L1-NAM-InS-025 - Design Requirements For Traction Bonding Plan

DESIGN PRACTICE NOTE
DESIGN/REVIEW REQUIREMENTS FOR TRACTION

BONDING PLAN
L1-NAM-INS-025 Version: 1 Effective from: 1st April 2014
Approval
Amendment Record
Approval Date Version Description

01/04/2014 1 Initial Issue under MTM
Approving Manager: Chief Engineer Approval Date: 01/04/2014 Next Review Date: 01/04/2016
PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION Page 1 of 7
BONDING PLAN
Table of Contents
1. Purpose .......................................................................................................................... 3
2. Scope .............................................................................................................................. 3
3. Abbreviations and Acronyms........................................................................................ 3
4. Definitions and Responsibilities ................................................................................... 3
5. Background .................................................................................................................... 3
6. The Issue ........................................................................................................................ 4
7. MTM Requirements ........................................................................................................ 4
8. Related Documents........................................................................................................ 5
9. References and Legislation........................................................................................... 5
10. Appendix A: Additional Clarification of Traction Power Bonding. ............................. 6
11. Appendix B: Additional Clarification of Signalling Impedance/Cross Bonding ........ 7
BONDING PLAN
1. Purpose
The purpose of this document is to clarify MTM requirements relating to the design and
installation of track bonding to ensure that both signalling and traction return current
functionalities are achieved safely.
2. Scope
This document applies to the design and installation of track bonding on the Infrastructure
Lease for maintenance, renewals and project works. The scope has two parts being:
the process to be followed by designers, design reviewers and installers; and,
the technical requirements to be incorporated into the design and installation.
3. Abbreviations and Acronyms

VRIOGS – Victorian Rail Industry Operators Group Standards
ARO – Accredited Rail Operator
MTM – Metro Trains Melbourne
4. Definitions and Responsibilities

The following persons are to note and comply with the terms of this Design Practice Note;
Signal Designers
o To incorporate requirements into all new designs
Project Managers
o To ensure requirements are incorporated into all design scope of works.
Electrical Network Staff
Signal Maintenance
Network Asset Managers
Signal Design Reviewers
Signal Design Approvers
Traction Power Engineer – To review and approve.
Traction Bonding Plan means “Track Circuits, Bonding and Signalling Apparatus Plan”.
5. Background
The “Track Circuits, Bonding and Signalling Apparatus Plan” is a vital safety critical
drawing which identify the types, length, locations of track circuits, insulated rail joints, rail
bonding, connection, cable routes, positioning of cable track crossing, cable pits, layout of
points, positioning of signals, train stops, TPWS and, where appropriate, the axle counters.
This plan also identifies the exact positioning of equipment boxes which permits an
opportunity to assess maintenance access to equipment along the corridor.
BONDING PLAN
The rails are used for the return path for the 1500 V DC power for the trains. The bonding
for traction return current is essential for the protection of personnel from electrical shock
and the protection of the overhead wiring asset.
The requirements for designing and installation of bonding from signalling and electrical
traction perspective are clearly spelt out in VRIOGS 010.7, VRIOGS 012.0, VRIOGS
012.1, VRIOGS 012.2 and Standard Drawing STD_G0097.
MTM Standard MEST 000002-05, Track Bonding For Signalling And Traction Return
Current will supersede the VRIOGS and Standard Drawing as specified on its issue and at
that time this Design Practice Note will be revised accordingly.
6. The Issue
In general the concept of bonding from a signalling perspective is understood and
compliant with the requirements contained within VRIOGS 010.7, VRIOGS 012.0, VRIOGS
012.1, VRIOGS 012.2 and Standard Drawing STD_G0097.
Signalling designers are required to fulfil the requirements relating to traction power
contained within VRIOGS 010.7 and Standard Drawing STD_G0097 when designing
bonding systems and in some of the cases this has become a major concern and a serious
safety risk, compromising the protection of the 1500 V overhead wiring.
Confusion exists between the bonding requirements for a substation and for a tie station. In
both cases the provisions of VRIOG 010.7 and Standard Drawing STD_G0097 shall be
complied with.
During the design phase, The “Track Circuits, Bonding and Signalling Apparatus Plan” is
not being reviewed by a Traction Power Engineer to ensure compliance with VRIOG 10.7
and Standard Drawing STD_G0097.
A recent incident occurred where no protection for the 1500 V overhead wiring was
considered as part of the design in accordance with VRIOG 010.7 and Standard Drawing
STD_G0097. The issue was only identified by MTM at the time of the final commissioning.
It is essential that any issues associated with non compliance to VRIOG 10.7 VRIOGS
012.0, VRIOGS 012.1, VRIOGS 012.2 and Standard Drawing STD_G0097 shall be
identified prior to the design release for final review.
7. MTM Requirements
From the date of this Design Practice Note the following procedure shall be adhered to;
A) A Competent Signal Designer shall complete a traction bonding plan design as per
the requirements of VRIOG 10.7, VRIOGS 012.0, VRIOGS 012.1, VRIOGS 012.2
and Standard Drawing STD_G0097. Assurance shall be provided that all the
requirements of the Accredited Rail Operator’s (ARO’s) Safety Management
System, including operational and functional requirements and the appropriate
standards, have been met.
B) The design shall be Independently reviewed for its functionality, maintainability,
reliability, constructability and compliance with the requirements of VRIOG 10.7,
VRIOGS 012.0, VRIOGS 012.1, VRIOGS 012.2 and Standard Drawing STD_G0097
by the contractor from both a signalling and traction power point of view. The
Contractor shall provide clear certification to the ARO as an evidence for the proof
of engineering.
BONDING PLAN
C) The design is to be released to MTM Engineering for the purpose of the ARO’s
design review process. MTM Signal Engineers shall ensure that overall Safety in
Signalling Design and Quality Assurance is considered by the Contractor. MTM
Signal Engineers shall also ensure that compliance to relevant standards through
the MTM design review process has been considered. The design shall also be
reviewed by a MTM Traction Power Engineer to ensure compliance to VRIOG 10.7
and Appendix A including other associated system requirements from a traction
power point of view.
D) Upon approval by MTM Engineering the design shall be checked against any
existing DC circuit breaker settings to ensure protection of the 1500 volt distribution
network is included.
E) All relevant parties shall then be informed that the design has been approved prior
to release. (Issued for Construction)
Refer to Appendix A and Appendix B of this document for further clarification to standards.
Note: If at any stage, it has been deemed that the process in Section 7 has not been
followed and/or the design has been identified to not comply with the requirements of
VRIOG 10.7, VRIOGS 012.0, VRIOGS 012.1, VRIOGS 012.2 and Standard Drawing
STD_G0097, the design shall be rejected and returned to the Contractor for review,
correction and re-submission.
8. Related Documents
MEST 000002-01 – Engineering Standard – Design Traction Substations and Tie Stations
VRIOGS 010.7 – Track Bonding, Track Circuit Connections and Traction Interfaces
VRIOGS 012.0 – Victorian Signalling Principles
VRIOGS 012.1 - Standard for Signalling Design and Documentation
VRIOGS 012.2 - Specification for Signalling Supply, Construction and Installation
Standard Drawing STD_G0097
9. References and Legislation

AS/NZS 3000 – Electrical Wiring Rules
AS 2067 – High Voltage Installations
ASNZS 3008.1.1-1998 Electrical installations - Selection of cables
EN 50122-1 - Earthing, Bonding and the Return Circuit
BONDING PLAN
10. Appendix A: Additional Clarification of Traction Power Bonding.
(a) Electrical Traction Substations/ Tie Stations: -

In principle the bonding requirements from inside the substation/tie station building to
the rail are the same; both require a connection to the rails for protection circuit
settings and operational safety. The only difference is in the cross-sectional area and
the number of bonding cables required.
Substations require the above bonding to allow,

The operation of circuit breaker control circuits, requiring minimal DC currents
Safety earthing of circuit breaker cubicles
Traction load currents of 3000-4000amps magnitude to return to the supply point
Tie stations
A tie station contains only circuit breakers that connect two different 1500V DC
electrical sections together to provide electrical protection. The track bonding at tie
stations is not designed to carry heavy traction return currents, the bonding is to allow;
The operation of circuit breaker control circuits (as in substations)
Safety earthing of circuit breaker cubicles (as in substations)
The bonding also covers short duration (milliseconds) short circuit fault currents
should an internal fault occur on the tie station DC switchgear.
Bonding from the Impedance bonds to the substation negative pillars (and the rails), or
from the impedance bonds direct to substation buildings must be by means of 95 mm 2
aluminum conductors unless written approval is given in the form of a Standard
Waiver.
(b) Track side bonding

In all instances, unless written approval is given in the form of a Standard Waiver, 300
mm2 aluminum cables shall be used for;
Connection to rail from impedance bonds
Current equalizing jumpers between rails
Voltage equalizing jumpers between tracks
Power bonding around any special work or junctions
The location and other requirements are clearly spelt out in VRIOG 10.7 and the
Standard Drawing STD_G0097
BONDING PLAN
11. Appendix B: Additional Clarification of Signalling Impedance/Cross Bonding

Track Circuits, Bonding and Signalling Apparatus Plan should also cover the Impedance
and Cross bonding information unless produced as a separate drawing. The principles and
the detail of the traction bonding, Impedance and Cross bonding to be followed is as per
MTM Standards on Traction Bonding along with all relevant VRIOGS. Positioning of air-
gaps should also be shown in the Track Circuits, Bonding, and Signalling Apparatus Plan.
Necessary site correlation is to be undertaken prior to the alteration of the effected design.
A Correlation report is to be submitted to the Engineering Group along with the Track
Circuits, Bonding, Signalling Apparatus Plan for review and audit.

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DESIGN PRACTICE NOTE

DESIGN/REVIEW REQUIREMENTS FOR TRACTION

Approval Date Version Description

3. Abbreviations and Acronyms........................................................................................ 3

4. Definitions and Responsibilities ................................................................................... 3

6. The Issue ........................................................................................................................ 4

7. MTM Requirements ........................................................................................................ 4

9. References and Legislation........................................................................................... 5

10. Appendix A: Additional Clarification of Traction Power Bonding. ............................. 6

11. Appendix B: Additional Clarification of Signalling Impedance/Cross Bonding ........ 7

3. Abbreviations and Acronyms

4. Definitions and Responsibilities

9. References and Legislation

10. Appendix A: Additional Clarification of Traction Power Bonding.

(a) Electrical Traction Substations/ Tie Stations: -

Substations require the above bonding to allow,

(b) Track side bonding

11. Appendix B: Additional Clarification of Signalling Impedance/Cross Bonding

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