VRIOGS 012.7.28 RevA - Public Transport Victoria

Victorian Rail Industry Operators Group StandardsVRIOGS 012.7.28Batteries for Railway SignallingApplicationsRevision:AIssue Date: 06/11/2009

VRIOGS 012.7.28 Revision AiiiPURPOSE OF THE STANDARDThe Standard has been created through the collaboration of members of theVictorian Rail Industry Operators’ Group (VRIOG) for the purpose of establishingstandards which, if implemented throughout the Victorian Rail Network, will facilitatethe interoperability of infrastructure.The use of the Standard is not prescribed by law but, if adopted, conformity with theprovisions of the Standard is mandatory in order that the purpose of the Standard beachieved.DISCLAIMERThe Standard is published by the Director of Public Transport for informationpurposes only and does not amount to any kind of advice.Each person is responsible for making his or her own assessment of all suchinformation and for verifying such information. The content of this publication is not asubstitute for professional advice.The Director of Public Transport and VRIOG accept no liability for any loss ordamage to any person, howsoever caused, for information contained in thispublication, or any purported reliance thereon.COPYRIGHT STATEMENT© Director of Public Transport 2005.This publication is copyright. No part may be reproduced by any process except inaccordance with the provisions of the Copyright Act.Where information or material is so used, it should be used accurately and theStandard should be acknowledged as the source of the information.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

ivVRIOGS 012.7.28 Revision ATABLE OF CONTENTSSECTION 1.0 CONVENTIONS ........................................................................ 1SECTION 2.0 DEFINITIONS............................................................................ 2SECTION 3.0 SCOPE AND APPLICATION .................................................... 33.1 Scope .................................................................................................. 33.2 Application ........................................................................................... 33.3 Quality Assurance ............................................................................... 33.4 Quality Assurance Documentation ...................................................... 33.5 Maintenance Manual ........................................................................... 33.6 Advisory Bulletins ................................................................................ 33.7 Occupational Health and Safety .......................................................... 3SECTION 4.0 OPERATING ENVIRONMENT.................................................. 44.1 Environmental Conditions.................................................................... 44.2 Lightning and Surge Protection ........................................................... 4SECTION 5.0 TECHNICAL REQUIREMENTS ................................................ 55.1 General................................................................................................ 55.2 Load Capacity...................................................................................... 55.3 Battery Life Details .............................................................................. 65.4 Valve Seal ........................................................................................... 65.5 Tests.................................................................................................... 65.6 Labelling .............................................................................................. 6SECTION 6.0 DELIVERABLE REQUIREMENTS............................................ 76.1 Inspections and Tests.......................................................................... 76.2 Certificates........................................................................................... 7SECTION 7.0 WARRANTY.............................................................................. 8SECTION 8.0 MAINTAINABILITY.................................................................... 9SECTION 9.0 PACKAGING AND DELIVERY................................................ 10SECTION 10.0 BATTERY DISPOSAL............................................................. 11SECTION 11.0 REFERENCES........................................................................ 12NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.28 Revision A 1SECTION 1.0CONVENTIONS1) Words or phrases that appear capitalised out of context are defined within theDefinitions section of this VRIOG Standard.2) The word “Shall” is to be understood as mandatory.3) The word “Should” is to be understood as non-mandatory i.e. advisory orrecommended.4) Uncontrolled Standards may not be referenced within the VRIOG Standards.These include former PTC Standards, Franchisee Standards, FranchiseeSubcontractor Standards and Infrastructure Lessee Standards.5) Controlled Standards, including Australian Standards and other VRIOGStandards, may be referenced but only if:• The referenced item can not be adequately explained with an amountof text that could not reasonably be inserted into the body of theStandard.• The reader is not referenced to another Controlled Standardnecessary for the item to be adequately explained i.e. one documentlink only.• The referenced document is a Figure or table and could notreasonably be included in the appendices of the Standard.6) The format employed in the VRIOG Standards is compatible with AustralianStandards, and will be used from this point on.7) The numbering system for the VRIOG Standards is chronologicallysequential from the point of introduction, and is not based on any form ofinterpretive system.8) The VRIOG Standards contain engineering information necessary to operatea safe Railway. VRIOG Standards will not contain any information that can beconstrued as a work instruction, procedure, process or protocol. Thisinformation forms the basis of each individual entity’s Safety AccreditationCertification, and, as such, is outside the scope of VRIOG Standards.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

2 VRIOGS 012.7.28 Revision ASECTION 2.0DEFINITIONSTerminology used and/or applied in this Standard is defined as follows:-TerminologyAccredited RailOperator (ARO)Application forVariation ofAccreditationASPurchaserType ApprovalVRIOGVRIOGSDefinitionAn Accredited Rail Operator who controls RailInfrastructure.An application to the Safety Director by an Accredited RailOperator for variation of its accreditation due to theAccredited Rail Operator proposing to make change to orto the manner of carrying out, accredited rail operationsthat may reasonably be expected:-• To change the nature, character and scope of theaccredited rail operations; or• To not be within the competence and capacity forwhich the Accredited Rail Operator is accredited.Australian StandardPerson or organisation to which the batteries are suppliedor being supplied.Note: They may not be a direct representative of the ARO.Consideration of form, fit and function under specifiedconditions to approve equipment suitability for me withinVRIOG infrastructure. (Refer to VRIOG “Standard forSignalling Design and Documentation” VRIOGS 012.1,Clause 4.2)The Victorian Rail Industry Operators’ Group comprisingthe following members:-• VicTrack• V/Line Passenger• Metro Trains Melbourne• Yarra Trams• Australian Rail Track Corporation (ARTC)• Public Transport Division of the Department ofTransport (PTD)Victorian Rail Industry Operators Group Standards.Table 1 - TerminologyNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.28 Revision A 3SECTION 3.0SCOPE AND APPLICATION3.1 ScopeThis Standard provides the minimum acceptance criteria for the design, manufactureand supply of batteries for use in signalling applications within the Victorian RailwayNetwork.3.2 ApplicationUnless otherwise specified, all batteries for railway signalling application shall beType Approved by the ARO and shall be designed, manufactured and supplied inaccordance with this specification.The battery shall be of sufficient capacity to provide proper operation for the systemunder normal operating conditions for a period to cover identification and rectificationof a problem with the main power supply.3.3 Quality AssuranceThe manufacturer shall be accredited to the appropriate Australian Quality Standardsor recognised international equivalent if the manufacturer is based overseas.It is considered that the following are appropriate Australian Quality Standards:-- AS/ISO 9001 - Quality Management Systems – Requirements- AS/ISO 9004 - Quality Management Systems – Guidelines for Performances3.4 Quality Assurance DocumentationQuality assurance documentation shall be in accordance with the requirements ofAustralian Quality Standard “Quality Management and Quality Assurance Standards”AS/ISO 9000.2 or recognised international equivalent if the manufacturer is basedoverseas.3.5 Maintenance ManualThe maintenance manual shall be in accordance with the requirements of VRIOGStandard “Specification for Signalling Supply, Construction and Installation” VRIOGS012.2, Section 25.3.6 Advisory BulletinsThe Purchaser shall check and act upon any related manufacturer and ARO issuedproduct bulletins in order to ensure that they are aware of and action any safetyrelated concerns regarding batteries.3.7 Occupational Health and SafetyThe manufacturer shall comply with the Victorian “Rail Safety Act 2006”, the“Occupational Health and Safety Act 2004” and the “Occupational Health and SafetyRegulations 2007”.The weight of the equipment shall be considered with regards to the current“Occupational Health and Safety Regulations 2007 & Codes of Practice” with regardsto safe handling by persons and with respect to the installation and maintenancerequirements.The manufacturer shall comply with a recognised international equivalent if themanufacturer is based overseas.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

4 VRIOGS 012.7.28 Revision ASECTION 4.0OPERATING ENVIRONMENT4.1 Environmental ConditionsThe battery shall comply with the category conditions specified in VRIOG Standard“Environmental Conditions” VRIOGS 012.7.25.(i)(ii)The battery shall be subject to the condition specified for CategoryB4 equipment if housed in steel or aluminium box.The battery shall be subject to the condition specified for CategoryA3 equipment if housed in control room signal box.4.2 Lightning and Surge ProtectionThe application of the battery shall comply with the VRIOG Standard “Lightning andSurge Protection – General Requirements” VRIOGS 012.7.9.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.28 Revision A 5SECTION 5.0TECHNICAL REQUIREMENTSThis section of the specification details the minimum acceptance criteria to beconsidered for the design and manufacture for maintenance free batteries.5.1 Generala) All batteries shall be maintenance free during the whole service life.b) The batteries shall have the capacity to maintain the full level crossingprotection installation under fault conditions for a minimum period of threehours in the metropolitan area and at least six hours for the country area.c) The manufacturer shall specify the batteries operational parameters in thebattery data sheet. These shall include but not be limited to the followinginformation:-i) Manufacturer Name and Contact numberii) Battery Details• Voltage (V)• Capacity (A/H)• Size (mm)• Weight (kg)• Maximum load current capacity (A)• Battery life• Cyclic operations without affecting battery life• Self discharge• Gelled Electrolyte descriptioniii) Valve Seal Information• Body material• Membrane material• Cover material• Operation pressure (mbar)• Closing pressure (mbar)• Valve testing conformancesiv) Battery Construction Details• Case material• Electrolyte acid density (kg per litre)• Positive plate material / thickness (mm)• Negative plate material / thickness (mm)5.2 Load Capacitya) The duty cycle must be performed within the first charge/discharge cycle ofthe battery.b) Any battery which fails this requirement will be deemed to be non-conformingand shall be replaced free of charge by the manufacturer.c) The capacity test of the battery shall be in accordance to AS 4029.2“Stationary Batteries – Lead Acid – Valve regulated type” or approvedequivalent international standard.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

6 VRIOGS 012.7.28 Revision A5.3 Battery Life Details5.3.1 Cyclic Operationa) The battery shall be able to perform 10 years float life with 200 cycles at 100%of rated capacity.5.3.2 Design Lifea) The battery shall has a design life of up to 18 years, be completelyrechargeable and can be stored up to 2 years at 20ºC without a recharge.5.3.3 Electrolyte Stratificationa) The battery shall use a “Recombinant Gelled Electrolyte System” to eliminateelectrolyte stratification.5.3.4 Deep Dischargea) The battery shall, after 30 days of being connected to a low resistance (≈ 1Ω)load be recharged within 48 hours at normal float voltage and recover aminimum of 75% of rated capacity.b) The 25% loss of capacity must be recovered within seven cycles inaccordance with DIN 43539 – (1985 – 05) “Storage Cells and Batteries:Testing: General Information and General Test Methods”.5.4 Valve Seala) Each cell of the battery shall be fitted with an automatically resetting one wayvalve to release gas in case of excess pressure.b) The valve shall be tested and approved to by a recognised authority to meettheir flame arresting requirements. The manufacturer shall submit the test filerecognition number or copy of the approval.5.5 Testsa) All batteries shall be supplied “Fully Charged” and ready for service. Themanufacturer shall have local facilities to charge batteries to their full stateprior to delivery.b) Any batteries not performing to specification will be rejected.5.6 Labellinga) An indelible label attached to the battery shall specify the following minimumdetails:-• Manufacturer’s name• Manufacturer’s unique serial number• Battery voltage & A/H capacityb) The battery shall have the following (indelible, embossed or engraved)labelling detailing :-• Positive and Negative terminal designations• Date of manufacturec) Labelling shall be in accordance with VRIOG Standard “GeneralRequirements for Labelling of Signalling Equipment” VRIOGS 012.7.30.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.28 Revision A 7SECTION 6.0DELIVERABLE REQUIREMENTS6.1 Inspections and Testsa) Each battery shall be subjected to a series of inspections and tests to confirmthat it conforms to the requirements stated in this specification.b) The manufacturer shall carry out all electrical and/or mechanical inspectionsand tests to verify that battery supplied conforms fully to the requirementsstated in this specification prior to delivery.c) All these tests shall be carried out at the manufacturer’s premises at theircost. The Purchaser reverses the right to witness these tests.d) All apparatus and instrumentation required for the tests shall be provided bythe manufacturer.e) The inspection and test records shall be retained by the manufacturer for aperiod not less than the nominated storage life and warranty period of theequipment.6.2 Certificatesa) The results of the inspections and tests are to be submitted in the form of asigned certificate on the manufacturer’s company letterhead.b) The manufacturer shall provide the completed Certificate of Compliance tothe Purchaser with the delivery of the battery.c) The certificate shall include but not be limited to the following information:-• Certificate number and Date of issue• Customer’s name and Contract number• Purchase order number• Date of manufacture• Quantity of delivery• Unique serial number for individual product or batch code assigned by themanufacturer• Inspection and test results• Date of the inspection and testing• Statement of compliance to certificate that the product meets all therequirements of this specification• Name and Signature of the manufacturer’s management representatived) The Purchaser shall have the right to request supporting Quality Assurancedocumentation to accompany the manufacturer’s Certificate of Compliance.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

8 VRIOGS 012.7.28 Revision ASECTION 7.0WARRANTYa) The manufacturer shall provide warranty to the Purchaser on all items ofequipment supplied.b) All goods supplied by the manufacturer shall be guaranteed against faultyworkmanship and/or materials for a period of 12 months from the date ofcommissioning of the equipment or 24 months from the date of delivery,whichever is the later.c) The manufacturer shall replace without expense to the Purchaser any part (orparts) of the equipment found to be not in accordance with this specificationthroughout this warranty period.d) The manufacturer shall warrant components bought-in from external suppliersfor a warranty period no less than that specified in Section 7(b) of thisspecification.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.28 Revision A 9SECTION 8.0MAINTAINABILITYa) The manufacturer shall provide a recommended maintenance plan for routinepreventative maintenance tasks, task frequencies and fault finding of theequipment to the Purchaser.b) These shall include but not be limited to the following information:-• Installation and maintenance instructions• Maintenance periodicities• Test equipment and specialist tools required to install, adjust, fault find andmaintain the equipment• Detailed drawings showing complete assembly details• Operational test plan• A troubleshooting guide (fault indications, their likely cause and suggestedsolutions)• Details on equipment repair and replacement procedures• Spare parts listNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

10 VRIOGS 012.7.28 Revision ASECTION 9.0PACKAGING AND DELIVERYa) All battery shall be individually and securely packed to avoid mechanicaldamage.b) All batteries shall be handled in such a manner that the delivery and storageof these units will not materially influence their subsequent in-serviceperformance.c) The packaging shall be labelled in accordance to VRIOG Standard “GeneralRequirements for Labelling of Signalling Equipment” VRIOGS 012.7.30,Section 4.4.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

VRIOGS 012.7.28 Revision A 11SECTION 10.0BATTERY DISPOSALa) All used lead acid batteries are hazardous waste and the disposal of usedlead acid batteries shall comply with the Victoria “Environment Protection Act1970”, “Environmental Protection (Prescribed Waste) Regulation 1998” andAustralia “Hazardous Waste (Regulation of Exports and Imports) Act 1989.NOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.

12 VRIOGS 012.7.28 Revision ASECTION 11.0REFERENCESThe following documents have been used and referenced for the preparation of thisStandard:-No. Ref No. Title1. AS/ISO 9001 Quality Management Systems – Requirements2. AS/ISO 9004 Quality Management Systems – Guidelines forPerformances3. AS/ISO 9000.2 Quality Management and Quality AssuranceStandards4. AS 4029.2 Stationary Batteries – Lead Acid – ValveRegulated Type5. DIN 43539 – (1985 – 05) Storage Cells and Batteries : Testing : GeneralInformation and General Test Methods6. VRIOGS 012.1 Standard for Signalling Design and Documentation7. VRIOGS 012.2 Specification for Signalling Supply, Constructionand Installation8. VRIOGS 012.7.9 Lightning and Surge Protection – GeneralRequirements9. VRIOGS 012.7.25 Environmental Conditions10. VRIOGS 012.7.30 General Requirement for Labelling of SignallingEquipment11. - Rail Safety Act 2006 (Victoria)12. - Occupational Health and Safety Act 2004(Victoria)13. - Occupational Health and Safety Regulation 2007(Victoria)14. - Environment Protection Act 1970 (Victoria)15. - Environmental Protection (Prescribed Waste)Regulation 1998 (Victoria)16. - Hazardous Waste (Regulation of Exports andImports) Act 1989 (Australia)Table 2 – ReferencesNOTE: This document is controlled only when viewed on the DOT Engineering Standards website.Any other copy of this document is uncontrolled, and the content may be inaccurate.