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

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.

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.

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.

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