
6.1 Contact wire material ................................................................................................................7
6.2 Contact wire wear .....................................................................................................................7
6.2.1 Measurements ...........................................................................................................7
6.2.2 Contact wire condemning size...................................................................................8
6.2.3 Removal of localised contact wire wear points..........................................................9
6.2.4 Contact wire elastic limits ..........................................................................................9
7 Conductor splices.................................................................................................................10
7.1 Catenary splices......................................................................................................................10
7.2 Contact splices........................................................................................................................11
8 Dropper arrangements .........................................................................................................11
9 Section insulators .................................................................................................................11
10 Insulated knuckles ................................................................................................................11
11 Surge arresters......................................................................................................................12
12 Wood pole support structures.............................................................................................12
13 Corrective maintenance triggers.........................................................................................12
13.1 General....................................................................................................................................13
13.2 Conductors..............................................................................................................................14
13.3 Conductor fittings ....................................................................................................................15
13.4 Switching and feeding arrangements......................................................................................16
13.5 Support and registration arrangements ..................................................................................17
13.6 Anchor arrangements..............................................................................................................17
13.7 Support structures...................................................................................................................18
14 Base safety or operating limits............................................................................................18
14.1 General....................................................................................................................................19
14.2 Conductors..............................................................................................................................20
14.3 Conductor fittings ....................................................................................................................21
14.4 Switching and feeding arrangements......................................................................................21
14.5 Support and registration arrangements ..................................................................................22
14.6 Anchor arrangements..............................................................................................................22
14.7 Support structures...................................................................................................................22
15 Data set associated with overhead wiring maintenance ..................................................23
1 Scope and application

Preventative maintenance of the RailCorp 1500V dc overhead wiring (OHW) system shall
be done in accordance with the RailCorp Technical Maintenance Plan.
This document sets out maintenance policies and parameters associated with the OHW
system including:
• Vegetation management
• Maintenance tolerances with respect to design
• Contact wire
• Catenary and contact splices
• Section insulators
• Insulated knuckles
• Surge arresters
• Wood pole support structures
It also includes
• OHW maintenance tolerances and conditions that trigger corrective maintenance
actions that do not require urgent repair work. The maximum times to complete
the corrective actions are also specified.
• Base safety or operating limits , which are the threshold conditions at or below
which urgent repair work to the overhead wiring work shall be carried out.
Except where immediate repair action is required as per this document, a risk analysis
shall be carried out immediately after a breach of any of the base safety and operating
limits is found. Restrictions on overhead wiring and/or train operations may have to be
imposed prior to the completion of the repair work. Such restrictions may include:
• Track speed limits

• Suspension of train services through the affected area
• Removal of power from overhead wiring
This document does not include maintenance triggers for overhead wiring structures and
their associated bonding arrangements. Overhead wiring structures are maintained by
the Civil discipline. Maintenance triggers for structure bonding arrangements are covered
in EP 12 20 00 01 SP “Bonding of overhead wiring structures to rail”. However, this
document requires the overhead wiring maintainer to report obvious visual defects to the
maintainers of these assets.
The following documents have been incorporated into this document and with the release
of this document are withdrawn:
EP 08 00 00 03 SP Overhead wiring base safety and operating standards

EP 08 00 00 06 SP Vegetation control near 1500V dc equipment (OHW)
State Rail Authority document EP 08 01 00 01 ST Contact wire condemning size and
measuring policy
2 References
2.1 Australian and international standards

EN 50119:2009 Railway applications – Fixed installations – Electric traction overhead
contact lines
EN 50122-1:2011 Railway applications – Fixed installations – Electrical safety, earthing
and the return circuit – Part 1: Protective provisions against electric shock
2.2 RailCorp documents

EP 00 00 00 00 MP Electrical Technical Maintenance Plan
EP 00 00 00 13 SP Electrical power equipment – Design ranges of ambient conditions
EP 08 00 00 12 SP Level crossings – OHW requirements
EP 08 00 00 15 SP Overhead wiring construction and commissioning
EP 08 00 00 16 SP Designations of overhead wiring conductor systems
EP 08 00 00 24 SP Contact wire
EP 10 01 00 01 SP Wood pole serviceability
EP 10 01 00 02 SP HV aerial line maintenance standards
EP 10 01 00 03 SP HV aerial line base safety and operating standards
EP 10 01 00 05 SP Requirements for electric aerials crossing RailCorp infrastructure
EP 12 20 00 01 SP Bonding of overhead wiring structures to rail
EP 19 00 00 01 SP DCCB and Delta I relay setting calculation method
ESC 210 Track geometry stability
ESC 330 Overhead wiring structures and signal gantries
ESR 0001-100 Minimum operating standards for rolling stock – General interface
standards
TMC 212 Survey
TMC 331 Design of overhead wiring structures & signal gantries
3 Definitions
Contact wire Ratio of the difference in height of the contact wire at two successive supports
gradient to the length of the bay.
Contact wire elastic The elastic limit for a material is the stress beyond which permanent
limit deformation will occur. For the purpose of this document, the elastic limit of a
contact wire is the thickness of a contact wire at a localised wear point below
which permanent deformation will result when the wire is subjected to the
maximum tension at the limits of design operating conditions.
Heel height The vertical distance between the contact wire at the pull off arm and the pivot
point at the heel of the pull off arm.
Passing clearance The minimum clearance required between live parts of overhead wiring
equipment and any earthed material or rail vehicle, or between the pantograph
and any earthed material, under any permissible conditions of operation and
maintenance of vehicles, track and overhead wiring equipment.
Static clearance The minimum distance required between live parts of overhead wiring
equipment (under any permissible conditions of maintenance when not subject
to uplift from a pantograph) and a structure or earthed part of the overhead
wiring equipment.
4 Vegetation clearances
Vegetation near overhead wiring shall be maintained and controlled so that it is not
within:
• 3m of live exposed 1500V equipment

• 1.5m of overhead wiring structures and guys, and dead overhead wiring
conductors
Vegetation that has been assessed to be at risk of falling into the overhead wiring shall
also be removed, even if it is located outside of the clearance envelopes specified above.
Allowance for regrowth between inspection and maintenance cycles shall be made when
undertaking vegetation control activities.
All vegetation control activities shall be undertaken in accordance with the requirements
of RailCorp’s Environmental Management System and Safety Management System.
5 Maintenance of overhead wiring to design

New or rebuilt overhead wiring shall be constructed and commissioned to the approved
and accepted design, and within the tolerances stipulated in EP 08 00 00 01 SP.
After commissioning, the OHW shall be maintained so that deviations from the approved
and accepted design are within the tolerances set out in 0. These tolerances are
required to ensure pantograph security with an effective pantograph half-width of 700mm
(see drawing CV 0131343), and with the allowable vehicle movement and track
tolerances specified in ESR 0001-100 and ESC 210 (see drawings EL 0006421-2).
The OHW design geometry at a structure is defined with reference to the relevant Track
Control Mark (TCM) for the structure. Within the Electrical discipline, this TCM is also
referred to as the “reference nail” (when installed on a mast) or “brass bar” (when
installed in rock foundation). Critical dimensions of the design track geometry relative to
the TCM at the structure location are given in the survey plaque associated with the TCM.
Refer to RailCorp documents ESC 210 and TMC 212.
If the track is positioned outside of tolerances, it may be necessary to temporarily adjust

the overhead wiring outside of the tolerances specified in 0 to allow for train running.
Under these circumstances, both track and overhead wiring shall be restored to within the
specified tolerances from design as soon as practicable.
Parameter Maintenance tolerances to design

Catenary height +/- 50mm
Contact height +/- 50mm, subject to minimum contact height
conditions in section 13.2
Contact stagger +/- 50mm
Pull off arm heel height +/- 25mm
Table 1 - OHW maintenance tolerances to design
6 Contact wire
6.1 Contact wire material

Contact wire material is identified by means of grooves provided at the upper lobe of the
wire. The number of identification grooves provided for each type of material is:
• Cadmium copper – Nil

• Hard drawn copper – 1
• Tin bearing copper – 2
Except as noted below, tin bearing copper contact wire in accordance with
EP 08 00 00 24 SP shall be used for replacement of existing contact wires.
Settings of relevant dccb’s shall be checked, and adjusted where necessary, in

conjunction with all contact wire replacement / renewal if the existing contact wires are
not tin bearing copper. Where the dccb settings do not allow the replacement of existing
hard drawn copper contact wires by tin bearing copper wires, hard drawn copper contact
wires in accordance with EP 08 00 00 24 SP shall be used for the replacement.
Replacement of localised worn hard drawn copper contact wire by a short piece (< 10m)
of tin bearing copper contact wire is permissible.
6.2 Contact wire wear
6.2.1 Measurements
The severity of localised contact wire wear is generally determined by measuring the
contact wire thickness at the thinnest point of the localised wear area. The thickness is
measured along an axis perpendicular to the bottom (wearing surface) of the contact
wire. However, where contact wire side wear (eg at wire junctions) is also observed, a
measurement along the axis perpendicular to the side wear surface shall also be made
and recorded. The cross section area of the contact wire at the thinnest point, and the
corresponding safety factor at limiting operating conditions, shall be determined from
these two measurements for contact wire with side wear.
Contact wire thickness measurement shall be taken with an instrument with an accuracy
of ± 0.05mm, and recorded in units of millimetres to the first decimal place, eg 8.9mm.
Contact wire thickness measurements shall be taken periodically in accordance with the
RailCorp Electrical Technical Maintenance Plan. Measurements shall be made at the
thinnest point as close as practicable at the following locations:
• Pull off arms

• Contact wire full splices
• Kinks in the contact wire
• Contact wire knuckles
• Pantograph forking in points
• Section insulators
• Wearing strips – Measurements shall be made for both the contact wire and the
wearing strip wire
• Other localised thin spots observed from sighting along the contact wire between
the above measurement locations
6.2.2 Contact wire condemning size

The contact wire condemning size is the contact wire thickness at a localised wear point
below which the localised wear has to be removed. See Table 8.
Condemning sizes of contact wires in the RailCorp overhead wiring network are given in
Table 2 and Table 3. The condemning sizes are determined with the following criteria:
• A minimum factor of safety of 2.0 at the limit operating conditions

• A margin of 10% is added to the maximum calculated conductor tensions, as
determined by the conductor system details and ambient conditions stipulated in
EP 00 00 00 13 SP and EP 08 00 00 16 SP. This margin is made to allow for
tolerances such as those in tension regulator weights and contact wire dimensions.
• The condemning contact wire thickness shall not be less than 8.1mm for 137mm2
contact wire, and 9.7mm for 193 mm2 contact wire. These dimensions correspond
to the thickness of a contact wire with the semi-circular section fully worn, plus a
safety margin of 1.5mm. See RailCorp Drawings EL 0040770 and EL 0189852.
• A margin of 0.6mm is added to the calculated condemning sizes for installations
inside tunnels to allow for difficulty in detecting thin wire spots from patrols
The nominated contact wire condemning sizes are not applicable to conductor systems
26 and 35 (fixed anchored with 137mm2 contact wire at a tension of 12.46kN at 21oC).
Refer to RailCorp Engineering if such systems are encountered in maintenance.
The values given in Table 2 and Table 3 are only valid for contact wires with no side
wear. For contact wires with side wear, the cross section area shall be determined using
the two measurements as set out in section 6.2.1. The wire shall be "condemned" if the
cross section area is less than or equal to the "Section area at condemning" listed in
Table 2 and Table 3.
It is unlikely to have a contact wire run to be uniformly worn down to the “50% worn”
section area in accordance with EP 19 00 00 01 SP before part or all of the wire run has
to be replaced to remove localised wear points. Contact wire resistance is therefore not
considered in the determination of condemning sizes.
Condemning Section area at

Material Configuration Location size condemning
(mm) (mm2)
Hard drawn copper Regulated All 8.1 81.1
Regulated All 8.1 81.1
Tin bearing copper Fixed twin contact All 8.8 90.7
Fixed single contact All 9.0 93.1
Cadmium copper Fixed twin contact All 8.8 90.7
Table 2 - Condemning sizes for 137 mm2 contact wire with no side wear
Condemning Section area at

Material Configuration Location size condemning
(mm) (mm2)
All areas
Fixed single contact except City and 11.6 141.5
Tin bearing copper
ESR tunnels
City and ESR
Fixed single contact 10.7 127.7
tunnels
All areas
Fixed single contact except City and 11.2 135.5
Cadmium copper
ESR tunnels
City and ESR
tunnels
Table 3 - Condemning sizes for 193 mm2 contact wire with no side wear
6.2.3 Removal of localised contact wire wear points

Localised contact wire wear points at or below the condemning size are to be removed by
replacing a length of the contact wire containing the wear point. The replacement length
shall be spliced into the existing contact wire run by approved contact wire splices in
accordance with section 7.2.
Where it is not practicable to have the localised wear point removed within the time
specified in Table 8, a contact wire wear strip may be installed in accordance with
RailCorp Drawing EL 0026992 as a temporary measure.
6.2.4 Contact wire elastic limits

For the purpose of this document, the elastic limit stress of contact wire is taken to be
55% of the ultimate tensile stress, and is the base safety or operating limit for localised
contact wire wear. Elastic limits of contact wires in the RailCorp overhead wiring network
are given in Table 4 and Table 5.
Refer to EP 08 00 00 02 SP for the identification of contact wires and the applicable

maximum conductor tensions.
The nominated elastic limits are not applicable to conductor systems 26 and 35 (fixed
anchored with 137mm2 contact wire at a tension of 12.46kN at 21oC). Refer to RailCorp
Engineering if such systems are encountered in maintenance.
The nominated limits are also not applicable to contact wires with side wear. For contact
wires with side wear, the cross section area of the wire shall be determined in
accordance with section 6.2.1. The maximum stress at the localised wear point shall be
calculated to determine if the elastic limit has been exceeded.
Elastic limit Section area at

Material Configuration Location elastic limit
(mm) (mm2)
Tin bearing copper Fixed twin contact All 8.2 82.4
Cadmium copper Fixed twin contact All 8.1 81.1
Table 4 - Elastic limits for 137 mm2 contact wire with no side wear
Elastic limit Section area at

Material Configuration Location elastic limit
(mm)
(mm2)
All areas except
Fixed single contact City and ESR 10.7 127.7
Tin bearing copper
tunnels
City and ESR
tunnels
All areas except
Fixed single contact City and ESR 10.4 123.0
Cadmium copper
tunnels
City and ESR
tunnels
Table 5 – Elastic limits for 193 mm2 contact wire with no side wear
7 Conductor splices
7.1 Catenary splices

Approved helical fittings (RailCorp stock codes 1567627, 1059393 and 1567643) shall be
used for splicing 165mm2, 270mm2 and 327mm2 catenaries. These fittings may also be
used to repair damages to these catenaries if less than 25% of the wires in the outermost
layer have been severed or have other equivalent damage.
Droppers, in-span feeders, and other fittings that clamp on the catenary wire may have to
be relocated so that they are clear of the helical fitting.
Splicing of 510mm2 catenary shall be done by terminating the conductors, installing a

suitable link between the terminating clamps and connecting the “tails” of the catenary
conductors together, in a manner similar to that shown in RailCorp drawing EL0011035.
The termination clamp shall be RailCorp fitting number 281/9 (drawing EL 0034083).
7.2 Contact splices

“In running” contact wires shall be spliced by RailCorp fitting number 462/8 (stock
code 1023894) with suitable wedges and shims in accordance with drawing EL 0002017.
For worn contact wires, copper shims are installed in the mouth of the splice fitting to
ensure that the running edge of the contact wire is flush with the underside of the splice.
Table 6 gives a guide to the number of shims to be used. The contact wire splice is not
suitable for contact wires with a thickness less than 9.9mm. Hence contact wire
replacement may have to be extended beyond the localised wear point.
As contact wire splices are “hard spots” for pantograph running, no more than 3 contact
splices shall be installed between two adjacent support structures.
Number of shims
Contact wire thickness
(Drawing EL 0034703)
(mm)
Fitting 462/6 (Long) Fitting 462/16 (Short)
16.4 – 15.5
0 0
(New 193mm2)
15.4 – 14.6 1 0
14.5 – 13.5
2 0
(New 137mm2)
13.4 – 12.5 1 1
12.4 – 11.5 2 1
11.4 – 10.5 1 2
10.4 – 9.9 2 2
Table 6 – Guide to shim installation requirements for contact wire full splice
8 Dropper arrangements
Where existing droppers have to be replaced, they shall be replaced by insulated
droppers in accordance with EP 08 00 00 01 SP.
9 Section insulators
Where existing section insulators have to be replaced, they shall be replaced by “Type 6”
section insulators in accordance with EP 08 00 00 01 SP.
10 Insulated knuckles
There is currently no suitable replacement for insulated knuckles with timber beams.
Existing overhead wiring with such insulated knuckles may need to be re-configured
when the knuckles are no longer suitable to remain in service. The Maintainer shall plan
the required modifications with sufficient time allowed for design and construction.
11 Surge arresters
Surge arresters had been installed on the overhead wiring at approximately mid-way
between substations in some areas of the RailCorp network. This practice is no longer
required. Existing “mid-way” surge arresters shall be removed at the next hands-on
inspection or when the overhead wiring in the area is modified.
Surge arresters are still required at cable to aerial feeder junction locations. See
EP 08 00 00 01 SP.
12 Wood pole support structures

Refer to EP 10 01 00 01 SP for serviceability criteria of wood poles.
Where an existing overhead wiring wood pole support structure has to be replaced, it
shall be replaced by one or more structure(s) satisfying the requirements of ESC 330 and
TMC 331.
13 Corrective maintenance triggers

Common conditions that trigger corrective maintenance actions are listed in the sub-
sections below. Care shall be exercised by the Maintainer to ensure that base safety and
operational limits (see section 14) are not breached before the completion of corrective
actions.
The values listed under “time to complete corrective action” are maximum allowable
times. Depending on the nature and extent of the defect, shorter time periods may need
to be applied for individual cases to ensure that the risks to personnel safety and train
operations caused by failure of the identified defect(s) are as low as reasonably
practicable. Longer time periods to complete corrective action may be approved by the
relevant Maintenance Engineer Electrical on a case by case basis if the time extension is
justified by a risk analysis.
13.1 General
Time to complete
Parameter Corrective maintenance trigger
corrective action
Cracked or chipped porcelain 3 months
Excessive pollution build up 6 months
Corroded cap or tongue 3 months

Insulators
Twist in polymeric insulator greater than 30o but less than 40o 3 months
Insulator skirt clearance above in running contact wire –

< 300mm for porcelain insulators 3 months
< 200mm for composite insulators
Small parts Signs of excessive corrosion, deformation (bending, cracks),

6 months
steelwork etc
Loose, missing or corroded fasteners that are not critical to

Fasteners the functioning of the fittings / assemblies (eg those with 6 months
redundancies in the number of fasteners)
Vegetation Vegetation within the clearance envelopes specified in section 6 months

clearance 4, or assessed to be potentially at risk of falling into OHW (Note 1)
Static clearance (normal) < 150mm 3 months
Static clearance to non-conductive material (eg non-reinforced

3 months
concrete or brickwork) < 120mm
Clearances Passing clearance (normal) < 200mm 3 months
(Note 2)
Passing clearance to non-conductive material (eg non-
3 months
reinforced concrete or brickwork) < 150mm
Vertical clearance from catenary to overline bridge less than

3 months
the minimum values stipulated in EP 08 00 00 01 SP.
Missing, obscured or wrong information on signs due to

Signs 3 months
vandalism, corrosion or degradation
Table 7 – Corrective maintenance triggers - General
Note 1 – An assessment should be made of the rate of vegetation growth. A shorter time
frame for completion of corrective action may be required as a result of the assessment.
Note 2 – Passing clearance to pantographs may be analysed and determined by the

RailCorp “PanGauge.xlt” spreadsheet program.
13.2 Conductors
Time to complete
corrective action
Signs of conductor stranding, annealing, burning, abnormal wear,

3 months
kinks, etc
Catenary / contact alignment across track at a dropper > 20% of

dropper length (except where the wires are designed to be not 6 months
aligned with each other, eg Liverpool to Glenlee)
Clearance of span wire above in running contact wire (without

General fender fitting 395 or 395/1 as per drawings EL0251310-1) < 3 months
300mm
Clearance between 2 parallel wires of different electrical sections

(eg mid-bay in open overlaps on tight curves) under worst case of 6 months
blowout < 150mm
Clearance to HV aerial lines less than that stipulated in

6 months
EP 10 01 00 05 SP
< 4.75m in open route 6 months

Contact wire
height < 4.65m at low bridges and tunnels 6 months
(Note 1) Contact wire height less than minimum stipulated in

6 months
EP 08 00 00 12 SP at a level crossings
Contact wire > 460mm (Priority 2 exceedence for OHW geometry measuring
6 months
stagger vehicle)
Contact wire Contact wire gradient exceeds maximum values listed in Table 1
6 months
gradient of EP 08 00 00 15 SP.
Contact wire Contact wire thickness at or below condemning size. See section
6 months
thickness 6.2
Signs of poor running performance such as arcing, burning and

Overlaps excessive wear; 6 months
Contact wire “scissor” in excess of 50mm
Catenaries
Clearance between catenary conductors < 20mm 3 months
crossing
Auxiliary Clearance of auxiliary feeder at support < 400mm above tie rod
6 months
feeder chain or portal boom
Table 8 - Corrective maintenance triggers – Conductors
Note 1 – For fixed anchored overhead wiring, minimum contact height at the maximum
design conductor temperature (generally 55oC for open route and 45oC in tunnels) shall
be determined by height and temperature measurements. RailCorp program MinCont
may be used to calculate the minimum contact height from these measurements.
13.3 Conductor fittings

Time to complete
corrective action
Signs of stranding, annealing, burning, abnormal wear,

General looseness, etc for feeding jumpers, potential jumpers and 3 months
in-span feeders.
Dropper broken or detached from contact wire with no

3 months
objects below contact
Dropper rubbing against another conductor or fouling

1 week
Droppers sliding knuckle
Vertical alignment of standard dropper along track > 20%

3 months
of dropper length (drifted droppers)
Vertical alignment of short dropper along track > 10mm 3 months
Vertical alignment of in-span feeder along track > 20% of

In-span 6 months
in-span feeder length
feeders
In-span feeder rubbing against another conductor 3 months
Contact wire Excessive wear indicated by the development of a “V”

6 months
full splice shape at the point where the contact wire enters the body
Signs of poor running performance such as arcing, burning

3 months
and excessive wear
Bent or damaged arcing horns, damaged or skewed

Section runners, guy slackness, loose attachment bolts, damaged
insulators insulator.
1 week
If a risk assessment determines that pantographs may
suffer damage then the base safety parameters are to
apply.
Signs of excessive degradation or corrosion, out of

Knuckles 3 months
adjustment, loose attachment bolts, etc (Note 1)
Over-run
Signs of damage or incorrect alignment 3 months
protection
Table 9 - Corrective maintenance triggers – Conductor fittings
Note 1 – Consideration should be taken for possible long lead times to implement
corrective maintenance actions for insulated knuckles with timber beams. See section 10.
13.4 Switching and feeding arrangements

Time to complete
corrective action
Signs of stranding, annealing, burning, abnormal wear,

General 3 months
looseness, etc for feeders and jumpers.
Signs of burning or overheating.

Misalignment of blade with jaws.
3 months
Blade not fully engaged with jaws when switch is in closed
position.
Surface deterioration or contamination of insulated operating

6 months
rod
Operating handle mechanism damaged or not operating freely

and smoothly
Switches Parts of mechanism loose or missing.
Operator platform damaged or missing 3 months

(Note 1)
Bonding between switch handle and operator platform
damaged or missing
Rail connection cable (where applicable) missing, damaged,

or disconnected from mast or rail.
Labels (switch identification and switch handle position) 3 months

incorrect, missing, obscured or not securely attached. (Note 2)
Clearance of aerial feeder to adjacent track < 1.5m when they

3 months
are of different electrical sections
Minimum electrical clearance of aerial feeders from other

Aerial
conductors at crossing under worst case (wind, wire 3 months
feeders
movement, temperature, etc) < 150mm
Feeders do not have sufficient slack to allow for full range of

3 months
conductor movement
Surge
Damaged or missing connection to earth electrode 1 week
arresters
Structure
earthing Switch or feeding structure not earthed or bonded to rail in 3 months
and accordance with design (Note 2)
bonding
Table 10 - Corrective maintenance triggers – Switching and feeding arrangements
Note 1 – Arrange for switch operation to be disabled immediately by appropriate locking

mechanism in accordance with the RailCorp Safety Management System, and arrange
for Advice of Alteration to Electrical Operating Diagrams.
Note 2 – Install temporary signs or warning labels immediately.
13.5 Support and registration arrangements

Time to complete
corrective action
Heel height negative but heel is clear of pantograph
Pull off arm 3 months
running from observation of the passage of trains
Deviation from design along track position > 100mm,
Catenary
having due regard to conductor temperature and distance 6 months
support
from fixed anchor
Table 11 - Corrective maintenance triggers – Support and registration arrangements
13.6 Anchor arrangements

Time to complete
corrective action
Excessive corrosion (with more than 10% loss in section)
Guy 6 months
or damage to guy rods, fittings or wires
arrangement
Lugs or fittings buried by ballast 6 months
Fixed
midpoint Signs of conductor movement through clamps 3 months
arrangement
Weights unable to move freely up and down with conductor
3 months
temperature changes
To be determined
Movement of weight stack through the design conductor
Weight from extent of
temperature range (as determined by RailCorp program
tensioner allowable travel
“WeightSet.xlt”) is impeded due to the presence of
arrangement and consideration
obstructions or incorrect position of weight stack.
of time of year
Yoke plate of combined weight tensioner arrangement
3 months
jammed
Damage (eg excessive corrosion or stranding) to tension
3 months
regulator wire rope
Table 12 - Corrective maintenance triggers – Anchor arrangements
13.7 Support structures

Time to complete
corrective action
Clearance to Clearance to high voltage aerial lines less than
6 months (Note 1)
HV aerial lines that stipulated in EP 10 01 00 05 SP
Structure Deformation of structures, eg twisting of mast or Report to Civil
deformation drop vertical discipline within 1 day
Report to Civil
Signs of movement in ground
Structure and discipline within 1 day
guy foundation Corroded steel work, eg bridge and tunnel Report to Civil
supports, anchor lugs, etc discipline
Clearance of drop vertical to superelevated
Drop verticals 3 months
centreline of adjacent track < 1500mm
Labels Incorrect, missing, or obscured structure labels 3 months (Note 2)
Structure Missing, damaged, or incorrect installation of
3 months
bonding structure bonding arrangement
Wood poles See EP 10 01 00 02 SP
Table 13 - Corrective maintenance triggers – Support structures
Note 1 – Temporary warning signs and / or access barriers to be in place within one day
Note 2 - Temporary labels to be in place for critical structures (eg structure with switch)
within one day
14 Base safety or operating limits

Common base safety or operating limits, as well as maximum allowable time to complete
repairs, are listed in the sub-sections below.
The values listed for “time to complete corrective action” are maximum allowable times.
Immediate action should be initiated if there is a risk of imminent failure. The maximum
allowable times may be varied by the Maintenance Engineer Electrical as a result of a
risk analysis with consideration given to the applicable site specific operating environment
and/or the implementation of temporary measures.
14.1 General
Base safety or operating Immediate checks and / or Time to complete
Parameter
limit temporary measures corrective action
Loss of insulation (eg broken

Stop trains Immediate
porcelain)
Sustained arcing across

insulator
Insulator at risk of detachment

failure due to excessive 1 day
corrosion of tongue or cap
Insulators
Twist in polymeric insulator > 40o 1 day
Insulator skirt clearance above

in running contact wire –
< 150mm for porcelain
1 day
insulators
< 75mm for composite
insulators
Small parts Risk of component failure due

1 day
steelwork to excessive corrosion
Vegetation Vegetation touching live

clearance overhead wiring or pantograph
Signs of arcing across an air gap Immediate
Install bonding to rail via a

Static clearance to “earthed”
spark gap if metalwork may be 1 day
Static metalwork < 50mm
touched
clearances
Static clearance to “earthed”
non-conductive material 1 day
< 20mm
Signs of striking by or arcing

from pantograph
Passing Install bonding to rail via a

Passing clearance to “earthed”
clearance spark gap if metalwork may be 1 day
metalwork < 50mm
touched
(Note 1)
Passing clearance to “earthed”
non-conductive material 1 day
< 20mm
Table 14 – Base safety or operating limits – General
Note 1 – Passing clearance to be pantographs shall be determined by the RailCorp

“PanGauge.xlt” spreadsheet program.
14.2 Conductors
Parameter
Clearance between 2 parallel

wires of different electrical
Advise Electrical Operating As per instruction
sections (eg midbay in open
Centre (EOC) immediately from EOC
overlaps) under worst case of
blowout < 100mm
Clearance of span wire above

General in running contact wire
(without fender fitting) Impose speed restriction under
1 day
continuous observation
< 75mm at support structure
< 150mm at mid bay
Object hanging below the in

running contact wire
Check with the EOC to see if the

< 4.47m relevant DCCB’s are tripping. 1 day
Perform immediate repairs if so.
< 4.9m at a public road level Advise Police (for public road
crossing, or at a service road level crossings) and use traffic
Contact 1 day
level crossing without a controllers to exclude high
wire height
warning frame vehicles from the level crossing.
< 0.3m above the maximum

Use traffic controllers to exclude
permissible vehicle height at
high vehicles from the level 1 day
a service road level crossing
crossing.
with a warning frame.
Observe passage of trains, and

> 500 mm (Priority 1
Contact impose speed restrictions (Note
exceedence for OHW 1 day
wire stagger 1) if contact wire is within
geometry measuring vehicle)
100mm of the pantograph horn.
Repairs may be deferred by up

to one day if the temperature
remains sufficiently high for fixed
Contact Contact wire thickness at or Immediate
anchored systems, or if the
wire below elastic limit. See
contact wire tension is reduced
thickness section 6.2.4.
temporarily by removing
sufficient number of weights
from the tension regulator.
Signs of damage (eg

Damaged stranding) with less than half
1 day
conductors the original conductor cross
sectional area remaining.
Table 15 – Base safety or operating limits – Conductors
Note 1 – Do not reduce speed on curve if excessive stagger is at structure but midbay
stagger is acceptable.
14.3 Conductor fittings

Parameter
Any damaged equipment (eg
broken / detached droppers, in-
General span feeders, wear strips, Stop trains Immediate
jumpers, knuckles, etc)
hanging below the contact wire
Cast
Cracked or fractured cast
tension Stop trains Immediate
tension fittings
fittings
Excessive wear with the the
distance from the end of the
Contact 1 day
splice to the vertex of the “V”
wire full shape > 135mm
splice
Deformation along the edge of
1 day
the “V” shape opening
Broken / detached runner or Stop trains, except that trains
guy or any outcome from a risk may proceed under continuous
Section
assessment that determines an observation if approved by the Immediate
insulators
unacceptable risk in damage to Maintenance Engineer
pantographs. Electrical
Signs of excessive burning that
Electrical
may cause imminent failure of Stop trains Immediate
connections
the conductors
Table 16 – Base safety or operating limits – Conductor fittings
14.4 Switching and feeding arrangements

Parameter
Aerial feeders hang below
contact wire
Aerial Feeder displaced and bridging
feeders 1 day, unless
two electrical sections
Advise EOC immediate repair is
(electrical protection
required by EOC
compromised)
Table 17 – Base safety or operating limits – Switching and feeding arrangements
14.5 Support and registration arrangements

Parameter
Dislodged pin or fastener
which may cause fitting (eg pull
Pins / off arm) to fall below contact
fasteners wire and/or in front of train
Partially dislodged pin / Monitor and observe passage
Immediate
fastener of trains
Signs of striking by pantograph Immediate
Pull off arm
heel height Clearance of pantograph to
Impose speed restriction 1 day
heel of pull off arm < 20mm
Table 18 – Base safety or operating limits – Support and registration arrangements
14.6 Anchor arrangements

Parameter
Patrol tension length and observe 1 day, if no other
Weights bottomed or pulley
performance of OHW with critical issue is
blocks in contact with each
passage of trains. Impose speed identified by the
other
restriction if required. patrol.
Patrol tension length and observe 1 day, if no other
Weight
performance of OHW with critical issue is
tensioner Weights “top out” at pulley
passage of trains. Impose speed identified by the
arrangement
restriction if required. patrol.
Damage (eg excessive
corrosion and/or stranding) to
1 day
more than half of the strands
of the wire rope
Table 19 – Base safety or operating limits – Anchor arrangements
14.7 Support structures

Parameter
Guy Guy foundation moving in Stop trains. Report to Civil
foundation ground Discipline immediately.
Bond wire hangs below
contact wire
1 day, if there is no
Bond wire hanging and Check spark gap arrangement.
Structure arcing and spark
touching or near live Repair immediately if arcing or if
bonding gap has not been
equipment spark gap has been activated.
activated
Damage to bond wire
Immediate
insulation at crossing with rail
Wood poles See EP 10 01 00 03 SP
Table 20 – Base safety or operating limits – Support structures
15 Data set associated with overhead wiring maintenance

The Maintainer shall ensure that the data set associated with overhead wiring, as
stipulated in EP 08 00 00 01 SP is up to date and in accordance with the as-built
configuration.
Any deviations from standard operating conditions, such as a maximum conductor

temperature higher than 60oC for regulated overhead wiring with “short” tension lengths,
shall be clearly indicated on the relevant layout drawing(s).
Where urgent repairs are carried out, the maintainer shall ensure that the data set
associated with the overhead wiring is updated in accordance with the as-built
configuration as soon as practicable, and not less than one month after the completion of
the repairs.

Technical Note: Issued Date 12 March 2015 Effective Date 12 March 2015

Uploaded by

Document Information

Original Title

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

Technical Note: Issued Date 12 March 2015 Effective Date 12 March 2015

Uploaded by

Copyright:

Available Formats

TN 013: 2015

For queries regarding this document

Issued date 12 March 2015

Name Wilfred Leung Neal Hook John Paff Graham Bradshaw

Position Principal Engineer Lead Electrical Acting Chief Principal Manager

Asset Standards Authority

OVERHEAD WIRING MAINTENANCE

Issued June 2013

Owner: Chief Engineer Electrical

Approved Neal Hook Authorised Neal Hook

UNCONTROLLED WHEN PRINTED Page 1 of 23

Summary of changes from previous version

1 Scope and application ............................................................................................................4

1 Scope and application

• Track speed limits

EP 08 00 00 03 SP Overhead wiring base safety and operating standards

2.1 Australian and international standards

2.2 RailCorp documents

• 3m of live exposed 1500V equipment

5 Maintenance of overhead wiring to design

If the track is positioned outside of tolerances, it may be necessary to temporarily adjust

Parameter Maintenance tolerances to design

6.1 Contact wire material

• Cadmium copper – Nil

Settings of relevant dccb’s shall be checked, and adjusted where necessary, in

6.2 Contact wire wear

• Pull off arms

6.2.2 Contact wire condemning size

• A minimum factor of safety of 2.0 at the limit operating conditions

Condemning Section area at

Condemning Section area at

6.2.3 Removal of localised contact wire wear points

6.2.4 Contact wire elastic limits

Refer to EP 08 00 00 02 SP for the identification of contact wires and the applicable

Elastic limit Section area at

Elastic limit Section area at

7.1 Catenary splices

Splicing of 510mm2 catenary shall be done by terminating the conductors, installing a

7.2 Contact splices

12 Wood pole support structures

13 Corrective maintenance triggers

Cracked or chipped porcelain 3 months

Excessive pollution build up 6 months

Corroded cap or tongue 3 months

Insulator skirt clearance above in running contact wire –

Small parts Signs of excessive corrosion, deformation (bending, cracks),

Loose, missing or corroded fasteners that are not critical to

Vegetation Vegetation within the clearance envelopes specified in section 6 months

Static clearance (normal) < 150mm 3 months

Static clearance to non-conductive material (eg non-reinforced

Vertical clearance from catenary to overline bridge less than

Missing, obscured or wrong information on signs due to

Table 7 – Corrective maintenance triggers - General

Note 2 – Passing clearance to pantographs may be analysed and determined by the

Signs of conductor stranding, annealing, burning, abnormal wear,

Catenary / contact alignment across track at a dropper > 20% of

Clearance of span wire above in running contact wire (without

Clearance between 2 parallel wires of different electrical sections

Clearance to HV aerial lines less than that stipulated in

< 4.75m in open route 6 months

(Note 1) Contact wire height less than minimum stipulated in

Signs of poor running performance such as arcing, burning and

Table 8 - Corrective maintenance triggers – Conductors