Regional Connector Transit Corridor Project

SECTION 34 23 71

OCS TESTING AND COMMISSIONING

PART 1 - GENERAL

1.1 DESCRIPTION

A. The Work specified in this Section includes final testing and commissioning of the
Overhead Contact System (OCS), and the furnishing of acceptance measurement
and test equipment required for the tests.

B. The Contractor shall furnish the special tools as specified in Section 34 23 70 for
acceptance measurement and test equipment:

C. During construction and acceptance measurements, the acceptance measurement

and test equipment shall remain the property of the Contractor, and be used by the
Contractor and Metro.

D. At completion of the work, all acceptance measurement and test equipment shall be
turned over to Metro in serviceable condition.

1.2 QUALITY CONTROL

A. Comply with Section 01 43 10, Project Quality Program Requirements –

Design/Build.

B. The Contractor shall perform the Work included in this Section in strict
accordance with the requirements of the Approved Contractor's Quality Control
Program.

1.3 REFERENCE

A. Pertinent provisions of the following listed standards shall apply to the work of this
Section, except as they may be modified herein, and are hereby made part of this
Specification to the extent required:

1. State of California, Public Utilities Commission (CPUC):

General Order No. 95 - Rules for Overhead Electric Line Construction.

B. Federal, State and Local Authorities: All applicable codes and regulations.

1.4 SUBMITTALS

A. The Contractor shall submit the following:

1. Resumes of field service engineer and instructors.

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2. Training course outline and lesson plans.

3. Training schedule.

4. Field service engineer's logs.

B. Test Program Plan: The Contractor shall submit a Test Program Plan for
acceptance. The purpose of this plan is to ensure that the Contractor has
considered all of the testing requirements contained in this and other sections of the
specifications, and has made adequate provisions for testing in his overall program
plans and schedules, and to achieve an early mutual understanding between the
Contractor and Metro on the range, depth and other aspects of tests to be
conducted. The Test Program Plan shall contain as a minimum the following data:

1. A flow diagram indicating the logical sequence of tests, starting with factory
tests and continuing on to conclude with field demonstration tests.

2. A list of test procedures (by test procedure number) to be submitted,

preliminary submittal schedule, a preliminary schedule of tests, and a brief
description of each factory and field test. The schedule portion of the Test
Program Plan shall be a dynamic document to be updated as the program
progresses.

3. An outline and format of the procedure and test data sheets for each type of
test.

4. Requirements and recommendations for witnessing by Metro or its

designated representative.

5. The acceptance measurement form and a description of the Contractor's in-

plant and field test organization.

6. A detailed Safety Program defining all precautions to be taken, notices,

signs and barriers to be posted concerning the safety of the public, work
personnel and equipment. The program shall define precautionary
measures to be taken prior to, during and following the test until such time
as normal work is resumed.

C. Test Procedures: Test procedures shall be submitted for acceptance. The test
procedure shall include, as a minimum: Objective and scope; test set-up; test
equipment to be used; personnel required for the test; estimated duration of the
test; pass/fail criteria; and samples of data sheets to be used. All tests must be
performed in accordance with the test procedures. No deviations will be allowed
unless accepted by Metro.

D. Test Reports: Six (6) certified copies of Test Reports shall be submitted for
acceptance. Test reports must contain all the data obtained during tests, an
analysis of the data and conclusions relating to the test pass/fail criteria outlined in
the test procedure. A test that fails must be repeated and any corrective action
taken to pass the re-test must be outlined in a new test report.

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E. Types of Tests: The types of tests to be covered in the Test Program Plan shall
include those required for testing and commissioning the Overhead Contact System
following completion of construction, as specified hereinafter in Part 3 of this
Section. The following commissioning tests are required:

1. Acceptance Measurements.

2. Visual Inspection of Completed Overhead Catenary/Conductor Rail.

3. Clearance Envelope Tests for Pantograph and Vehicle.

4. Overhead Contact System Electrical Tests.

5. Live Line Run Testing.

F. General: Refer to Section 01 33 00, Submittal Procedures.

1.5 PERSONNEL QUALIFICATIONS

A. The field service engineer and operation and maintenance instructors shall be
qualified to perform the functions as indicated. The Contractor shall submit a
resume for each individual nominated, a minimum of 120 days prior to the approved
scheduled date for the commencement of training.

PART 2 - PRODUCTS

2.1 MATERIALS

A. General

1. The Contractor shall provide tools, instruments, calibration devices, meters,

and other equipment necessary to connect, monitor, and adjust during start-
up and testing.

2. The Contractor shall provide spare parts as required to conduct the start-up
and testing.

3. The Contractor shall furnish the special tools, and all other equipment and
personnel services necessary to make Acceptance Measurements. The
Contractor shall also provide all the electrical equipment and personnel
services required to perform the OCS Electrical Tests.

PART 3 - EXECUTION

3.1 FIELD SERVICE ENGINEER

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A. The Contractor shall provide the services of a qualified field support engineer at the
project site, to assist as required during startup and system integration testing.

B. Upon approval, the field service engineer shall advise Metro on traction power
system energization and start-up.

C. The field service engineer shall have a thorough knowledge of the Overhead
Contact System as well as installation, start-up, and testing requirements for all
components furnished under this Contract.

D. The field service engineer shall be available on site 5 working days after notification.
Weekly logs shall be maintained and submitted. Logs shall show tasks performed
with dates and duration.

3.2 START-UP

A. Upon successful completion of the testing, adjustment, and calibration as specified

herein and as indicated in the sections pertaining to the components of the
Overhead Contact System, Metro shall be notified when each line section is ready
for energization. Ten working days subsequent to the notification, Metro will
complete arrangements for the provision of power by the utility company
concerned.

B. When approved by Metro, each line/conductor rail section shall be energized.

3.3 INTEGRATED SYSTEM TEST SUPPORT

A. The Contractor shall provide labor and tools to support integrated system testing.
Testing support includes:

1. Provision and connection of testing equipment in accordance with the

system test plan.

2. Calibration and adjustment of protective devices in accordance with

equipment manufacturers' instructions.

3. Witnessing the testing.

4. Disconnecting testing equipment when testing is completed.

B. The Contractor shall advise Metro regarding test procedures, analysis of results,
and recommended correction actions.

3.4 TEST PROCEDURES AND EQUIPMENT

A. The acceptance measurement and test equipment will be used by the Contractor
and Metro for checking the location of the contact wire, and verifying that the
registration assemblies conform to the clearance requirements of the pantograph
clearance envelope. Each item of equipment will be used as follows:

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1. Insulated telescoping height measurement sticks will be used to measure

the heights of conductors and guys, track clearances to undersides of
catenary/conductor rail structures, and other installed details.

2. Optical stagger gauges will be used to verify the measurements given by

the Contractor in the Acceptance Measurement Form.

3. The mobile height and stagger gauge will be used only on electrically de-
energized overhead catenary/conductor rail, and for two purposes:

a. For visually checking the location (height and stagger) of the contact
wire throughout the completed new electrified lines/conductor rails.

b. To confirm that the contact wire registration assemblies are installed

in conformance with the requirements of the pantograph clearance
gauge.

B. One insulated telescoping height measuring stick, and one optical stagger gauge,
shall be readily available for use at any time during the construction and acceptance
measurement periods.

C. All measuring tapes, poles, sticks, etc., used to collate data when the OCS is
energized must be non-conducting. In no circumstances will use of metallic or
conductive measuring tapes, chains and other devices be permitted.

3.5 ACCEPTANCE MEASUREMENTS

A. Upon completion of all construction, the Contractor shall measure the contact wire
height, stagger, and other required dimensions and record the readings on an
Acceptance Measurement Form, in the presence of Metro.

B. The Acceptance Measurements shall be used to determine compliance with the

design and will inform the Contractor of necessary corrections.

C. The Contractor shall execute corrections at no further cost to Metro, except for
adjustments required by Metro which are changes beyond the requirements
specified in the Contract Documents.

D. After execution of corrections, the Contractor shall remeasure and record affected
data and submit the results to Metro.

E. The work of this Section will not be complete until corrections are completed and
accepted by Metro.

F. Completed Acceptance Measurement Forms shall be submitted in accordance with

the requirements.

3.6 VISUAL INSPECTION OF COMPLETED OVERHEAD CONTACT SYSTEM

A. At Contact Wire Level, the Contractor shall make the following checks, and remedy
unsatisfactory conditions uncovered therein:

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1. Check fit and tightness of all components.

2. Check split pins and locknuts are secure.

3. Check contact wire for kinks, rolls, and damage.

4. Check messenger wire for damage to strands. Check conductor rail fittings.

5. Check correct steady arm fittings.

6. Check heel settings.

7. Check that jumpers are of correct type, have adequate travel capability, are
properly fitted, and are well formed to reduce fatigue failure.

8. Check posture of pulley plates.

9. Check that hinge fittings have freedom to move under load.

10. Check that a wire passing through a cantilever and not attached to it will
clear any part of this cantilever by at least 3 inches throughout the
temperature range 25-130 degrees F.

11. Check clearance between adjacent or crossing catenaries/conductor rail.

12. Check installation at locations of possible interference with passage of

pantographs to ensure that proper mechanical clearance is maintained at
registration arms or tunnel supports, and that the pantograph will ride
smoothly across crossing wires and insulated units without entanglement.

B. From the Ground, the Contractor shall make the following checks:

1. Check that counterweights have freedom to travel and that counterweight

band does not bear on guide pipe.

2. Check that cantilevers have correct along-track offset.

3. Check that hangers are plumb and within design position. Check the
conductor rail is installed plumb with adequate insulation and supports.

4. Check out safety requirements in accordance with General Order No. 95,
and other applicable safety codes.

5. Check the system integrity like section gaps and insulated overlaps, and
ensure all the installation in compliance with the design of Engineer Record.

3.7 CLEARANCE ENVELOPE TESTS FOR PANTOGRAPH AND VEHICLE

A. General: The purpose of these tests is to verify the mechanical and electrical
clearances of the light rail vehicle (LRV) units on each section of the system. The

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tests shall be conducted after all installations are complete. Any section found to
have insufficient clearance shall be adjusted to provide the required clearance.

B. Pantograph Clearance Envelope: Tests shall be performed initially with a rail

mounted height and stagger gauge having the same profile as the vehicle
pantograph. This gauge shall be used to verify the mechanical clearances between
the pantograph and OCS components such as conductor rail supports, the heels of
steady arms and contact wire clamps, and the electrical clearances between the
OCS/pantograph combination and civil structures such as tunnel. Following these
tests, final tests shall be performed with an actual LRV to verify the initial simulated
results.

C. LRV Clearance Envelope: Tests shall be performed with an LRV towed or pushed
through each track section. The following tests shall be performed:

1. Dead Slow Tests at Walking Speed: The driver of the towing unit must be
prepared to stop at short notice during these tests.

a. Trackside Structural Clearances to LRV Body and Pantograph: This

includes poles, tunnels, awnings, wayside signaling and electrical
equipment housings.

b. LRV body clearances shall be checked at:

1) The ends of each unit.

2) The midspan between trucks.

2. Slow Speed Tests listed above under Sub-paragraph 1 shall be repeated at

higher LRV speeds. Test speeds shall be raised in successive increments
recommended not to exceed 5 mph each. The maximum LRV dead wire
run speeds shall be as recommended by the LRV manufacturer.

3.8 OVERHEAD CONTACT SYSTEM ELECTRICAL TESTS

A. Circuit Continuity and Loop Resistance:

1. General: The purpose of this test is to obtain the DC loop resistance of

each OCS section. This test checks both the OCS and the rail return
system for electrical continuity and the absence of high resistance
connections or inadvertent ground connections.

2. Procedures: The test entails short circuiting a discrete section of the OCS
by connecting the OCS to its rails at one end, and applying a DC voltage at
the other end. The length of section under test should be about 1 to 2
miles. The test shall be carried out in the following steps:

a. Along-track feeders which are electrically common to the OCS shall

be connected to the OCS.

b. A DC source is required which will provide a current of nominally

100 amperes with an applied voltage of 24 volts (e.g. 2 car batteries

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in series).

c. Measurements shall be made of the DC voltage and DC current, the

circuit resistance calculated from the measured values of voltage,
and current shall be compared with the design value.

d. Any section having a discrepancy of more than 20 percent between

the design value and the measured value shall be rechecked to
ensure that all electrical connections are correctly made, or that
there are no inadvertent ground connections to the OCS which are
reducing the total length of the loop.

e. DC voltage shall be applied as shown in attached Figure C-1.

f. The following items shall be recorded for each section, using

attached Table C-1:

Length of section (miles)

DC volts
DC amps
Ohms
Ohms/mile

3. Precautions: The tests required for the loop resistance require passing
relatively high DC currents through the OCS and rails. Proper regard must
be paid to safety. Test zones shall be clearly identified. All safety
requirements established in the Safety program concerning the public, work
personnel and equipment shall be strictly enforced. Personnel not directly
associated with the tests should be clear of the tracks. The section of OCS
and associated feeders under test must be isolated from the adjacent
sections of the system.

B. Hi-Pot Insulation Testing:

1. General: DC Hi-pot tests shall be performed on the Overhead Contact

System (OCS). The Hi-pot tests serve the following purposes:

a. Components such as insulators and feeders are checked for

leakage.

b. The electrical withstand of minimum clearance areas, such as

tunnel, are verified under static conditions.

c. The electrical withstand of section insulators and disconnect

switches are verified.

d. The test provides a means of periodically checking for any reduction

in the insulation level of the OCS sections, by comparing voltage
and leakage current with previously measured values.

A nominal DC Hi-pot voltage of 2 x OCS rated voltage plus 1 kV

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shall be used for the test. Hi-pot tests shall be carried out on the
OCS sections as soon as possible after the continuity tests have
been completed, in order to ensure that all of the section being
tested is electrically continuous and is subjected to the test voltage.
Leakage currents between 0 and 5 mA can be expected for section
lengths of 1-2 miles.

2. Procedure for Main Line Tracks: Along-track feeders which are electrically
common to the OCS but disconnected from the substations. Adjacent OCS
sections which are electrically isolated from the section under test shall be
grounded by connecting the OCS to the rails. All surge diverters shall be
disconnected from the section under test. A DC test voltage shall be
applied to each OCS section in 1 kV increments up to the nominal test
voltage. The test voltage shall be held for 30 seconds at each increment.
Circuit connections shall be as shown in Attached Figure D-1. The leakage
current at each value shall be measured and recorded as shown in attached
Table D-1, together with the weather conditions and temperature.

3. Precautions: The Hi-pot measurements require application of high voltage

to the OCS. Proper regard must be paid to safety. Test zones shall be
clearly identified. All safety requirements established in the Safety program
concerning the public, work personnel and equipment shall be strictly
enforced. Personnel not directly associated with the test should be clear of
the tracks. Sections of OCS and associated feeders under test shall be
isolated from the adjacent sections of the system, and all OCS sections
adjacent to the section under test shall be grounded.

C. Section Proving:

1. Section Proving is a process of verification of the correct connection and

isolation of each electrical segment of the OCS.

2. Contractor shall verify that:

a. TPS feeder breakers are connected to the correct OCS section

and not to any other OCS section.

b. Disconnects and load break switches connect the correct sections

of OCS together and are connected to any other OCS section.

c. OCS sectionalization, provided through section insulators and/or

insulated overlaps, ensures isolation of one OCS section from all
other adjacent OCS sections.

3. The means of testing shall be through the energization of the OCS from
Traction substations and the applicable opening and closing of circuit
breakers, load breaks and disconnect switches. Contractor shall prove
that appropriate sections of OCS are energized and de-energized by
means of OCS voltage detection equipment. Any section of OCS that
should be de-energized, but is found to have a voltage of 50 volts or
greater will be deemed to have failed.

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D. Ground Resistance Measurement at Surge Arresters:

1. General: The purpose of this test is to measure the ground resistance at

each surge arrester location where the arrester is connected to a ground
rod(s).

2. Procedure:

a. The ground resistance megger shall be connected as shown in the

attached Figure B-1. The lead from P1/C1 shall be as short as
possible, and the electrodes and the ground rod should be in a
straight line. It is not essential that the electrodes be parallel to the
track, but this configuration will probably be the most convenient.

b. The electrodes shall be positioned at distances as shown in

attached Table B-1 test position 1, i.e., with x = 66 ft. and y + 105 ft.
Current and potential electrodes shall be inserted into the earth to
about six to ten inches. For very dry soil, water shall be poured
around the current electrodes. To ensure acceptable values of
resistance, the ratio of distances (x/y) must be approximately 62
percent. The resistance, shall be measured and recorded.

c. Keeping the x dimension the same as in step b, the current

electrode shall be re-positioned to y + 6 feet (test position 2), and the
resistance measured and recorded.

d. The resistance values obtained in steps b and c shall be compared.

If the readings obtained are within 5 percent of each other, no further
measurements are required, and the average value shall be used as
the actual resistance. If the readings differ by more than 5 percent,
x shall be increased by ten feet and y made equal to (x + 10)/0.62
approximately (test position 3), and steps b, c, and d shall be
repeated as necessary.

e. This procedure shall be repeated for each surge arrester location for
which a ground resistance measurement is required.

f. A measured ground resistance value of 5 ohms or less is desirable.

Values ranging between 5 and 20 ohms, or as recommended by the
manufacturer, may be acceptable with Metro's acceptance, with
values greater than 20 ohms will require remedial action.

3.9 LIVE LINE RUN TESTING

A. General: The purpose of these tests are to evaluate:

1. The current collection performance between the LRV and the OCS.

2. The adequacy of the power supplied by the OCS for required vehicle
performance.

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3. The operating parameter between overhead contact wire and pantograph.

The documentation can be used as bas for the reduce maintenance work
and efficiency for the OCS.

B. Procedures:

1. Current collection performance tests shall be performed at LRV speeds in

increasing increments of 5 mph each up to the in service speeds permitted
by track speed limits. LRV test speeds shall not exceed the specified track
speed limits or as directed by the Public Utilities Commission regulations for
test vehicles.

2. During the current performance tests, particular attention shall be paid to:

a. Behavior of the paragraph on various contact wire profiles for signs

of loss of contact.

b. Overlaps, cross-contacts, turn-outs, tunnel approach spans, and

section insulators for smooth running and takeover.

c. Take-over points at overlaps, cross contacts, turn-outs and section

insulators for smooth transitions.

d. Dynamic clearances at tunnel fittings, fascias, crossing and parallel

contacts, clearances to uplifted steady arms and supports.

e. Midspan offsets, stagger effects and contact wire sweep.

3. Locations where problems are observed shall be recorded for its

recommendations on corrective action.

4. The Contractor shall provide equipment for video recording of the current
collection performance tests. The video taping of one or more round trips
on the LRT extension is necessary to obtain significant data regarding
pantograph behavior and wire test. Provide a file with test data, which can
be printed, and record the force between the wire and the pantograph, wire
height, wire stagger, arcing (if any), distance travel and speed and location
of the specific event. The contractor shall deliver five videotapes with
recorded data in Excel format, which shall be used to facilitate detailed
analysis of the OCS after the tests have been made.

5. If adjustments are made to the OCS or to track alignment after the initial
tests, the tests shall be repeated on the affected sections, and their results
documented in the same manner as detailed in the preceding paragraphs.

3.10 ANALYSIS OF RESULTS

A. Analysis of test results shall be performed jointly by Metro, the Overhead Contact
System designer, and the LRV manufacturer.

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B. Recommendations of system changes shall be jointly evaluated for feasibility by the

above listed parties.

3.11 ACCEPTANCE RECORDS

A. Records shall be made of all tests listed under Paragraph 3.06, 3.07, 3.08, 3.09 and
3.10 in accordance with the requirements of the:

1. State of California Public Utilities Commission Regulations Engineer.

2. Overhead Contact System Designer.

3. Light Rail Vehicle Manufacturer.

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Exhibit A

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Exhibit B

DATE: _______________________________________

WEATHER CONDITIONS: ________________________________________

TEMPERATURE: ________________________________________

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Exhibit C

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Exhibit D

DATE: _______________________________________

WEATHER CONDITIONS: ________________________________________

TEMPERATURE: ________________________________________

END OF SECTION

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