Old Oak Common

RJ Power Rail has completed its electrical and mechanical decommissioning contract works on behalf of Principal Contractor Colas Rail, for the Stage 2 and 3 decommissioning of Old Oak Common Depot. The scope also included civil engineering activities such as Under Road Crossings (URX’s), Ducting and Troughing Route works and Protective Barrier installation works.

As part of Phase 1 of the HS2 rail network, a new interchange station is being constructed at Old Oak Common to provide a rapid and convenient access for passengers between High Speed 2 (HS2), Crossrail and the Great Western Main Line (GWML) services.

The site, which is occupied by both Great Western (GWR) and Heathrow Express (HEx), required decommissioning and was a critical piece of work for the overall HS2 programme in order to facilitate the commencement of the HS2 enabling works associated with the GWML.

The works included four Sub-Stations:

  • Sub-Station B1
  • Sub-Station B5
  • Sub-Station T
  • Sub-Station S

and a number of 6.6kV HV Feeders:

  • Cable 43A
  • Cable 43C
  • Cable 44
  • Cable 45

In order to achieve the space requirements for the OOC interchange station, the relocation of GWR and HEx services from the existing Old Oak Common Depot was necessary.

A number of challenges were faced, however, RJ Power Rail’s capabilities in the multi-disciplined and HV market, combined with its ability to offer additional works and engineering input made it the ideal contractor for this project. With vast experience as a Tier-2 contractor for major schemes, RJ Power Rail offered a consistent, reliable and flexible service, through exceptional expertise and proven project delivery.

RJ Power Rail commenced its works in December 2018, decommissioning the Depot in a number of stages, in order to ensure that operations were maintained. RJ Power Rail’s works covered Stages 2 and 3 (which in the end were combined) and successfully completed all of its works in May 2019.

The successful delivery of the project enabled the undertaking of the next stage of HS2 works – a project with the promise of developing a faster and more efficient rail network for the UK.

Project Deliverables

RJ Power Rail’s work scope included providing all necessary stakeholder management and permits to work for the project and consisted of the following deliverables. All works were fully tested and commissioned and involved the provision of all necessary hand back and handover documentation including certificates and redline drawings for as-built purposes:

Mechanical Works

  • Decommissioning and isolation of gas supplies within depot, including purging pipes and cutting sections of pipes
  • Decommissioning and isolating of the lubricating oil, diesel oil, and coolant pipe supplies within the depot, including draining down reservoir tanks and pipes and also cutting pipes
  • Isolation of water supplies to the water tower at water meters and supply to the HST shed
  • Isolation of depot fire hydrant pipework system back to the first fire hydrant located at depot entrance ensuring this hydrant remains operational
  • Decommissioning of compressed air supply and associated equipment in HST shed
  • Diversion of the water supply to the Heathrow Express train wash shed – this also included:

Civil Engineering and groundworks for the relocation of the water meter covering:

  • Under Road Crossing (URX) complete, including excavation and reinstatement
  • Installation of access chambers and buried routes using 150mm ducting
  • Installation of buried routes using C/1/9 trough
  • Installation of C/1/9 surface laid trough routes
  • Installation of protective barriers

Electrical Works

  • Isolation and decommission of LV supplies to multiple equipment located in all parts of the depot.
  • Decommissioning of LV supply transformers
  • Diversion and installation of existing and new LV cables to points heating control cubicles and the Heathrow Express train wash shed
  • Installation of new lighting columns, associated cabling, column bases and route works, including concrete troughing and buried ducting
  • Relocation of points heating control panel, track side boxes, 110v transformers. Installation of concrete bases associated cabling and route works
  • Decommissioning and recovery of points heating equipment for track plain lining
  • Isolation and diversion of the high voltage 6.6kv ring main circuit
  • Installation of new HV cable, jointing of HV cable, testing and commissioning
  • Spiking and recovery of redundant HV cable
  • Isolation and slew/diversion of the HV 25kv OHL feeder cable into new route

This also included the following:

Civil Engineering Works

  • Installation of raised Armco GRP trough and concrete trough route for containment of 6.6kv ring main and 25kv

Challenges and Solutions

Site Logistics

During the works, careful logistical traffic management was implemented by RJ Power Rail, with all deliveries being pre-planned and sequenced in accordance with a Traffic Management Plan. All vehicles accessing the site had to be in line with the directives given by the site Traffic Marshals.

All plant/pedestrian interfaces had to be managed around the nominated site storage and parking areas too. To combat this, segregated walking zones were created and a Banksman was present during the transportation and lifting into position of all materials for the works.

Stakeholder Interface

RJ Power Rail faced challenges with the timescale of this project due to the number of different project interfaces during the course of these works. With the works being of a multi-disciplinary nature and with multiple contractors needing to negotiate access arrangements, RJ Power Rail’s team needed to be extremely flexible and work collaboratively with others, when approaching and delivering key milestones in their programme.

This liaison was particularly important, as the electrical and water supply services were still required to be available within the depot. RJ Power Rail carefully interfaced with the Colas Rail team, Heathrow Express and GWR in order to programme and plan a phased decommissioning and diversion of the services, so as to ensure as little disruption as possible.

Unknown Buried Services

The project was further challenged, when it was found that the civils design through the depot access road was not achievable, due to the presence of a large amount of unknown buried services and the radius bend of the existing waterpipe.

RJ Power Rail proposed to move the excavation to one side of the access road, away from the middle of the road, allowing the road to remain partially open, which also gave enough distance from the existing buried surfaces and allowed the excavation to run straight rather than stagger around other buried services. This in turn made the installation of the water pipe easier, due to the fact that it could only change direction by an angle of either 45° or 90°.

Roadway Construction

The road plates were required to sit flush to the road to eliminate tripping hazards. To achieve this the design showed a 45mm recess to be broken out either side of the excavation, with a 20mm cementitious grout laid for the steel road plates to sit on. Due to the composite construction of the road this proved to be unachievable due to the amount of re-bar present.

RJ Power Rail provided a solution that involved excavating the full width of the road plates, applying shuttering to either side of the trench width and then building back up to the recess level, in order to achieve a flush road plate.

The design also showed the excavation connecting onto an existing oil/diesel pipe trench, however, during the works, the trench was found to be full of diesel and oil.

RJ Power Rail resolved this by core drilling through the walls of the existing trench to allow the waterpipe and 6.6kv HV cables to divert over the diesel and oil. This enabled the excavation to continue and run parallel with the oil trench, until such a time when it could be diverted and then connected back to the originally designed route.

6.6kv Ring Main and 25kv HV System

The diversion of the 6.6kv ring main and 25kv OHL high voltage system was an extremely challenging undertaking.

Old Oak Common Depots’ electrical distribution is fed from a vast network of 6.6kV substations (B5, B1, T, S, D and E) in the form of a ring main derived from an 11kV Scottish and Southern Energy (SSE) supply. The ring main is operated with a normally open point as two radial 6.6kV circuits of which the HV switching equipment was locally controlled/operated with no indication or operation control from the railway electrical control room.

The two traction 25kv OHL feeder cables originated from Kensal Green Feeder Station and terminated at structure J/05/125 in the Hex depot and were affected by the Stage 3 works, with both cables running in parallel for the entire length.

One of the two 25kV cables is a feeder cable carrying traction current from Kensal Green Feeder Station section KAGA/805/HV/L and terminated to the sealing end of structure J/05/125.

The other 25kV cable is a traction return cable from Kensal Green Return Current Bus Bar (RCBB) section KAGA/HV/805/N and terminated on spider plate SP/05/101.

This complex HV power arrangement, necessitated the need for alternative HV feeds for both the 6.6kv ring main and 25kv OHL HV circuits to enable continuous supply to the railway infrastructure while the diversions/slewing of the HV cables were also undertaken.

RJ Power Rail’s highly qualified substation level `A`, liaised closely with the substation maintainer, electrical control room and Scottish and Southern Energy, to produce a clear and defined sequence of HV switching operations, for both the 6.6kv ring main and the 25kv traction cables, which enabled a continuous high voltage supply to the operational railway whilst works were undertaken.

The Benefits

RJ Power Group’s collaborative working approach allowed seamless integration into Colas Rail’s S&C Alliance practices.

As a vastly experienced, multi discipline and High Voltage service provider, RJ Power Rail was able to call on its expert knowledge to provide consultation on design and delivery elements of the project.

This extended to best practice advice, following an unexpected cable outage at the project. RJ Power Rail’s project team organised and presented an HV awareness presentation to Colas Rail, advising on all necessary standards and applicable guidelines.

Testimonial

“RJ Power Rail’s project and engineering teams pulled out all stops to ensure this electrification support project was delivered on time and to specification. In addition to this, the team worked collaboratively with us to support changes in design and perform additional works that will benefit the wider scheme.

“I would like to thank all involved for their efforts in this completing this project.”

Joseph Smales
Project Manager – Infrastructure
Colas Rail

Great Western Modernisation Earthing and Bonding

RJ Power Rail were engaged by long-term partner Amey Rail and their Thames Valley Area (TVA) Project team, to install earthing and bonding systems for various trackside assets. The bonding systems were required to enhance the system protection by providing a sufficiently low impedance earth for Locations within the OLE ‘dewirement’ zone. This ensured that in the event of the OLE coming into contact with the location, that the traction return path can conduct the voltage for a sufficient time until the OLE system protective devices operate.

To complete the works, RJ Power Rail supplied 10 installation teams during the various stages of the project over approximately 100 linear miles covering a wide geographical area from Maidenhead to Bristol.

The Great Western Route Modernisation (GWRM) programme is tasked with the delivery of a 25KV OLE railway with more frequent/faster train services providing more seats and improved stations. In short, this represents the biggest investment for this part of the national rail infrastructure since it was first created in the 1830s.

This GWRM programme covers approximately 10 years of continuous railway infrastructure enhancement works inclusively of a number of major works such as Track Remodelling, Resignalling and overall Electrification.

Project Deliverables

RJ Power Rail deliverables were to carry out surveys to identify lineside assets and the review of designs for providing bonding Systems to be able to electrify the GWML Project. Our scope was to install all types of bonding systems, whether we were connecting to the existing Return Screen Conductor (RSC) using Pfisterer ground tap connections, 120mm bonding cables to extraneous metalwork, or Cross bonding from Spider Plates to Angle Cleats, RSC or to Track. Once the bonds were installed all torque settings were recorded, bonds fitted with heat-shrink markers and fitted with Traffolyte labels.

Pre-commencement stage

  • Undertake site surveys to identify assets that require bonding

Implementation stage

  • Installation and commissioning of lineside assets
  • Installation and commissioning of cross bonding change to the RAM

Challenges and Solutions

Multi-functional solution
Ensuring that a facility is properly grounded and bonded at the design and construction phase can reduce expensive downtime and equipment failure in the future. Most importantly, it can eliminate any potential safety issues.

RJ Power Rail provided optimal protection of personnel and facilities with earthing concepts that suited the client’s needs, including calculation rail potential and touch voltages.

Our earthing and bonding solutions ensured minimal electrical resistance, good corrosion resistance and the ability of dissipating high fault current effectively.

Why RJ Power Rail

RJ Power Rail provides design, installation and commissioning expertise for of all types of earthing and bonding systems including sub-station earthing. This is prevalent when it comes to “Hot Sites” which are locations where the voltage between the sub-station and or switching station earth bar and the local earth (UTE), exceed a defined voltage limit (UTE MAX), during a phase-to-earth fault. RJ Power Rail can provide valuable support in both consulting and designing efficient earthing rectification covering:

Sub-Station Earthing – from early engagement and consulting with Network Rail Engineers, RJ Power Rail can design, install and commission all types of earthing arrangements from “Hot Site” rectification, to new installations using the standard methodology of driving earth rods into the ground utilising pneumatic drivers, to core drilling and installing earthing systems using Marconite Conductive Concrete.

Bonding – from new installations to maintenance of existing systems in predominantly 25kV areas, RJ Power Rail can design and install all types of bonding systems whether it be connecting from the existing Return Screen Conductor (RSC) using Pfisterer ground tap connections or connecting 120mm bonding cables to extraneous metalwork.

DC Cable Doubling Wessex

This DC cable renewal project involved the installation, testing and commissioning of new DC Cables which was derived from the DC Cable Refurbishment Woking – Basingstoke Route Requirements Document issued by Network Rail (NR).

RJ Power Rail were invited to competitively tender and subsequently secured the full scope of works for the renewal and modification of DC LV Cables and the doubling of identified +ve cables at the Open Route sections/locations between St Johns and Barton Mills Sub-Stations.

The line of route between St Johns (near Woking station) and Barton Mill (near Basingstoke Station) on the Bournemouth Main Line was identified as being at particularly high risk of failure, hence the urgent requirement for this project. The third rail electrification system in NR’s Wessex area has large number of DC distribution cables used as part of its traction power system. The age and condition of certain cables and problems with the reliability of lugs has resulted in failures impacting directly on train performance.

RJ Power Rail’s contract covered replacement and modification work on positive DC cables to enhance traction power performance in this area, increasing the life expectancy of the cables and reducing the amount of future faulting work for NR’s maintenance teams.

During the first part of the works, cables and cable lugs were provided free-issue. During the second part of the works, RJ Power Rail supplied all materials for the works. All materials were delivered to the RJ Power Rail secure facility, which allowed the rail team to deliver a fully logistically managed solution.

Works, which were fully managed and self-delivered by RJ Power Rail’s in-house team, required completion during TIII possessions, requiring full access planning and arrangements in conjunction with NR’s Works Delivery Team.

The project was successfully completed to meet Network Rail’s requirements.

Project Deliverables

The scope of works was to survey, produce detailed reports and install new 750v DC Traction cables at various locations between St Johns Substation to Barton Mills Substation stretching over 20 linear miles:

Pre-commencement stage

  • Undertake site surveys of 4 operational lines along 20 linear miles (26m 00ch to 46m 00ch)
  • Update Network Rail’s existing conductor rail drawings
  • Compile a detailed asset report of the existing infrastructure to allow NR Works Delivery to manage scope
    change to the RAM

Design stage

It was agreed with Network Rail that this particular project would not require the usual Form A & B design process as the works entailed replacing existing infrastructure. The scope would be, therefore, defined by the workbank reports and the updated conductor rail drawings. This process was agreed by the Network Rail RAM and project team.

Implementation stage

  • Surveys
  • Produce survey data reports
  • Production of DC Traction cables
  • Installation of DC Traction cables
  • Test and produce relevant ITP’s
  • Hand back

Challenges and Solutions

Critical planning

All the works associated with this project required TIII possessions. As there were not enough 27hr or 52hr possessions, most of the works had to be delivered in mid-week night possessions providing a maximum of 3hrs clear working time. The works involved were super critical, due to the number of previous failures within the infrastructure. The RJ Power Rail Access Team and the Network Rail Possessions Access Manager worked collaboratively to ensure an achievable programme was developed.

Logistics management

RJ Power Rail took delivery of approx. 40 cable drums that were free issued from Network Rail. These cable drums were delivered into RJ Power Rail’s own secure depot facility. All the drum numbers and their locations were attributed to a ‘workbank datasheet’ to provide full supply and installation traceability. The second part of the project required RJ Power Rail to supply the materials and log them in the same method.

Using the workbank datasheet, all the cables were then cut to the required length and one end of the cable was lugged in readiness. These cables were then palletised and numbered relating to the mileages and the route numbering scheme.

The site team then loaded the pallets onto our lorry and delivered them to the site on a ‘just in time’ basis prior to the possession.

Delivery knowhow

Given the tight time constraints of the access regime, the experienced in-house team led by Adam Lovegrove were able to deliver and install on average 15 cables per week. This quantity, in restricted locations and during small possession durations, could only have been achieved with the years of knowledge and experience that the RJ Power Rail Team has.

Why RJ Power Rail

RJ Power Rail has an established Team that combines design, engineering and delivery expertise across all rail electrification activities and can be trusted with the most complex and demanding of projects.

The company offers the full range of rail electrification and power services from one-off cable repairs to multimillion-pound HV, LV and Scada D&B projects.

They are an experienced power solutions delivery provider who work collaboratively with their clients and own supply chain as a reliable partner, providing exceptional expertise and proven project delivery in respect of HV Electrification and DC Switchgear schemes.

Installation of New Cast Resin Transformer and Housing, Ring Main Unit and associated HV cabling at Plantation place

The Networks Team recently completed an extremely challenging project for CBRE as a preferred supplier within Plantation Place at 30 Fenchurch Street, installing a new Cast Resin Transformer and Housing, Ring Main Unit and associated HV cabling.

Project Deliverables

RJ Power Networks scope of works included the following:

  • Prelims works
  • Supply and installation of a Ringmaster RMU RN2c T2
  • Bus bar Modifications (Subject to Transformer Construction Drawings)
  • HV Cable Terminations of all equipment and the supply of adequate Materials to complete the job
  • Transformer Internal HV Connections
  • Supply of adequate Earthing
  • Containment/bespoke Monoblock fabrication
  • Labour to install, test and commission
  • Supply and management of lift and shift Sub Contractor labour
  • Project Management
  • Mobile access equipment supplied to enable the construction of TX housing and Bespoke Busbar fabrication
  • Supply and management of UK Power Networks attendance

Challenges and Solutions

The Networks team faced many challenges during the process of this project, with one of the most demanding aspects being the logistics of the sequenced changeover, the removal process and positioning of the replacement equipment within a third basement level, as it was only achievable via a lift shaft and a narrow corridor system.

Due to the difficult nature of the plant movement process, the job required a collaboration of specialist contractors to achieve a successful outcome, with all demonstrating their skills to achieve the highest level of engineering competence.

The plant movement was completed by Radius, with the process of removing the old transformer and installing the new transformer commencing at the top of a lift shaft. The old transformer needed to be lifted two floors where it was temporarily stored in the clients carpark. The new replacement transformer was manoeuvred down to the basement using the same lift path. These works had to be completed in a 24-hour window, which was extremely challenging to all involved, and required a lot of pre-planning between the Networks team, Radius and the client for the plant movement to be a complete success.

A bespoke LV Busbar Chamber and 4000A LV Busbar had to be manufactured off site, this was an extremely challenging process as the Networks team were unable to determine the exact measurements of the transformers LV connections. RJ Power Networks panel fabrication and Copper specialist, Darren Young, executed this task faultlessly and the equipment installed was inch perfect.

The team were faced with a miss delivery of parts by the manufacturer. The HV Bushings and HV Termination Box, which bolted onto the transformer housing, was not included on the original delivery from the manufacturing warehouse in France. It was only discovered that these essential parts were missing midway through the project, as a result the team were put under extreme pressure to locate the missing parts to ensure the job was kept to the extremely strict and tight schedule of works. After intense conversations with the supplying manufacturer the parts were located in the warehouse and delivered from France via a specialist courier service, which worked through the night to ensure the parts arrived to us on a next day delivery before the energisation phase of the job took place. The manufacturer really performed and understood our clients needs to ensure the project did not slip behind schedule.

The new equipment needed to be installed during the week without any interruptions to the client’s day to day running of its multi tenanted building. The method of installation had to be revised numerous times until RJ Power Networks identified a solution to all of the issues that had been originally encountered.

The overall job went extremely well, the extraction of the old transformer and installation of the new was a success and a great achievement for all staff and contractors involved. Most importantly the client was extremely happy with the end result.

Thank you to the RJ Power Networks team as well as all of our specialist contractors used to complete this job. The project ran smoothly despite the demanding logistics.

Why RJ Power Networks

RJ Power Networks undertakes a range of installation, of HV to LV equipment in private distribution networks, as well as maintaining existing HV and LV equipment, making us the ideal company for this project.

We continually strive to offer a consistent, reliable and efficient service to all of our clients and future clients. The Networks divisions is a business led by passionate individuals that care about the quality of the work produced, and retaining collaborative and sustainable partnerships, with the ultimate goal of securing customer loyalty and forging strong long-term business relationships.

Refurbishment of 2 No Existing 6.6kV/433V Substations

RJ Power Networks’ (RJP) team has completed a total refurbishment of 2 No existing 6.6kV/433V substations at the Victoria and Albert Museum (V&A).

The existing HV switchgear within substation B at the V&A was past its operational life cycle and obsolete in regard to obtaining spares. The upgrade works to the substation were designed to form part of the reinforcement of the existing HV network to accommodate any future site load increases.

The V&A is the world’s leading museum of Art and Design, housing a collection of around 2.3 million objects spanning over 5000 years of creative history. The museum attracts visitors from all over the globe and is an iconic part of London’s make up. We are proud to have been chosen to deliver this project for them.

PROJECT DELIVERABLES

The overall objective of the project was to replace all the equipment to the very latest specification to be able to accommodate any future load increases, with the minimum of disruption to the V&A’s busy schedule.

RJ Power Networks proposed solution included the following works:

  • All associated High Voltage Switching to ensure minimal interruption to the museum
  • Phased removal of existing switchgear
  • Organisation of adequate red route road closures
  • Organisation of entire lift and shift activities
  • Carry out all associated fabric works to aid in a smooth deliver for the lift and shift aspect of the project.
  • Organisation of the manufactures attendance to site to build, test and commission the transformers and ring main units
  • High voltage cable replacement, terminations and associated pressure testing
  • Associated low voltage cable works
  • Upgrade of the substation earthing system to ensure adequate resistance to earth
  • Installation of substation EPO circuit
  • Associated Site Acceptance Testing
  • Upgrade of substation lighting
  • Substation compliance works (first aid kit, appropriate Health and Safety signage etc)
  • Painting of substation walls, ceiling and floors
  • Safe removal and disposal of hazardous waste
  • Issue of Operations and Maintenance manual on job completion

THE CHALLENGES AND SOLUTIONS

The project duration was four weeks and at no time was the public access to the museum to be affected, as it was scheduled to run over a school holiday which is peak footfall times for the museum. With this in mind, there was only allowance for minimal shutdown times, with each shutdown to be completed overnight on Sunday to the early hours of Monday morning – with one shut down providing the Networks team only two hours to complete all live testing, commissioning and HV switching.

The logistics of the project meant the project was extremely challenging, the team had to work with the equipment suppliers and our logistics and plant movement company, DSM Ltd, to create a bespoke installation solution involving multiple challenging lifts with a crane – with little room for error (40mm). This also proved challenging when it came to the transportation of the team’s own materials and equipment down to the moat.

The use of the crane for the project required two road closures of Cromwell Road to be able to operate the crane safely, however the scheduling of the road closure took extensive prior planning and cooperation between RJ Power Networks, Royal Borough of Kensington and Chelsea council and the museum to be able to organise a date and time that suited all parties. Both road closures were a success and the lift and shift completed by DSM Ltd was outstanding.

As a result of the tight space and unique installation plan, the RJ Power Networks Team had to organise the two transformers to be shipped and delivered in parts. Each transformer had to be manoeuvred through a single door opening with 20mm clearance. The manufacturers were then required to attend site to build, fill with oil, commission and hermetically seal the two transformers in situ within the substation at the V&A Museum.

RJ Power Networks teams’ extensive planning and preliminary works that took place enabled the project to run without delay or failure, the team were successful implementing this plan and as a result the job ran smoothly.

Special praise to Callum Turner the lead Project Engineer, for the well organised and executed job. The Victoria and Albert Museum job was completed to the high standard that is both expected by our client and always delivered by the RJ Power Networks team.

TESTIMONIAL

“The V&A museum commissioned the design of a complete refurbishment of 2 No existing 6.6kV/400V substations. RJP provided pre-construction advice and supported the client’s design team during the design development stages of the project.

“Following the contract award, RJP were quick to mobilise and provide the necessary CDM advice and documentation. The projects’ budgetary constraints meant that it was necessary to separate the equipment procurement from the execution of the works; which RJP supported and delivered the project over two financial terms.

“RJP; unprompted provided all necessary construction documentation to the clients team; avoiding the need for a protracted approvals process at the critical stage of the construction programme.

“The installation of the transformer was a challenging operation and RJP worked with their logistics company to provide a bespoke equipment installation solution; meeting the requirements of the local authority and addressing the client’s concerns with respect to the moving of equipment close to the listed building fabric. The Midel filled Transformers were installed in the constrained substation in modular form and reassembled by the specialist equipment supplier; who provided full testing certificates.

“The installation of the 2 No. 800kVA Transformers and associated Ring Main Units was executed and delivered on time and on budget. Importantly the replacement of the equipment resulted in only a minimal programmed isolation of the electrical supply to the building.”

Mark Freeman
JRG Electrical Consulting

WHY RJ POWER NETWORKS?

RJ Power Networks undertakes a range of installation and maintenance works, from control cabling through to the provision of high voltage ring-main systems in private distribution networks, as well as maintaining existing HV equipment, making us the ideal company for this project.

We continually strive to offer a consistent and reliable service to all of our clients and future clients, as Networks is a business led by passionate individuals that care about quality, environmental processes and procedures and developing collaborative and sustainable partnerships, with the ultimate goal of securing customer loyalty and forging strong long-term business relationships.

Emergency Replacement of LVAC Panel

RJ Power Rail (RJPR) has successfully installed, tested and commissioned a Technivel panel, which included providing a design for re-routing the cables, for this LVAC panel at Streatham substation on behalf of Network Rail (NR).

The rail team provided a tender and were subsequently awarded the LVAC panel replacement works, which came about as a result of a catastrophic failure to NR’s Allen West LVAC panel located in Streatham substation’s A rectifier room, which is being fed by 2No 415V supplies derived from the 33kv network and 1No 415V back up supply from the DNO.

The proposed replacement Technivel LVAC panel was actually a decommissioned panel located in Lewisham substation and due to the serious nature of this failure, RJPR immediately mobilised in order to assess both the condition and suitability of the pre-used Technivel panel. On confirmation, RJPR formed their design and constructability teams within just 48 hours, met with NR to agree the action plan and commenced their Form B E&P design.

The plan was to disconnect and remove the pre-used panel from its original location in Lewisham and install in Streatham substation’s HV switchgear room. Incoming supplies to the LVAC panel were derived from AT516, AT552 and a DNO isolation transformer. Incoming supplies were rated 140kVA, 200A. The new Technivel LVAC panel was rated 300A.

Logistics at both ends were always going to be a challenge for this emergency replacement. By utilising machinery and equipment removal specialists, due to the panel size, weight and shape, RJPR were able to effectively manage the movement of the panel at both ends, with minimal impact on other adjacent stakeholders.

Once the panel was at Streatham, RJ Power Rail’s Testing and Commissioning Engineers took control and commenced the important task of stripping down and testing the panel. After a period of intensive work, it was determined that the panel was in good condition. After the replacement of all BS88 fuses and the tightening of all the busbars the panel was ready to be connected.

The only route for the supply cables from the transformers to the LVAC panel were at high level on an existing ladder tray. With the ground beneath uneven, the erection of GRP scaffolding to allow existing supplies to be removed and new cables to be installed was also challenging. Once in place, the RJPR installation team laid all new cable route to internal areas using ladder tray and then safely installed the heavy duty LV power cables on top of the ladder tray and along the external containment.

RJ Power Rail’s Lead Test and Commissioning Engineer (Peter Jackson) then formulated a complex and multiple staged changeover plan, in order to commission the LVAC panel and de-commission and make safe the existing damaged panel.

We are delighted to announce that all works were completed on time to an exemplary standard and to the complete satisfaction of the client Network Rail.

PROJECT DELIVERABLES

The project entailed the emergency replacement of a failed LVAC panel within Streatham substation B, without disrupting the railway or endangering personnel. RJ Power Rail’s scope included for the full Form B E&P design in respect of the collection, delivery, installation and commissioning of a freeissue Technivel LVAC panel at Streatham Substation. The existing Allen West LVAC panel at Streatham substation was also to be disconnected and removed.

RJ Power Rail’s delivered a fully risk managed staged solution, providing all necessary HV assessments and delivering a fully tested and commissioned project for entry into service, which included the following works:

Pre-commencement stage

  • Condition assessment at Lewisham substation of the pre-used LVAC Technivel panel to determine its suitability for use at Streatham
  • Lift, Shift and Delivery of the LVAC panel from Lewisham to Streatham substation
  • Stripping down and testing of the panel

Design Stage

  • Constructability assessments and Form B Design

Implementation Stage 1

  • Install the new Technivel LVAC panel.
  • Verify correct installation of LVAC panel control wires
  • Install all new cables
  • Terminate all new cables at the Technivel LVAC end
  • Terminate cable MC001 into the HV switchgear marshalling cabinet following disconnection and removal of the existing wiring
  • Carefully terminate cable MC002 into the Supervisory marshalling cabinet following disconnection and removal of the existing wiring
  • Pre commission the interface between the Technivel LVAC, the Selhurst ECR and the Streatham HV switchgear
  • Technivel LVAC panel 110V control supply is derived from 3No 750VA, 415/440 to 110V transformers

Implementation Stage 2

  • Confirm the Streatham PSP is supplied from PSP Supply No.1
  • Isolate AT552 LV in order to isolate PSP Supply No.2 at the Allen West LVAC panel
  • Isolate PSP Supply No. 2 at the PSP to prevent backfeed to the Allen West LVAC panel
  • Terminate the new 95mm2 cable “TX552-LVAC C2” at the AT552 secondary
  • Energise the Technivel LVAC panel from AT552
  • Divert the existing 70mm2 PSP Supply No.2 cable from the Allen West to the Technivel LVAC panel
  • Energise PSP Supply No.2 at the Technivel LVAC panel

Implementation Stage 3

  • At the PSP, changeover supply from PSP Supply No.1 to PSP Supply No.2
  • Isolate AT516 LV. This will in effect isolate PSP Supply No.1 at the Allen West LVAC panel
  • Isolate PSP Supply No.1 at the PSP to prevent backfeed to the Allen West LVAC panel
  • Terminate the new 95mm2 cable “TX516-LVAC C1” at the AT516 secondary
  • Energise the AT516 feed into the Technivel LVAC panel
  • Divert the existing 70mm2 PSP Supply No.1 cable from the Allen West to the Technivel LVAC panel
  • Energise PSP Supply No.1 at the Technivel LVAC panel

Implementation Stage 4

  • Divert Substation A domestic supply from the Allen West to the Technivel LVAC panel
  • Divert Substation B domestic supply from the Allen West to the Technivel LVAC panel
  • Isolate the DNO isolation transformer. Terminate the cable “DNO TX-LVAC C3” Into the isolation transformer secondary
  • Energise the DNO transformer feed into the Technivel LVAC panel

Implementation Stage 5

  • Disconnect and remove the Allen West LVAC panel

CHALLENGES AND SOLUTIONS

Critical planning
Due to the project criticality, the planning, programming and coordination of the works was jointly carried out by RJ Power Rail and Network Rail, which involved several workshops being organised to ensure that all aspects of the project were covered and agreed well in advance of the commencement on site.

Multi-functional works
RJ Power faced challenges with the timescale of this project due to the number of different project interfaces during the course of these works. With the works being of a multi-functional nature and with access arrangements being key, RJ Power Rail’s team needed to be extremely flexible and work collaboratively when approaching and delivering key milestones in their programme.

Design interface
The design complexities around the signalling interface, necessitated a staged approach. By completing a pre-commencement stage in advance of the design work and then five separate implementation stages, RJ Power Rail’s flexible approach, allowed the project to be effortlessly delivered, with a high degree collaborative interface throughout.

Logistics management
Careful logistical management in connection with the pre-used panel was required by RJ Power Rail. All deliveries were pre-planned in accordance with a detailed logistics and TM Plan. All vehicles accessing the site had to be compliant, and in line with the directives given by Traffic Marshals. All plant/pedestrian interfaces had to be managed around the nominated site area, with segregated zones provided and Banksman present during the transportation and lifting of the panel at both Lewisham and its final destination at Streatham substation.

Delivery knowhow
Poorly identified supervisory control, indication and alarm terminals also had to be identified with no drawings available for the 1950’s supervisory marshalling panels. Original LVAC panel wiring had to be identified and carefully removed through fragile wiring and terminals. When, new supervisory wiring was installed and tested, a supervisory fault was traced to a blown fuse in the supervisory, which was also replaced. A number of fuses were found to be missing from all outgoing ways, these were sourced quickly and replaced, this prompted the question of what else had been removed or interfered with whilst the unit was out of use, a thorough investigation revealed no further issues.

WHY RJ POWER RAIL?

RJ Power Rail has an established team that combines design, engineering and delivery expertise across all rail electrification activities and can be trusted with the most complex and demanding of projects.

The company offers the full range of rail electrification and power services from one-off cable repairs to multi-million-pound HV, LV and Scada D&B projects.

They are an experienced power solutions delivery provider who work collaboratively with their clients and own supply chain as a reliable partner, providing exceptional expertise and proven project delivery in respect of HV Electrification and DC Switchgear schemes.

Network Rail Sussex Renewals

The Redhill Platform Development Project was intended to develop a number of complimentary enhancements that, together, allow additional splitting/jointing of services at Redhill and provide additional resilience to facilitate operation of the proposed post-Thameslink K02 timetable.

In order to create this flexibility and increase train capacity at Redhill Station, an additional platform (referred to as Platform 0) was planned to be constructed. The new platform will be positioned over the current No.2 Up Siding, Snow Plough Siding and Up Siding Turnouts. The current Goods Loop will be converted to a passenger line (referred to as Up Loop 0) to allow trains to serve the new platform.

As part of the second stage of the Redhill Station redevelopment works, BAM Nuttall awarded RJ Power Rail the contract for the design, build, installation, test and commissioning of a new DC switchgear module at Holmethorpe substation. The aim is to provide additional resilience to the existing infrastructure and increase the operational flexibility by providing an additional DC circuit feed (B113) from both Holmethorpe and Redhill A substations to support the new Platform Zero and associated train services.

The contract to RJ Power Rail was awarded in September 2016 and was successfully commissioned into service December 2017.

Project Deliverables:

RJ Power Rail’s work scope had a number of key deliverables which relied on the experience of the operations and delivery team. These included:

  • The design, build, installation, test and commissioning of a new DC switchgear module at Holmethorpe substation including craneage
  • The procurement of DC switchgear equipment from Hawker Siddley switchgear and SCADA equipment from Sella Controls for supply and fitment into the purpose-built module fabricated by Bradgate containers
  • Providing a separate DC circuit feed from both Holmethorpe substation and Redhill A substation
  • De-commission and remove the existing DC module and dispose
  • Manage the switch-over of the supply from the existing unit to new DC module
  • Supply and install all supply an feeder cables for the DC module
  • Provision of a Design and Construction CRE to engage and manage the engineering assurance process as per NR/L2/INI/02009
  • Managing the diversion of the existing HV feeder F3003 to enable the location of the new DC module within the available footprint of the Holmethorpe site
  • Provision of all handback and operational information to handover the module to Network Rail Maintenance

Further additional works were undertaken by RJ Power Rail as the overall scope of works evolved to incorporate areas of the wider Redhill re-development scheme. These included:

  • Additional HV feeder diversion works to support the Redhill Platform Zero footprint and additional HV cable containment between Redhill Station and Holmethorpe substation
  • Undertaking the full ETE scope of DC traction power cable supply and installation at both Redhill A and Holmethorpe substation in support of B113 Redhill Up Loop Platform Zero
  • Full replacement of DC traction power cables for existing circuits at Holmethorpe substation

Challenges and Solutions

Staged Works

The contracted works had to be delivered in a number of stages to support the overall client programme:

Initially RJ Power Rail supported the early decommissioning of redundant assets in order for BAM Nuttall to clear the old railway sidings to make way to the new Platform Zero enabling works. This included, relocation of points heating supplies, decommissioning of siding lighting columns and the temporary diversion of the existing HV feeder and pilot cables.

The DC module for Holmethorpe underwent design and construction and then installation of the internal equipment before a series of factory acceptance tests.

RJ Power Rail supported BAM Nuttall in preparing the Holmethorpe site for the new DC module by working with their civils team, to relocate existing earthing arrangements and slew cables from existing locations.

On completion of the Holmethorpe civils enabling works, RJ Power Rail delivered and lifted the module into site during a possession using a road crane. BAM Nuttall were then able to complete the ETE trough routes associated with the new DC breakers.

The ETE connections work scope grew during the course of the contract. RJ Power Rail were asked to support a change of scope to include the supply and installation of new DC cabling from the DC module to the conductor rail terminations for each breaker to a remote TIS unit.

RJ Power Rail worked closely with our client BAM Nuttall and the wider rail community involved in the Redhill Redevelopment works including Network Rail and the S&C Alliance to agree other areas of work-scope which required specialist electrical support. This led to the award, of another significant scope change to incorporate new ETE cable connections and test and commissioning works required to support the energisation of a spare circuit breaker within the Redhill A DC module, now designated as B113.

ETE connections between the newly installed Holmethorpe DC module and associated conductor rail and TIS termination points were undertaken during a series of pre-planned possessions using both mechanical and manual cable pulling techniques. The ETE connections for Redhill A DC circuit breaker also utilised some of the same possessions to maximise efficiencies.

The pre-commissioning and commissioning strategies of Holmethorpe and Redhill were also independent of each other as the breakers B107, B108, B109 and B110 were required to be commissioned into service during week 33, enabling the de-commissioning and removal of the redundant DC module during week 37, for supply to Network Rail as strategic spares.

Clarification of Technical Scope of Work

The delivery of the Redhill Station re-development programme was split into specific packages of technical scope of work to be delivered by multiple parties. Our client BAM Nuttall were working alongside both Network Rail and the S&C Alliance to deliver the renewal of assets, including buildings and civil structures, electrification and plant, track renewals and signalling.

Where the scopes crossed, there were a number of opportunities for items to fall between these independent scopes of work. RJ Power Rail worked both pro-actively to highlight opportunities for these gaps and reactively where our client identified a requirement for assistance.

An example of this is where RJ Power Rail identified a potential gap in coverage for the ETE connections between Redhill A substation and the connection to the track isolation switch, which formed part of the S&C Alliance scope of works for installation only.

RJ Power Rail attended several technical review meetings with both the client and wider programme delivery organisation, to offer technical guidance to the overall delivery strategy and offered solutions that RJ Power Rail were able to deliver with our technical expertise. This resulted in RJ Power Rail being awarded this scope of works, which was installed in line with the clients’ requirements without any extension to our programme.

Decommissioning of Existing SCADA Communications

In order for the new DC module to be brought into service, the existing SCADA lines had to be migrated over from the RTU within the existing DC module. There were known to be reliability issues with the existing comms system and therefore concerns were raised regarding any potential loss of communication during migration due to the condition of some of the existing cables.

RJ Power Rail contacted the Network Rail Maintenance team during the initial site surveys at project commencement, to obtain an understanding of the works involved and build a working relationship with them, so that when the programme reached the installation phase, our team had the necessary end user technical support for transferring circuits within the existing infrastructure.

New telecoms cables were also pre-installed by RJ Power Rail to the trackside telecoms cabinets. Network Rail Maintenance agreed to support these works and supplied some of their own telecoms specialists to support key shifts whilst the communications circuits were migrated.

The flexible relationship that was developed and technical support from the Network Rail Maintenance team was a key contributor to the successful migration and entry into service.

Removal of Redundant DC module

Due to the absence of records for the redundant DC module, a lifting strategy had to be developed to accommodate a number of lifting options. The proposed roof mounted lifting eyes were inaccessible due to a temporary roof being fitted that could not be removed without causing damage. The bottom mountings used to secure the module were a second option considered, however, over the years had deteriorated in condition and could not be considered suitable for lifting purposes.

RJ Power Rail contacted our specialist lifting contractor and agreed to undertake an additional survey to review further lifting options on site and determine an option based on the safest and most practical approach, in consideration of the presented constraints.

The solution selected, involved manually jacking the module off the ground and positioning lifting strops underneath to lift in a cradle configuration. This method was successfully undertaken during week 37 and the unit was subsequently delivered to Network Rail.

Final Commissioning

The commissioning and energisation had to be performed in two separate stages due to the readiness of project deliverables outside of the RJ Power Rail scope of works.

The first commissioning stage, encompassed energisation of four of the DC circuits within the new DC module at Holmethorpe substation which replaced the DC breakers within the existing module. This activity was not restricted by any third party works and was achieved on time in Week 33.

The second and final commissioning stage was technically more complex as it was dependant on the completion of third party works by the S&C Alliance during the Christmas 2017 blockade.

The commissioning strategy was to energise DC circuits B113 at both Holmethorpe and Redhill in tandem with the track installation works undertaken by the S&C Alliance for the new Platform Zero and the associated section proving of the new track configuration.

RJ Power Rail raised a request for a review of the commissioning strategy and suggested that this should be undertaken in an interactive forum to enable consideration of all parties’ work to remove any conflictions, to ensure that the necessary testing and commissioning activities could be achieved for the new platform to be entered service to meet the New Year operating timetable. This forum was attended by the project stakeholders, which raised several items requiring action by multiple parties to ensure the successful delivery of the Christmas blockade works.

Testimonials

“Following the successful relocation of the last telecoms cable at Redhill over the weekend, I am glad to be able to state that we have now completed the signalling, telecoms and power diversion works at Redhill. Thank you all very much for your hard work and dedication through this extremely challenging and sometimes painful phase of the works. It was certainly not easy and some of the issues we had to deal with were so far outside of our control they could never have been foreseen.

“It was a pleasure working with you all on this element of the works and I hope to work with you again in the future.”

Dave Hennigar
Project Manager
BAM Nuttall Limited

Replacement of LV equipment

RJ Power Networks carried out the safe removal, disposal and recycling of all the old equipment and then installed, tested and commissioned a new LV panel, power factor correction panel, battery tripping unit, remote generator connector panel and all containment and cabling, including the provision of health and safety file at 1 Future Walk in Derbyshire.

Following the failure of their Power Factor Correction section of the LV Switchboard, the client invited RJ Power Networks to tender for the replacement of the existing equipment. As part of the competitive tender process RJ Power Networks was one of three specialist market leaders in the power industry invited to quote for the works.

In addition to providing a competitive quotation and innovative technical solution, RJ Power Networks’ long standing relationships provided the necessary confidence to both the network maintainer and the client, which led to RJ Power Networks being awarded this prestigious contract.

Project Deliverables

The overall objective of the project was to replace all the equipment to the very latest specification with the minimum of disruption and to a fixed programme in order to minimise the running of the building off a temporary generator supply.

RJ Power Networks proposed solution included the following works:

  • The migration of the services to a temporary generator switchboard, prioritising the essential services
  • The removal of the existing plant and equipment
  • Installation of the new plant and equipment
  • The migration of existing cabling back to the new switchboard
  • Installation of a new stainless steel remote generator connection panel
  • Installation of a new power factor correction panel
  • Installation of a new battery tripping unit
  • LV cable installation from the LV switchboard to the external generator connection panel Testing and commissioning
  • Compilation of a health and safety file including; operating and maintenance manuals, as built drawings and test certificates

The Challenges and Solutions

Due to the project time scales the planning, programming and coordination of the works was jointly carried out by the client, network operator and RJ Power Networks, which involved several workshops being organised to ensure that all aspects of the project were covered and agreed well in advance of the commencement on site.

In addition to the enabling and pre-installation works, the RJ Power Networks team and the network operator worked over two very busy weekends to carry out the changeover works from mains power to the temporary power in order to enable the old substation equipment to be removed, and changeover from the temporary power back to mains after the installation of the new substation equipment and reinstatement of cabling.

As the existing cables were to be re-used, the new switchboard was designed and manufactured to match the cable connection positions of the original switchboard. This was also made more difficult due to restricted access for installation of the new switchboard and the logistical challenges that this created. In order to combat these challenges, the new Switchboard was designed and manufactured 300mm smaller in height than the original.

RJ Power Networks was delighted to have the opportunity to work once again with one of their longterm clients and enjoyed working with new people within the client’s team. RJ Power Networks and the client continue to build and strengthen their relationship.

Why RJ Power Networks?

RJ Power Networks undertakes a range of installation works, from control cabling and relay works, through to the provision of high voltage ring-main systems in private distribution networks, making us the ideal company for this project.

We continually strive to offer a consistent, reliable and flexible provision as well as always looking to improve and adapt our methods, works, equipment and services to maintain our cutting edge.

The business is led from the front by passionate individuals that care about quality, environmental processes and procedures and developing collaborative and sustainable partnerships, with the ultimate goal of securing customer loyalty and forging strong long-term business relationships.

CP5 HV Feeder Renewals Kent Route

As part of a five-year framework on behalf of Network Rail Infrastructure Projects (NR), to deliver electrification and plant upgrades and renewals in the southern region, RJ Power Rail was awarded a contract for the replacement of HV and Pilot cables at Feeder 1607 Northfleet Grid to Northfleet Substation and 1608B Stone Crossing Substation to Ebbsfleet Substation.

RJ Power Rail as a specialist rail electrification contractor with in-house jointing, test and commissioning resource, was approached by civil engineer and long term strategic partner BCM Construction – one of the framework contractors – to specifically deliver the full electrical scope, which included the refurbishment and replacement of high voltage feeder cables between the substations, replacing existing 185mm Aluminium cabling with new 300mm Copper 33kV cabling, renewing pilot cables and installing optical fibre telecommunication cables.

Working in collaboration with both BCM’s civil engineering team and the project designers RPS, RJ Power Rail has been successfully delivering HV feeder renewals throughout the South and was seen again as the partner of choice for these works.

These E&P upgrades and renewals, form part of Network Rail’s investment programme to enhance the rail infrastructure to cope with future requirements of increased train frequency and also higher capacity services.

Project Deliverables

RJ Power provided a full GRIP 6-8 construct, test, commission and handback service, delivering a fully project managed offering on time and to budget. The company had to prepare a prioritised programme of works to meet the client’s requirements, incorporating delivery milestones in order to meet other key stakeholder requirements. This encompassed detailed hour-by-hour schedules of installation, test and commission activities across concurrent working locations, which took into consideration track access availability and the asset condition. RJ Power supplied all necessary logistics management and co-ordination of all resources to support the project programme in accordance with the following rail electrification work scope:

F1607 Northfleet Grid to Northfleet Substation

This site location includes the replacement, renewal and disposal of life expired cables in respect of F1607, between Northfleet Grid and Northfleet Substation in respect of the HV feeder renewals project. The principal objective was to replace the existing 3x single core 185mm2 Al XLPE cable with a new 3x single core 300mm2 Cu XLPE LSZH cable and then install a new modern equivalent 20-pair pilot cable to replace the existing 30-pair pilot cable for control and indication.

F1608B Stone Crossing Substation to Ebbsfleet Substation

This site incorporated the partial renewal of F1608B and the installation of a new pilot cable to encompass Stone Crossing substation, Swanscombe TP Hut (proposed substation) and Ebbsfleet substation for the HV feeder renewals project. Swanscombe TP Hut was then to be converted in to a substation where F1608B was to be terminated. The principal objective of this scope of work was to replace life-expired cables with modern equivalents, which involved the replacement and subsequent recovery of the existing HV oil filled cables with brand new XLPE cables and the installation of a new modern equivalent 20-pair pilot cable to replace the existing 48-core pilot cable for control and indication.

Challenges and Solutions

There were numerous access issues that were identified. These were primarily based around lack of working space on site and also restricted track access availability.

To overcome the lack of access – particularly in areas of railway cutting and embankments for cable installations – RJ Power Rail worked with BCM to re-route cables to the very top of embankments. This lessened the need for track access and also allowed the programme to accelerate.

Having their own Level A testing resource also allowed RJ Power Rail to maintain a consistent delivery approach in terms of quality and supply availability for key test and commissioning activities and provided them with the ability to flex their resource pool to meet the challenging track access arrangements without impacting the completion date.

A strong collaborative approach to this project enabled RJ Power Rail to successfully complete the project and this, coupled with their thorough understanding of the interdisciplinary nature of other parties works, enabled them to deliver an efficaciously managed project with a high degree of quality.

Why RJ Power Rail?

RJ Power Rail has an established team that combines design, engineering and delivery expertise across all rail electrification activities and can be trusted with the most complex and demanding of projects.

The company offers the full range of rail electrification and power services from one-off cable repairs to multi-million-pound HV, LV and Scada D&B projects.

They are an experienced power solutions delivery provider who work collaboratively with their clients and own supply chain as a reliable partner, providing exceptional expertise and proven project delivery in respect of HV Electrification and DC Switchgear schemes.

Testimonial

“Whilst managing these HV feeder projects, I found RJ Power’s team to be very professional and proactive with their works and when assisting BCM with the commissioning and liaison with the grid engineers. There was also a good relationship with between respective Construction Managers’ and PMs, which helped to get Package 2 over the line.

“They submitted paper work (WPPs’) on time for approval and attended construction/look ahead meetings to help with the progress on site.

“Site operatives were also easy to approach to discuss and help overcome any site issues, providing us with both design and health and safety support.”

John Allum, Project Manager, BCM Construction

Ilford Depot

The Ilford Yard Stabling Project was a rail infrastructure scheme to provide additional stabling for new Crossrail rolling stock along the north-eastern section of the Crossrail network. The works involved the partial demolition of existing facilities at Ilford Depot to accommodate the proposed Crossrail stabling sidings and location of new operations and welfare facilities on the Ilford Depot site. Upon completion, this project forms part of Crossrail, one of the largest schemes of its kind in Europe.

Having had previous success with depot electrification projects at Three Bridges and Williams Way with Volker Fitzpatrick (VFL), RJ Power Rail (RJ Power) was invited to tender for the provision, installation and subsequent test and commissioning of the electrical power works associated with Stages 3-7 of the Ilford Yard Stabling works.

Under the expert guidance of Matt Woolley, Sales Director of RJ Power Rail, and having submitted a most compelling offer, RJ Power was subsequently awarded the points heating, signalling and general power supplies contract works with a commencement date of August 2016.

RJ Power was also awarded an electrical enabling works package in preparation for the main improvement works. These works included:

  • Installation of temporary LV supplies to depot support buildings including the yard controller’s office and mess rooms
  • Cable pulling, installation, termination and testing
  • Final testing and commissioning of portacabin supplies

The awarded sub-contract package was RJ Power’s largest contract to date and was testament to the quality of the bid submitted, which required RJ Power to supply all access and operative accreditation for below ground cabling installation and cable installation plant. The bid included a carefully thought through methodology in respect of the off-loading and lifting of all fixed equipment into final position on site and provision of part time on site management for the two months leading up to construction, to support effective and collaborative planning and co-ordination with the PCL, to achieve a series of milestones and to ensure that the exact start date for the fixed plant installation was met. It was also a requirement for the team to supply full time site management for the duration of the on site works up to the acceptance date from Crossrail and for energisation of all services installed.

Project Deliverables

RJ Power’s contracted electrical power scope of works for the project consisted of the following extensive deliverables:

Installation of HV and LV substation, cabling and switchgear consisting of:

  • Provide support to UKPN in connection with the installation of 2No brand new Ring Main Units (RMU)
  • Supply and installation of a new Bombardier Transportation (BT) prefabricated substation which included 1No HV distribution panel, 2No 1 MVA 11KV/400V transformers and 1No LV distribution panel
  • Supply and installation of Workshop ‘A’ new switchroom and LV switchboard
  • Supply and installation of a new AGA 500kVA packaged substation
  • Provision and installation of power to DNO cubicles
  • Provision of associated earthing and bonding to all locations

Installation of 650V signalling power system including:

  • Supply and installation of new 3-core 650V feeder cables using the third core as the Continuous Protective Conductor (CPC), connected in parallel with the cable armour to ensure that all locations on the feeder were equipotentially bonded
  • A new Principal Supply Point (PSP) as a point of common connection for all sources of electricity from which power could be distributed. The PSP housed a full remote condition monitoring system
  • Provision of Functional Supply points (FSP) to house the necessary power supply equipment required to supply the signalling functional circuits of 120V and below

Installation of points heating equipment, consisting of:

  • 2 no. three phase Points Heating Control Cubicles (PHCC), each with a dedicated fuse way situated on the LV side of a new 500 kVA Operation and Welfare Building Substation
  • A total of 19 no. point ends heated comprising AV, BV and AVT type switches. Each point had a 5kVA, 230/110V transformer with dual isolated secondary windings
  • Trackside connection boxes installed and located adjacent to each point end to provide a means of local termination during testing and maintenance procedures

Challenges and Solutions

Complex project interfacing

RJ Power faced challenges with the timescale of this project due to the number of different project interfaces during the course of these works. With the works being of a multi-disciplinary nature and with multiple contractors needing to negotiate access arrangements, RJ Power’s team needed to be extremely flexible and work collaboratively when approaching and delivering key milestones in their programme.

Careful logistical management was also needed as multiple electrical assets were being supplied by RJ Power. All deliveries were pre-planned in accordance with a Traffic Management Plan. All vehicles accessing the site had to be Crossrail compliant, and in line with the directives given by Traffic Marshals. All plant/pedestrian interfaces had to be managed around the nominated site storage area, with segregated walking zones provided and Banksman present during the transportation and lifting into position of all materials for the works.

As a result of some of the client programme delays, RJ Power was presented with a number of resourcing conflictions due to requirements on concurrent projects. Close communication and liaison between the project teams was vital in highlighting any potential risks and providing a safe and comprehensive solution. RJ Power’s role as team player with a collaborative working approach was commended by VFL Head of Commercial Andy Gardiner, who praised the project team for their fantastic achievement in helping to achieve 500,000 project delivery hours without any incidents or accidents following completion of a major blockade at the end of 2016.

Installing a rare joint

As part of this complex E&P scope, RJ Power was also asked to complete a unique and rare joint at Ilford Depot.

The existing cable (25kV) was installed in 1959 and was a Mass Impregnated Non Draining cable. RJ Power was asked to joint this to a modern XLPE cable, using a unique joint that needed commissioning by specialist Tyco in Germany.

With an 8-10 week lead-time on the joint, careful planning was needed. The residual risk being that if the joint, on arrival from Germany, did not fit the two separate cables or was unsuitable, the programme would have been severely disrupted.

RJ Power engaged its procurement and logistics team, which managed the purchase and shipping of the joint in close liaison with Tyco, to enable seamless delivery of this specialist joint.

The company’s skilled jointers then took over to deliver this high-risk element of the works, successfully completing them and delivering a first class solution, the sort of which RJ Power’s experienced electrical team thrives upon.

Why RJ Power Rail?

Our electrical engineers offer a reliable and flexible service with exceptional expertise, providing engineering solutions in the power sector.

Having two complementary divisions, which cover both rail and private networks, enables us to understand the requirements of all relevant power installations on the railway infrastructure. It is this knowledge that consistently allows us to meet and exceed our customers’ requirements in respect of the design, installation, testing and commissioning of both high and low voltage power applications in the UK.

Our pride in providing outstanding quality to our clients through an open and honest approach, has led to the establishment of many long lasting relationships.

Testimonial

“Congratulations from me to everyone involved. This is a testament to the excellent collaboration and dedication which you’ve established on the project. We’re on the verge of commissioning our new sidings in support of Crossrail’s Stage 1 opening after many people thought it couldn’t be done. That will be a great achievement. Thanks to everyone for your hard work.”

Bill Tucker, Section Delivery Director, Crossrail