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Rail Signal Testing & Commissioning Guide

This document outlines WestNet Rail's code of practice for signal system testing and commissioning. It details responsibilities, required staff qualifications, test plans, inspection and testing procedures, documentation requirements, and acceptance criteria.

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0% found this document useful (0 votes)

149 views76 pages

Rail Signal Testing & Commissioning Guide

Uploaded by

abidmehmod118

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

WestNet Rail Pty Ltd

CODE OF PRACTICE FOR SIGNAL SYSTEM TESTING

AND COMMISSIONING

CONTENTS

1. PURPOSE
2. SCOPE
3. APPLICATION
4. REFERENCES
5. DEFINITIONS
6. RESPONSIBILITY
7. TESTING AND COMMISSIONING STAFF
8. TEST EQUIPMENT
9. COMMUNICATIONS EQUIPMENT USED BY CONTRACTORS
10. PROJECT INSPECTION AND TEST PLAN
11. WEEKLY NOTICE INSERTIONS
12. EXAMINATION, INSPECTION, TESTING AND COMMISSIONING
13. ACCEPTANCE OF THE WORKS
14. TEST DOCUMENTATION

REVIEWED BY AUTHORISED BY

SIGNAL SYSTEMS MANAGER CONTROL & COMMUNICATIONS SYSTEMS

MANAGER

RAILWAY Page
WestNet Rail Pty Ltd SAFETY
Standard Procedure MANAGEMENT 1 of 29

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© 18/01/01
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STANDARD PROCEDURE
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CODE OF PRACTICE FOR SIGNAL SYSTEM TESTING AND
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DOCUMENT REVISION HISTORY

ORIGINAL ISSUE 1.00
DATE 15 February 2000
PREPARED BY MHM Engineering
REVIEWED BY Signal Systems Manager
AUTHORISED BY Control & Communications Systems Manager
REVISION No 1.01 REASON FOR REVISION
DATE 18 January 2001 Amend for WestNet Rail
PREPARED BY
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AUTHORISED BY Control & Communications Systems Manager
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CODE OF PRACTICE FOR SIGNAL SYSTEM TESTING AND
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Table of Contents
1. PURPOSE 5
2. SCOPE 5
3. APPLICATION 5
4. REFERENCES 5
5. DEFINITIONS 6
6. RESPONSIBILITY 8
7. TESTING AND COMMISSIONING STAFF 9
7.1. General 9
7.2. Precautions Against Common Cause Failure 10
7.3. Test and Commissioning Engineers 10
7.3.1. Test and Commissioning Work Undertaken by WestNet Rail 10
7.3.2. Test and Commissioning Work Undertaken by Contract 10
8. TEST EQUIPMENT 11
9. COMMUNICATIONS EQUIPMENT USED BY CONTRACTORS 11
10. PROJECT INSPECTION AND TEST PLAN 12
10.1. Analysis of Inspection and Testing Requirements 12
10.2. Documenting the Project Inspection and Test Plan 13
10.3. Developing the Project Inspection and Test Plan 13
10.3.1. General 13
10.3.2. Inspection, Testing and Commissioning Strategy 13
10.3.3. Outline of Inspection, Testing and Commissioning Plan 14
10.3.4. Detailed Project Inspection and Testing Plan 16
10.4. Review And Approval Procedure for Works by Contractors 17
10.5. Reports 17
11. WEEKLY NOTICE INSERTIONS 17
12. EXAMINATION, INSPECTION, TESTING AND COMMISSIONING 18
12.1. General 18
12.2. Examination and Inspection 18
12.3. Testing 19
12.4. Notice of Testing for Contract Works 19
12.5. Testing and Commissioning 19
12.5.1. General 19
12.5.2. Design Details 20
12.5.3. Factory Acceptance Testing Drawings 21
12.5.4. Pre-Commissioning Testing Drawings 21

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12.5.5. Commissioning Drawings 21

12.5.6. Stages of Testing and Commissioning 21
12.5.7. Factory Acceptance Testing 21
12.5.8. Installation Testing 23
12.5.9. System Function Testing and Validation 25
12.5.10. Certification and Acceptance of Testing 25
12.6. Master Test Certificate 26
12.7. Equipment Removal 26
12.8. Plan Revision and Issue 26
12.9. Permanent Testing Record 26
12.10. Asset Register 27
12.11. 28 Day Acceptance Test for Work Performed by Contract 27
13. ACCEPTANCE OF THE WORKS 27
13.1. Joint Inspection 27
13.2. Acceptance Criteria for Work Performed by Contract 28
14. TEST DOCUMENTATION 29
14.1. Test Records 29
14.2. Test Logs 29
14.3. Methods of Annotation 29

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CODE OF PRACTICE FOR SIGNAL SYSTEM TESTING AND
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1. PURPOSE

This document defines the WestNet Rail code of practice in relation to the testing and
commissioning of additions and alterations associated with safety-related railway signalling
systems.

2. SCOPE

The testing and commissioning practices specified in this document apply to both WestNet Rail
and Contractor performed alterations and additions to Principal’s railway signalling systems,
irrespective of the technology used.

The practices also relate to the "Integration and Test" and "Commissioning" phases of the
railway signalling system life cycle [AS 4292.4].

3. APPLICATION

The practices required to adequately test and commission additions and alterations to the
Principal’s railway signalling system will be highly dependent upon:

a) the technology used; e.g. Relay based interlocking versus processor based interlocking.

b) the complexity; e.g. Alterations to a location versus a new yard interlocking.

c) the potential risks, e.g. the type of train service and operations.

The selection of the inspection, testing and commissioning activities required shall take
all of the above issues into consideration.

Testing and commissioning activities which are specified in this Code of Practice, but are
not to be performed in the testing and commissioning of the Works, shall be supported by
fully documented justification submitted for approval of the Principal.

4. REFERENCES

4.1 AS 1768 - General Conditions of Contract

4.1 AS 2124 - General Conditions of Contract

4.2 AS 4292 part 4 - Railway Safety Management: Signalling and Telecommunication

Systems and Equipment

4.3 AS 4300 – General Conditions of Contract for Design and Construct

4.4 WestNet Rail Code of Practice W190-600-005 for Signalling Construction

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4.5 WestNet Rail General Appendix section 7 Procedure for Accreditation for Track Access

4.6 WestNet Rail Book of Rules and General Appendix to the Book of Rules

4.7 WestNet Rail procedure W110-600-002 for Issue of Keys to Contractors

4.8 WestNet Rail procedure W110-600-001 for Signal Design

4.9 WestNet Rail procedure W110-600-005 for Signal Sighting

4.10 WestNet Rail procedure W110-600-007 for Witnessing of Contractor Performed

Signalling System Commissioning

4.11 WestNet Rail procedure W110-600-008 for the Signalling System Testing and
Commissioning Process

4.12 WestNet Rail procedure W110-600-017 for colouring of a drawing for Control &
Communications Systems

4.13 WestNet Rail procedure W110-600-041 for calibration of control and communications
measuring equipment

4.14 WestNet Rail technical instruction 288E parts 1 to 4 for earthing and bonding in the 25
kV electrified area

5. DEFINITIONS

5.1 C&CS Manager: The person within WestNet Rail responsible for the management of all
signalling, communication and electrical assets

5.2 Commissioning Engineer: The person nominated by the Contractor and approved by the
C&CS Manager or Signal Systems Manager or the person approved by the C&CS
Manager or Signal Systems Manager, with the responsibility and authority to oversee the
commissioning of the new or altered signalling works. The Commissioning Engineer and
Testing Engineer may be the same person

5.3 Contractor: An organisation contracted to install, test and commission additions and
alterations to the Principal’s railway signalling system. The Contractor will usually be
engaged under Conditions of Contract AS 2124 or AS 4300, with additional special
Conditions of Contract by the Principal

5.4 Inspection And Test Plan (ITP): Documentation prepared by the Contractor, reviewed
and approved by the Superintendent in the case of Works performed by contract,
alternatively by the Signal Systems Manager, and incorporating quality control
procedures and procedures for the inspection, testing and commissioning of all additions
and alterations to the Principal’s signalling system. In the case of contractor works, the

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ITP shall include provision on all testing, inspection and commissioning documents
including drawings, schedules and the like, for signature by the Witness

5.5 Issued For Construction (IFC): Drawings, plans, schedules and other documentation for
the Works that have been prepared, checked and approved by the Contractor and
reviewed by the Superintendent, or prepared, checked and approved under WestNet Rail
control, and granted “approval to proceed” status for construction of the Works

5.6 Systems Maintenance Manager: The person within WestNet Rail responsible for
development, implementation and management of signalling maintenance activities.
Sometimes this function is delegated to a Regional Signals Superintendent

5.7 Principal: The term “Principal” is as defined in AS4300 and shall be the Western
Australian Government Railways Commission (WestNet Rail)

5.8 Project Engineer: The person or group appointed by WestNet Rail to manage technical or
engineering aspects of a project that includes signalling construction work. In certain
cases the Project Engineer may fulfil the role of Project Manager or Witness

5.9 Project Manager: The person or group appointed by WestNet Rail to manage a project
that includes signalling construction work

5.10 Regional Signals Superintendent (RSS): A person within WestNet Rail responsible for
implementation and management of signalling maintenance activities in a nominated
region of WestNet Rail’s rail network

5.11 Signal Checking Engineer: the person responsible for checking the validity of the
signalling design. This shall be a different person to the Signals Designer

5.12 Signal Design Approving Engineer:

For work performed by WestNet Rail, this is a person nominated by the C&CS Manager
or Signal Systems Manager with the responsibility and authority to approve signalling
design drawings and documents.
For work performed by contract, the Signal Design Approving Engineer within a
contractor or consultant organisation is the person nominated by the Contractor to have
the responsibility and authority to approve signalling design drawings and documents.
This person will be a suitably competent engineer designated in the Contract Quality Plan
and acceptable to WestNet Rail. Approval by this person is approval for the drawing or
document to be transmitted to the Superintendent for review

5.13 Signal Designer: Sometimes referred to as the Lead Signal Designer - the person or
group responsible for the design to be used for Contractor additions and alterations to the
Principal’s railway signalling system. Qualifications and experience shall be as further
defined herein. The Lead Signal Designer shall be a different person to the Signal
Checking Engineer

5.14 Signal Systems Manager (SSM): The person within WestNet Rail nominated as
responsible for signalling standards & project work. This includes design and

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construction, standards for signalling systems and level crossing protection, project
management, testing, commissioning and witnessing of contract works. Where the Signal
Systems Manager is referred to in this document, it is taken that the duties,
responsibilities or actions assigned to that position may be delegated by the SSM to others
as required

5.15 Superintendent: The entity appointed by the Principal to administer the Works, as
defined in AS4300 Conditions of Contract

5.16 Test Copy: A suitably stamped copy of drawings, plans, schedules and other
documentation for the Works that have been certified by the Contractor and issued to the
Testing Engineer in the case of works performed by contract, alternatively by the Signal
Systems Manager, for testing of the Works

5.17 Testing Engineer: The person nominated by the Contractor and approved by the
Principal, or nominated and approved by the C&CS Manager or signal Systems Manager,
to test the additions and alterations to the Principal’s railway signalling system. The
Testing Engineer and Commissioning Engineer may be the same person

5.18 Witness: The person nominated by the Superintendent or the C&CS Manager or Signal
Systems Manager to witness the testing and commissioning of additions and alterations to
the Principal’s railway signalling system. Qualifications and experience of the Witness
shall be as defined in WestNet Rail document No. W110-600-007 “Procedure for
Witnessing of Contractor Performed Signalling System Commissioning”

5.19 The Works: The additions and alterations to the Principal’s signalling system, as
contracted to be supplied, installed, tested and commissioned by the Contractor in
accordance with the contract conditions.

6. RESPONSIBILITY

6.1 Where the Works are performed by contract, The Contractor shall be responsible for the
performance of the Works in accordance with AS 2124 or AS 4300, as the case may be,
and as further contracted by the Principal.
Where the Works are undertaken by WestNet Rail staff, the Signal Systems Manager is
responsible for the all aspects the Works including preparation, checking and approval of
the design, installation, testing, commissioning of the signalling and any temporary work
for maintaining safe train operations during the Works.

6.2 The Superintendent shall be responsible for administering the Works in accordance with
AS 2124 or AS 4300, as the case may be, and in accordance with any additional
contractual requirements of the Principal.

6.3 The Superintendent, alternatively the C&CS Manager or Signal Systems Manager,
depending on circumstances and the scale of the Works, is responsible for nominating a
competent person with knowledge of WestNet Rail’s inspection and testing procedures as
the Witness.

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6.4 The Lead Signal Designer shall be responsible for the design of all additions and
alterations to the Principal’s railway signalling system. Where the Works contains major
or complex interlockings, or where specified by the Principal, the Lead Signal Designer
shall also assist the Commissioning Engineer with the commissioning of the Works.

6.5 The Signal Design Approving Engineer shall be responsible for personally reviewing,
verifying and approving all design concepts, standards and so forth; together with
assuring adherence to and compliance with all specifications, procedures and suchlike,
prior to submission of the signal design documents to the Superintendent or Signal
Systems Manager for review.

6.6 The Commissioning Engineer shall be personally responsible for commissioning and
placing into service, the additions and alterations to the Principal’s railway signalling
system in accordance with the approved design and the Contractor’s approved ITP.
Where it proves necessary to deviate from the approved design during the commissioning
of the Works, it shall be the responsibility of the Commissioning Engineer to ensure that
such alterations are performed in a safe manner and are fully tested and verified to ensure
safe operation of the railway signalling system.

6.7 The Commissioning Engineer shall ensure that sufficient labour is available to safely and
fully test and commission the Works.

6.8 The Testing Engineer shall be personally responsible for testing the additions and
alterations to the Principal’s railway signalling network in accordance with the approved
design and the Contractor’s approved ITP. Where it proves necessary to deviate from the
approved design during the construction of the Works, it shall be the responsibility of the
Testing Engineer to bring the required alterations to the attention of the Lead Signal
Designer; and to ensure that any alterations are performed in a safe way and are fully
tested and verified to ensure safe operation of the railway signalling system.

6.9 The Witness shall be personally responsible for witnessing the Contractor’s testing and
commissioning tests and inspections, and for signing test documentation as witness to
testing, after first verifying that the Contractor has followed all the testing and
commissioning procedures described in the ITP and that testing and commissioning has
been undertaken by suitably competent personnel.

7. TESTING AND COMMISSIONING STAFF

7.1. General
Testing and commissioning of the Works shall be performed by competent staff, of a
number required to complete the testing and commissioning within the time frame
allowed in the approved ITP for the Works.

Where the work is undertaken by contract, all labour to fully test and commission the
additions and alterations to the Principal’s signalling system shall be provided by the

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Contractor. During all testing and commissioning activities, sufficient personnel shall
be provided by the Contractor to ensure:

a) efficient testing and commissioning of the Works;

b) protection and safe passage of all rail and road traffic in the vicinity of the Works
(i.e. Flagmen), and;

c) any faults found or alterations required to the Works by the Superintendent or

Commissioning Engineer can be safely, practically and efficiently rectified.

7.2. Precautions Against Common Cause Failure

Unless approved otherwise, independence of the testing and commissioning staff from
the design and construction staff is a mandatory requirement. This is to reduce the
likelihood of common cause failure. Allocation of staff for testing and commissioning
activities shall be planned so that the possibility of common cause failure is eliminated.
Independent verification shall be considered where necessary.

7.3. Test and Commissioning Engineers

7.3.1. Test and Commissioning Work Undertaken by WestNet Rail

Where the work is undertaken by WestNet Rail the C&CS Manager or Signal
System Manager shall appoint suitable Engineers to test and commissioning
the Works. Where the complexity of the Works permits, one engineer may be
appointed with the dual role of testing and commissioning.

7.3.2. Test and Commissioning Work Undertaken by Contract

Where the work is undertaken by contract, unless nominated otherwise by the
Principal, the Contractor shall employ a minimum of one Engineer to perform
the duties of the Testing Engineer and the Commissioning Engineer (the Test
and Commissioning Engineer). The Test and Commissioning Engineer shall
have current proven experience in the testing and commissioning of Railway
Signalling Systems. The Test and Commissioning Engineer shall oversee,
control and certify all of the “Testing and Commissioning Procedures” to be
undertaken for the Works as further detailed in the approved project ITP.

Any engineer offered by the Contractor for the role of Testing Engineer and/or
Commissioning Engineer shall be subject to the approval of the Principal.
The fact that staff offered by the Contractor may meet the following
requirements for competencies and qualifications, does NOT guarantee
acceptance by the Principal.

Unless approved otherwise by the Superintendent, the Testing Engineer and/or

the Commissioning Engineer shall, as a minimum:

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a) hold qualifications and have experience suitable for admission to the

Institution of Engineers Australia as a Chartered Professional Engineer,
or;

b) be a member of the IRSE, and;

c) have at least ten (10) years current experience in the testing and
commissioning of relay based interlocking controlled railway signalling
systems, and concurrently;

d) have at least five (5) years current experience in the testing and
commissioning of processor based interlocking controlled railway
signalling systems.

Any other “Engineer” used to assist in the testing and commissioning of the
Works shall, as a minimum have:

(i) Post Trade Technical Qualifications suitable for admission to The

Institution of Engineers Australia as a Engineering Associate status, and;

(ii) have at least three (3) years current experience in the testing and
commissioning of railway signalling systems.

All Engineers used for Testing and Commissioning of the Works will be
required to hold WestNet Rail track access accreditation sufficient to perform
safeworking duties (Level WPW05, WPW15 or WPW21).

8. TEST EQUIPMENT

Where the Works are undertaken by contract and unless otherwise nominated in the technical
specification, the Contractor shall provide all test equipment to fully check and verify equipment
functions and system performance for the Works. The Contractor shall submit full details of all
proposed test equipment in the project ITP.

Where testing and commissioning requires calibrated results, test equipment shall be fully
calibrated in accordance with WestNet Rail procedure W110-600-041 or the applicable
Australian Standard as appropriate, prior to the commencement of any tests to be performed.
Where calibration is essential to a successful outcome, the test equipment shall be re-calibrated
prior to the commencement of testing for each separable portion or stage of the Works. The
Contractor shall make the test equipment calibration certificates available for inspection by the
Superintendent before testing starts.

9. COMMUNICATIONS EQUIPMENT USED BY CONTRACTORS

Where the Works are undertaken by contract, the Contractor shall provide an approved means of
co-ordinating commissioning of the Works which shall generally be a sufficient number of
approved hand-held and base station radios to assist in efficiently and safely performing the

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testing and commissioning of the Works. The proposed number of radios shall be listed in the
project ITP.

Where radio communications are to be used, the Contractor shall provide at least one (1)
additional hand held radio for use by the Superintendent.

Where radio communications are to be used, the Contractor shall not use WestNet Rail radio
frequencies for testing and commissioning but shall also have at least one radio fitted with the
appropriate WestNet Rail radio channels. This shall be available on-site during all testing and
commissioning activities. The Superintendent will advise the WestNet Rail frequencies required
to be fitted to the radio/s.

All types of radios and operating frequencies proposed to be used by the Contractor shall be
subject to the approval of the Superintendent.

10. PROJECT INSPECTION AND TEST PLAN

10.1. Analysis of Inspection and Testing Requirements

Where the Works are undertaken by contract and after the award of contract, the
Contractor shall immediately commence an analysis of the inspection and testing
requirements for the safety and quality certification of the Works. This shall include
consideration of the quality and safety inspection and testing requirements of the design,
manufacturing and installation processes.

The Contractor shall also include the provision for arranging the verification and
certification of inspections and testing performed by others, not under its direct control
where such inspections and testing affect the outcome of work by the Contractor.

Based on the analysis of the safety and quality requirements for the Works, the
Contractor shall then produce a project Inspection and Test Plan (project ITP) for
approval by the Superintendent. The project ITP shall distinguish all certification
inspections and tests to be performed for safety assurance, from all other inspections and
tests to be performed for quality assurance.

Where the Works are undertaken by WestNet Rail staff, the Signal Systems Manager
shall ensure that an Inspection and Test Plan is prepared for the Works.

Quality assurance inspections and tests for other than the certification of the safe
operation of the installation need not be the exclusive responsibility of the Testing
Engineer or the Commissioning Engineer. Such inspections and tests may be performed
by personnel with lesser qualifications and experience, but under the control of the
Testing Engineer or the Commissioning Engineer.

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10.2. Documenting the Project Inspection and Test Plan

The project ITP shall be a fully resourced and scheduled document, with all inspection
and testing processes divided into tasks and presented in work packages, such as
installation packages, testing packages and commissioning packages for each stage or
separable portion of the Works.

Each work package shall be supported with test documentation, which details the tests to
be performed and the test schedules and/or certificates to be completed as certification
that the inspection and testing process has been successfully completed.

The Project ITP shall include a summary of all safety-related inspection and testing
activities, nominating the certifying Testing Engineer and /or Commissioning Engineer
responsible for each activity, together with the related documentation to be certified.

10.3. Developing the Project Inspection and Test Plan

10.3.1. General
Other than for relatively minor works, the Project Inspection and Test Plan
shall be developed in a minimum of three clearly identifiable stages:

(a) the development of the inspection, testing and commissioning strategy;

(b) the further development of the strategy into an inspection, testing and
commissioning outline plan, and finally;

(c) the development of the Project Inspection and Testing Plan.

10.3.2. Inspection, Testing and Commissioning Strategy

The inspection, testing and commissioning strategy is intended to broadly
identify all the quality and safety issues for the Works, for later analysis and
breakdown into elements attached to activities such as factory acceptance
testing, installation testing, circuit testing, function testing, commissioning and
the like.

The development of the inspection, testing and commissioning strategy shall

take the following into account:

(a) the extent of new signalling equipment

(b) the extent of alterations required to existing signalling equipment

(c) the extent of existing signalling equipment to be made inoperative/removed

(d) the extent of the Principal’s limitations on stagework, track access, track
possession, working hours, support staff availability and the like

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(e) the extent of inspection and testing requirements at interfaces with the
existing signalling system and the proposed method for performing these
tasks without disrupting existing services

(f) track possession requirements; location, times and duration

(g) track access requirements; location, times and duration

(h) co-ordination with other trades and sub-contractors involved with the
Works

(i) Testing and Commissioning staff requirements

(j) Testing and Commissioning staff transport requirements

(k) Testing and Commissioning staff Communications equipment

requirements

(l) test equipment requirements

(m) contractual obligations and availability of the Superintendent’s staff

(n) equipment spares requirements

(o) requirements for training the Principal’s staff

(p) reviews and approvals required - schedule of reviews and approvals

required from the Superintendent such as:

i) documentation reviews

ii) inspection and testing staff reviews

iii) possession approvals; and

iv) access approvals

(q) requirements for the Principal’s staff such as Safeworking Inspectors.

10.3.3. Outline of Inspection, Testing and Commissioning Plan

The next stage of developing the project ITP is to expand the strategy into an
inspection, testing and commissioning outline plan, preferably in a matrix
format.

Each stage or separable portion of the works must be dealt with as a separate
module.

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For each stage or separable portion of the Works, a matrix or other method
must be generated to identify at least the following for each Activity:

a) the “Activity Type” - which may fall into the following broad categories:
(i) design control
(ii) integrity procedure
(iii) factory acceptance inspection and testing of manufactured
equipment
(iv) circuit testing
(v) apparatus function testing
(vi) system function testing
(vii) commissioning tests
b) the “System/Apparatus/Element” – this is a summary of all the signalling
components identified for the stage or separable portion of the Works. At
this point it is not necessary to identify each signalling element
individually, but rather the types and quantities of each element;

c) “Certified By” - describes the category and competency of the person who
will certify the successful completion of the Activity and that all quality
and safety procedures have been complied with;

d) “Standards and Procedures” - describes the reference documents to be used

against which the Activity will be tested and certified;

e) “Certification Documents”- describes the document types that will be

provided to record tests results and the certification of the Activity;

f) “Time” - describes the time when the Activity is planned, and is related to
the programme for the project;

g) “Duration” - describes the duration of the Activity, and is related to the

programme for the project;

h) “Staff Resources” - Describes the staffing resources required to undertake

the Activity;

i) “Other Resources” - describes the other resources such as test equipment,

vehicles, radios and the like, required to undertake the Activity.

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10.3.4. Detailed Project Inspection and Testing Plan

The detailed project ITP shall be based on the outline plan and contain all the
information presented in that plan, with additional resource and timing detail
provided.

Each element of the outline plan must be broken down into clearly identifiable
modules based on each stage or separable portion of the Works. For each
module, it is necessary to provide the following in detail, for each Activity, as
previously identified. An acceptable method of presenting much of the
required information is in the form of a Gant chart. The following detail shall
be provided:

a) a unique quality number/code used to identify the Activity and all

documentation associated with it;

b) a short description of the Activity and all associated signalling Elements

assigned to it (e.g. Forrestfield Yard - Factory Acceptance Test SER1 PBI,
SER2 PBI; Factory Acceptance Test location case F6.1, F7.2, F12.5;
Function Test location F6.1, Commission Forrestfield South, etc.);

c) name and designation of the Contractor’s staff responsible for certifying

the satisfactory completion of the Activity;

d) a complete list of the testing and certification documentation and

certificates applicable the Activity;

e) a short description of all the procedures required to be undertaken to fully

inspect and test the signalling Elements associated with the Activity;

f) a further breakdown of the signalling Element to be inspected and tested

into individually identifiable components on the Test Copy and/or
Commissioning Copy of the drawings;

g) the time over which the Activity is programmed to occur in terms of:
(i) Factory acceptance, installation, site testing or commissioning phase
(ii) Programmed date and time, depending on the nature of the activity
(iii) duration in terms of days or hours, depending on the nature of the
activity;
h) Resources to be allocated to the Activity in terms of:
(i) team identification number;
(ii) number of people in team, and
(iii) category of each of the personnel in the team, including names and
designation;

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(iv) special resources required.

10.4. Review And Approval Procedure for Works by Contractors

Unless nominated otherwise in the contract documents, at least four (4) weeks prior to
the programmed date for the commencement of the first inspections or tests, The
Contractor shall submit two copies of its proposed project ITP to the Superintendent for
review and approval.

Within two (2) weeks of receipt of the proposed project ITP, the Superintendent will
return one copy of the proposed project ITP to the Contractor, with any required
alterations and comments, and marked “approved to proceed”.

10.5. Reports
The Test and Commissioning Engineers shall prepare and maintain comprehensive test
reports and records of all factory acceptance testing, site tests, function tests,
commissioning test and the like, carried out during the manufacturing, installation, pre-
testing, setting to work, testing and commissioning phases of the Works.

The Test and Commissioning Engineers shall produce signed test reports setting out the
results of all tests carried out in relation to each Activity of the approved project ITP.
All reports shall be signed by the Testing Engineer. Contractors shall submit reports in
duplicate, with one soft copy, to the Superintendent at least two (2) working days prior to
the commencement of any commissioning activities.

Immediately following completion of each commissioning Activity, the Commissioning

Engineer shall prepare and sign a report certifying that all of the approved “Testing and
Commissioning Procedures” have been complied with, commissioning of that portion of
the Works has been satisfactorily completed and that portion of the Works has been
brought into service in a safe manner.

For works performed by contract, within two (2) weeks of receiving approval of the
Contractor’s reports and on completion of all stages or separable portions of the Works,
all acceptance testing, site testing and commissioning documents shall be consolidated
into one or more bound volumes and two (2) copies shall be submitted to the
Superintendent as a permanent record of the procedures and results applied to the
installation.

11. WEEKLY NOTICE INSERTIONS

For any proposed work that will affect the operation of rail traffic in any way or alter the
position, numbering or function of any signal, track circuit, points or switchlock, the Test and
Commissioning Engineer shall prepare a Weekly Notice insertion. Contractors shall submit this
for approval by the Superintendent.

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Weekly Notice insertions shall be prepared a minimum of two (2) weeks prior to the date for
commencement of the proposed works.

Each Weekly Notice insertion shall provide full details of the proposed works, including the
location, the number of staff, the duration and details of any signalling equipment which will be
affected.

The Weekly Notice insertion shall include “Diagrams of Signalling” or “Scale Signalling Plans”,
as required, to fully describe the extent of the works.

12. EXAMINATION, INSPECTION, TESTING AND COMMISSIONING

12.1. General
The examination, inspection, testing and commissioning activities nominated in the
relevant clauses of this Code of Practice and the referenced documents, shall be carried
out so as to:

(a) confirm that the Works comply with the requirements of the technical specification
and the approved design;

(b) identify and rectify any deficiencies in the approved design, prior to bringing the
Works into service;

For works performed by contract, all materials, equipment and workmanship undertaken
by the Contractor during the design, supply, manufacture, assembly, installation, testing
and commissioning of the Works, whether at the manufacturer’s works or at site, are
subject to inspection by the Superintendent.

For works performed by contract, inspections of all critical stages of the Works will be
made by the Superintendent to ensure all aspects of the technical specification and any
other instructions issued throughout the duration of he Works have been adhered to. The
Contractor shall allow the Superintendent reasonable access at any time for this purpose.

The Superintendent may reject any materials, equipment or workmanship which does not
meet the requirements of the technical specification or the Principal’s relevant Code of
Practice.

12.2. Examination and Inspection

The Test and Commissioning Engineer shall perform examination and inspection of the
Works in accordance with the approved project ITP, using personnel independent of the
manufacturing and construction processes.

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If a contract specification for Works undertaken by contract requires notice of

examination and inspection to be given to the Superintendent in respect of any part of the
work under the Contract, that part of the work shall not have further work placed thereon
or be covered up or put out of view without the prior approval of the Superintendent.

12.3. Testing
The Test and Commissioning Engineer shall perform testing of the Works in accordance
with the approved project ITP, using the approved personnel.

For contract works, where there is any doubt as to the suitability or adequacy for the
intended purpose of any materials, equipment or workmanship to be supplied under the
Contract, the Superintendent may direct that specific additional tests be carried out on
the Works in question. Such tests will be executed by others under the direction of the
Superintendent. The Contractor shall not proceed with any further installation of
materials, equipment or workmanship subject to such testing, until tests are satisfactorily
completed and the approval of the Superintendent has been given.

12.4. Notice of Testing for Contract Works

Not less than fourteen (14) days notice of all examination, inspection and testing
activities shall be given to the Superintendent, so that the Superintendent and/or the
Principal may be represented during performance of these activities.

12.5. Testing and Commissioning

12.5.1. General
“Test” copies of documentation and drawings shall be produced from the
“Construction” documentation and drawings for each stage or separable
portion of the Works by the Contractor in the case of work done by contract,
alternatively by the Signal Systems Manager in the case of work performed by
WestNet Rail Staff. No testing work shall commence on site until “Test”
documentation and drawings are provided. Test documentation and drawings
shall be stamped “Test Copy”, signed and dated by the Testing Engineer.

Test documentation and drawings shall be marked up with test ticks on wires,
at terminations and the like, as tests proceed and in accordance with the
Principal’s standard procedures. Each document or drawing shall be signed
and dated after testing, by the Contractor’s Testing Engineer.

For contract works, the Test Copies of all documentation and drawings shall be
retained by the Contractor until completion of the Works, and shall be
available for inspection by the Superintendent, at all times. At the end of the
Works, all test and commissioning copies shall be provided to the Principal.

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Upon completion of the testing of equipment at each location, “Installation”

drawings left on site shall be immediately marked up with any changes, signed
and dated by the Testing Engineer.

Changes required during testing and commissioning of the Works shall be

transferred onto the “As Constructed” drawing sets, within two (2) weeks of
the completion of the commissioning of each stage or separable portion of the
works.

12.5.2. Design Details

One set of independently checked and approved plans and drawings shall be
provided for the exclusive use of testing personnel. The range of plans and
drawings may include: -

· Scale Signalling Plan (Track Plan)

· Equipment Room Drawings
· Location drawings
· Track bonding plans
· Signal construction/cable running plan
· Signal power distribution circuits and diagrams
· Signal circuit diagrams
· Location/Frame/Rack layouts, termination lists, wiring diagrams, relay
contact analysis
· Control console and diagram
· Signal control tables
· Signal aspect charts
· Stagework plans
· Signal interlocking data or logic files
The copy of the design details provided for testing shall be identified for this
purpose by using an approved method which clearly distinguishes them from
drawings issued for other purposes.

All plans and drawings shall be stamped with “Test Copy”.

Once design details have been issued, any required modifications shall marked
up on the Test Copy drawings and produced as a checked and approved
amendment in accordance with the Principal’s established design procedures.

All design documentation shall be kept under strict version control and
configuration management.

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12.5.3. Factory Acceptance Testing Drawings

A master Test Copy of all drawings shall be produced prior to the
commencement of factory acceptance testing of pre-wired apparatus. The
drawings shall be updated to include any changes found necessary during
manufacture.

12.5.4. Pre-Commissioning Testing Drawings

Any modifications performed as a consequence of factory testing shall be
incorporated on the Test Copy drawings and on-site pre-commissioning testing
shall be performed utilising the Test Copy drawings. Any errors or
modifications shall be marked up on the Test Copy drawings as the master
record and also on LOCATION COPY drawings provided for each location at
locations where work is required to be performed.

12.5.5. Commissioning Drawings

Prior to commissioning being performed, any amendments marked up on the
Test Copy of drawings shall be incorporated into the master drawings which
shall be used to produce commissioning documentation as follows:

· master COMMISSIONING COPY and 3 copies thereof for distribution as:

· LOCATION COPY, to be retained on site at the end of commissioning;
· RSS COPY and
· OFFICE COPY (WestNet Rail), to be provided before commissioning .
Any amendments found to be necessary during commissioning shall be marked
in waterproof red ink on all 5 sets of commissioning documentation.

12.5.6. Stages of Testing and Commissioning

The testing and commissioning process shall include the following stages:

· Factory Acceptance and Installation Testing

· System Function Testing and Validation
· Certification and Acceptance Testing

12.5.7. Factory Acceptance Testing

Factory testing may not be applicable where changes are made solely to
existing in-service equipment or the work is of a minor nature. In all other
instances, normal practice shall be to test as much of the Works as practical
under controlled conditions off-site.

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Relay Based Equipment

Where relay based location cases or relay racks are pre-wired before
installation on site, testing of these items of equipment shall be carried out in
the workshop.

The tests performed shall include:

· General apparatus inspection

· Bell tests/continuity tests
· Insulation tests
· Wire count
· Null count
· Function test where practical.
All tests shall be recorded in accordance with standard WestNet Rail practices.

This shall involve the production of a Test Certificate for each test and the
marking up of the Test Copy of the drawings.

Modifications found necessary whilst carrying out pre-site testing shall only be
applied and installed once they have been approved by the Superintendent or
Signal Systems Manager for contract-performed works and works performed
by WestNet Rail staff, respectively.

If any part of the pre-site testing cannot be completed due to missing

equipment or internal wiring, then these deficiencies must be listed on the Test
Certificate.

The Superintendent or Signal Systems Manager for contract-performed works

or works performed by WestNet Rail staff, respectively, may, at his discretion,
instruct the Contractor to complete all deficiencies before despatching the
Works to site.

Processor Based Interlocking Equipment

All Processor Based Interlocking (PBI) equipment shall be assembled on racks

in the factory, loaded with software and fully factory acceptance tested (FAT),
prior to dispatch to site.

Unless the PBI equipment is supported by a fully verified and validated

simulation and test system, for which a safety case has been submitted to and
accepted by the Principal or C&CS Manager for contract-performed works or
works performed by WestNet Rail staff, respectively, all PBI function tests
shall be performed by connecting the equipment in its final configuration.
This shall include the interfacing of all I/O, non-vital and vital

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communications ports and the like, with switches, relay contacts, relay coils,
modems, etc.

Where the PBI equipment is to be remotely controlled, the PBI equipment

shall be connected to a test Control Panel via its normal non-vital control
communications port. The Control Panel shall be used to input all controls
and receive all indications and shall communicate with the PBI equipment in
the same data protocol as will be used in the final installation.

In those instances where:

the PBI equipment is required to be connected by vital communications
port/s to other PBI equipment at remote locations, AND
where an approved simulation system is not available,
the Contractor or Test and Commissioning Engineer respectively for contract-
performed works or works performed by WestNet Rail staff, shall FAT all
interconnected PBI equipment together at one time.

The PBI tests performed shall include:

· General apparatus inspection

· Bell continuity tests of permanently fixed wiring/cables.
· Wire count (where required)
· Null count (where required)
· Full Function Test
All tests shall be recorded in accordance with standard WestNet Rail practices.

Where the FAT identifies the need for any changes to the application software,
the complete Function Test shall be repeated after such changes have been
made, unless approved otherwise by the Superintendent or Signal Systems
Manager respectively for contract-performed works or works performed by
WestNet Rail staff.

12.5.8. Installation Testing

Site Testing

Detailed tests shall be carried out in accordance with the approved project ITP
and the procedures of Appendix A, to ensure that:

· each contact is electrically opened and closed by operation of its

controlling device and has been correctly adjusted;
· each contact, fuse, and link effectively opens and closes the circuit under
test;

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· the insulation of the circuit meets the required standards.

Following satisfactory completion of the above items, the circuit as a whole
shall be functionally tested.

Cables tests

Tests as detailed in the project ITP and as performed in accordance with the
procedures of Appendix B, shall be carried out on each core of each cable, to
check:

· Continuity of conductors
· Insulation resistance
· Correct terminations

Apparatus Tests

Tests as detailed in the project ITP and as further specified in Appendix C,

shall be carried out to verify that each item of signalling apparatus equipment
operates safely and in accordance with the approved design.

Setting to Work

All new and modified existing working equipment for each part or separable
portion of the Works shall be set to work and adjusted. All setting to work
shall be performed in accordance with WestNet Rail’s “Engineering
Maintenance Instructions and Schedules for Signalling Equipment”, amended
where appropriate to reflect new equipment types and designs.

Any such amendments shall first be made by the Contractor and approved by
the Superintendent for contract-performed works, or Signal Systems Manager
for works performed by WestNet Rail staff, prior to setting the signalling
equipment to work.

Setting to Work shall include:

(a) adjustment of all power supply voltages, transformer tappings, circuit

breaker trip settings and power supply current limits;

(b) adjustment of control system equipment and communication device line

levels;

(c) adjustment of battery charger levels;

(d) adjustment of track circuit equipment feed and receiver levels and
sensitivities;

(e) adjustment of voltages to signal and flashing light lamps;

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(f) alignment of signal heads;

(g) adjustment of point machine operated points sets.

12.5.9. System Function Testing and Validation

Function Tests shall be carried out to verify that both the installation and the
design are functionally in accordance with the approved concept and design
specification.

Further tests shall then be carried out to validate that the installed system
operates in accordance with the required signalling principles and safeworking
rules and WestNet Rail regulations.

The following test procedures, which may be carried out concurrently, shall be
specified in the approved project ITP and shall be performed generally in
accordance with the procedures detailed in Appendices D-F inclusive:

· Function Testing
· Testing to Control Tables
· Aspect Sequence Testing

Principles Testing is normally performed at the same time as testing to the

Control Tables and relies on the tester's knowledge of signalling principles,
safeworking rules and regulations, statutory requirements and operating
requirements. The Engineer performing the Principles Testing shall confirm
the integrity of the interlocking design by trying to defeat it, attempting to set
up conflicting conditions, checking that all operational conditions that should
be able to be simultaneously set up can be: e.g. parallel routes, checking
operation under possible failure conditions, and simulating train movements
for both long and short trains.

12.5.10. Certification and Acceptance of Testing

General

Before the installation is handed over to the Superintendent for contract-

performed works or to the Maintenance Manager or his representative for
work performed by WestNet Rail staff for placing into service, the Test and
Commissioning Engineer is responsible for:

(a) collection and inspection of all test logs to ensure that they are completed
and signed off by the tester who performed the tests. Where a test log is
not completed due to, for instance, the installation is not complete, or in
the tester's opinion, the installed system does not conform to the railways
signalling standards, the tester shall endorse the test log with the reason for
non-completion. The Test and Commissioning Engineer shall, if satisfied

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with the endorsement, counter sign the endorsement and shall obtain
agreement to the concession by the Superintendent. Both the Test and
Commissioning Engineer and the Superintendent in the case of contract
works or the Maintenance Manager or his representative in the case of
works performed by WestNet Rail staff shall countersign the endorsement.

(b) collection and collation of all plans, diagrams and certification, and for
ensuring that all such documents have been received and are properly
annotated. Where it is not practicable to return completed documentation
to the Test and Commissioning Engineer prior to the handover, the Test
and Commissioning Engineer shall be notified in writing by the tester
responsible for the activities documented. The completed documentation
should be returned to the Test and Commissioning Engineer within 72
hours of such notification.

(c) as-built mark-up of plans and drawings for maintenance.

12.6. Master Test Certificate

When all Test Certificates and documentation have been collected and dealt with as
required, the Test and Commissioning Engineer shall certify that the testing is complete,
using the Master Test Certificate. The installation may then be signed into use by the
Superintendent in the case of contract works or the Maintenance Manager or his
representative in the case of works performed by WestNet Rail staff.

A suggested format for the Master Test Certificate is given in Appendix H.

12.7. Equipment Removal

All released or surplus signals, signalling equipment, relays, cables and wiring shall be
promptly removed from site. Also all surplus insulated rail joints temporarily bonded
during commissioning should be removed and rails either welded or permanently
bonded.

12.8. Plan Revision and Issue

All plans, drawings and tabulations shall be promptly revised to include any
modifications to circuit designs or terminations as recorded on the official testing copies,
and re-issue new and dated 'as in service' plans and drawings, as required by WestNet
Rail’s drawing control system.

12.9. Permanent Testing Record

All marked up and certified copies of test drawings, tabulations, test certificates, check
lists, etc. shall be consolidated into a permanent record of the testing and commissioning

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of the project and these records shall be retained as required by WestNet Rail’s record
management system.

12.10. Asset Register

The type, location, name and serial number of all equipment installed and released shall
be kept in a permanent record for maintenance purposes, as required by WestNet Rail’s
asset management system.

12.11. 28 Day Acceptance Test for Work Performed by Contract

Upon completion of the changeover and commissioning of each stage or separable
portion of the Works, that portion of the Works shall be put on test for a twenty-eight
(28) day period. During this period any system failures or problems shall be recorded
and immediately rectified by the Contractor's site staff. Any major failure shall cause
the “28 day” test period to be restarted.

Each stage or separable portion of the Works shall only be deemed to be operating
correctly once it has successfully passed a “28 day” test without a major failure. Major
failures shall not include events such as derailments caused by reasons unrelated to the
Works.

During the “28 day” test period, the Contractor shall provide sufficient staff on site to
ensure that any faults found or alterations required by the Superintendent during the test
period, can be practically and efficiently rectified by the Contractor.

13. ACCEPTANCE OF THE WORKS

13.1. Joint Inspection

Prior to the Superintendent accepting any stage or separable portion of contact works,
the Contractor shall arrange with the Superintendent and the Principal to undertake a
detailed joint inspection of that portion of the Works to confirm that all of the Works
have been correctly supplied, manufactured, assembled, installed, tested and
commissioned in accordance with the contract specifications. The Superintendent shall
invite the Maintenance Manager or his representative to participate in the joint
inspection.

Where the Works are performed by WestNet Rail Staff, the Signal Systems Manager
shall arrange a joint inspection attended by the Project Manager and Maintenance
Manager or his representative.

Upon completion of the joint inspection, the following shall be prepared by the
Contractor (for work performed by contract) or Project Manager (for work performed
by WestNet Rail staff):

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(a) a list of all outstanding work to be completed

(b) a list of all defective items requiring attention which shall be rectified forthwith
(c) a list of all defective items to be rectified at a later date.
For work performed by contract, the Contractor must attend to these items, and properly
complete the Works to the satisfaction of the Superintendent and by the time nominated
by the Superintendent. Failure to attend to these items will render the Contractor in
breach of the Contract and the Superintendent will then arrange for performance of these
Works at the Contractor's expense.

For work performed by WestNet Rail, the Project Manager must attend to these items,
and properly complete the Works to the satisfaction of the Signal Systems Manager and
within the time to do so advised to the Signal Systems Manager and Maintenance
Manager.

13.2. Acceptance Criteria for Work Performed by Contract

The Superintendent will advise his acceptance, in writing, of any stage or separable
portion of the Works only when all of the following criteria have been met for that
portion of the Works:
(a) All work has been completed in accordance with the “Principal’s Project
Requirements”, including reinstatement of surfaces, removal of any waste or
redundant equipment and all other rectification as may be required to bring the
Works up to approved standards.
(b) The Superintendent has undertaken, and successfully completed a detailed joint
inspection of the Works.
(b) The Contractor has successfully tested and commissioned the Works, in accordance
with the approved Project ITP, in the presence of the Superintendent and to the
approval of the appropriate Regulatory Authorities; including any remedial work
required to be performed.
(d) The Contractor has provided a report signed by the Testing Engineer certifying that
all of the approved Contractor’s “Testing and Commissioning Procedures” have
been complied with, and commissioning of the Works has been satisfactorily
completed.
(e) The Works are operating satisfactorily and have been brought into service by the
Contractor ready for handing over to the Principal (i.e.: upon completion of the 28-
day test).
(f) The Contractor has provided all “As Constructed” documentation, drawings and
software for the Works.
(g) Training of the Principal’s staff has been completed.

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14. TEST DOCUMENTATION

14.1. Test Records

The testing copy of the design details shall be the primary auditable record of testing
achievement.

Individual tests shall be recorded on the test copies using check marks specified in the
approved project ITP.

Certificates and checklists should be used as necessary to demonstrate that all testing
activities have been fully carried out, their format being dependent upon the nature of the
testing involved. Certificates themselves should be kept as simple as possible.

The progress of the testing shall be monitored. The current status of what has been
completed and what is still to be done should be clearly visible. The use of a 'Summary
Check List' upon which the Test and Commissioning Engineer endorses each check list
item, is a method that would satisfy this monitoring requirement. The format for
Summary Checklist shall be detailed in the Approved project ITP. A suggested format
for Summary Check List is given in Appendix H.

14.2. Test Logs

A Test Log shall be used to record any queries, disagreements or deficiencies that have
occurred from the beginning to the end of a test.

The Testing Engineer shall initially fill in the Test Log detailing the problem as it is
seen. The symptoms shall be clearly identified and, where necessary, shall give
guidance to the person from whom the response is expected.

Each item should be entered on a separate Test Log.

All design modifications shall be independently checked by a competent person.

All resulting modifications shall be subject to a retest. Such re-testing shall include all
parts of the installation which could have been affected by the alteration.

14.3. Methods of Annotation

The methods of annotation to be employed in recording tests shall be defined as early as
possible and detailed in the Approved project ITP. Decisions need to be made on:
(a) a precise method of confirming the successful completion of a test;
(b) a precise method of confirming a second test on the same item on the same primary
records of test;
(c) a clear identification of who carried out the test, e.g. printed name and position;

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(d) the allocation of specific marking colours to be used by each tester;

(e) a method of adding reminder notes and comments to documents;
(f) a precise methods of confirming completed sections, e.g. individual sheets, series of
tests, stageworks, etc.;
(g) a method of identifying errors and invoking corrective action in the event of failed
tests;
(h) the maintenance of test logs showing the tests failed and the remedial action taken.
A uniform system of check marks, notations and colouring shall be detailed in the
Approved project ITP.

A suggested uniform system of check marks, notations and colouring is given in

Appendix G.

DETAILED CIRCUIT TESTS

A1. SCOPE

This Appendix describes detailed circuit tests to satisfy the requirements contained within
Code of Practice W190-600-002.

These requirements are restated here with examples of means of compliance.

Detailed circuit tests shall be carried out to ensure:

a) "Every contact, terminal, wire, and functional item shown on the circuit diagram is
actually in the circuit exactly as shown"
This requirement is generally satisfied by the performance of a 'Continuity Test' and
wire count.
See Appendix A, Section 2 and Appendix B, Section 3.
b) "Each contact is electrically opened and closed by operation of its controlling device
and is correctly adjusted"
This requirement is generally met through the use of:
- sealable relays manufactured and tested to comply with an appropriate
railway safety standard
or where equipment cannot be sealed, by
- adjustment and test certification for each item of installed equipment.
(See Appendix C, "Apparatus Tests").
c) "Each contact, fuse, and link shown on the circuit diagram effectively opens and
closes the circuit under test"
This requirement is generally satisfied by the performance of a 'Strap and Function
Test' (see Appendix A section 6) unless it can be demonstrated that the aggregate of
other physical and functional tests to be carried out will verify the presence and
effectiveness of the particular contacts in the circuit.
d) "The circuit does not include any contact, terminal, or wires not shown in the circuit
diagram"
This requirement is generally satisfied by the performance of both a 'Wire Count' and
a 'Null Count' test. See Appendix A, sections 3 and 5.
e) "The insulation of the circuit is satisfactory"
This requirement is generally satisfied by the performance of insulation and resistance
tests. See Appendix A, section 4 and Appendix B, sections 2 and 3.

A2. CONTINUITY TEST (INDIVIDUAL WIRES)

A continuity test (sometimes referred to as a bell or buzzer test) is a test undertaken in

conjunction with a wire count to ensure that each individual wire, forming part of an
overall circuit, conforms to the circuit and/or wiring diagram. It shall be carried out using
a device that shall not indicate continuity if the loop resistance is greater than 1.0 ohms.

On new installations, where practical, the test shall be carried out with all wires
terminated and all relay connectors locked into their base positions but with all relays,
fuses and links removed.

On existing installations, wires shall be tested prior to termination, and then be

appropriately labelled and insulated. A check shall be made to ensure that all loose wire
ends are suitably insulated. All labels shall remain until the wires have been finally
terminated during changeover and testing is completed.

The tester on verifying each wire is correctly run and terminated shall mark the
corresponding line on the circuit diagram. Where the wire cannot be terminated
immediately it shall be checked as being present and ready for termination, suitably
insulated and identified by its permanent label. Its subsequent termination shall then be
overseen by a tester who shall also repeat the continuity test of the wire when both ends
have been terminated and carry out a wire count on the affected terminals to ensure the
terminated wiring is in accordance with the diagrams.

A3. WIRE COUNT AND NULL COUNT

A3.1 WIRE COUNT

A wire count is a visual inspection to verify that the correct number of wires are
connected at each termination point in accordance with the circuit diagrams and/or wiring
diagrams and that the relay contact wire identification sleeves correspond with the relay
base position number. This count will normally be done at the same time as the wire
continuity test or as a separate exercise. The wire count should not be carried out until all
wires are terminated and all relay or plug connectors are inserted and fully locked into
their relay/plug base positions.

The tester shall examine the apparatus and the corresponding circuit wiring diagram and
analysis sheets, and verify the number of conductors terminated at a particular point is as
shown on the circuit wiring diagrams.

There should normally be no more than two wires attached to any single termination
point in the case of a plug-in relay and one wire in the case of a clamp type terminal.

The wire count shall include checking the wiring identification labels on each wire
connected to a terminal and verifying that the labels correctly identify the termination
point of the wire. Rail mounted fuses should be closely checked to verify the presence or
absence of common connections.

The tester on verifying that the correct number of wires is attached to each termination
point shall mark the individual ends of each wire on the Test Copy circuit diagram (see
Appendix G).

The tester shall check that terminations and crimps are correctly made, wires are not
trapped under adjacent terminals and spade type crimps are correctly locked into plug
boards or terminal blocks.

Prior to proceeding with the next test, the person who is marking up the circuit books
shall check that cross-references in the documentation (contact analysis/fuse/terminal
analysis, etc.) correspond with wire-count results.

Once it has been verified that the circuits and analysis documentation are correct and in
agreement then testing may continue.

When internal parts of a circuit are tested separately from the external part of a circuit the
wire count on both sides of the external cable termination link shall be performed by
every person who tests the circuit either side of the cable termination link. That is, by the
persons doing circuit testing of the internal wiring, by persons doing circuit testing of the
external wiring, and by persons doing through circuit tests.

The wire count on both sides of the external cable termination link shall be recorded on
the circuit diagram in the standard manner by the person conducting the circuit testing of
the internal wiring and verified by the person conducting the through testing

All wires in vital signalling circuits shall be checked to be shown as wire-counted on the
testing copy of the circuit diagram by the person responsible for testing the circuit

When wire counting, all conductors connecting to a terminal whether wires, busbars,
links or other strapping shall be checked.

Wire counts, bell continuity tests, and insulation tests shall include the external wiring
run to
- signal head transformer terminal or lamp terminals,
- point machine terminals,
- switch lock terminals,
- electric lock terminals,
- level crossing mechanism terminals,
- highway and boom lights terminals and
- all operating mechanisms and contact terminals of operating mechanisms.

Wire counts, bell continuity testing and insulation testing of the internal wiring within
equipment mechanisms may be carried out and carried in pre-site tests and factory
acceptance tests. Certificates are required.

A3.2 NULL COUNT

The Null Count is carried out after the Bell Continuity Test and Wire Count have verified
the wiring connecting to the respective terminals.

The tester shall examine relay bases, other operating equipment terminal assemblies, and
fuse and terminal racks and the corresponding analysis sheets, and: -

(a) verify that there are no conductors connecting to terminals shown as spare in the
contact/fuse/terminal analysis sheets in the circuit book; and

(b) verify that there are no contacts/fuses/terminals shown in use in the circuit book
analysis sheets that are spare and without connected wires, and

(c) mark the spare contact, fuse or terminal with a tick on the analysis sheets, to indicate
the test is successfully completed.

In conjunction with the Bell Continuity Test and the Wire Count, the Null Count, if
carried out over the whole installation, provides assurance that there are no 'rogue'
connections in the circuits. Null Counts on a portion of the equipment in a circuit control
area will provide less assurance.

A4. INSULATION RESISTANCE TEST

In signalling installations where safety integrity is dependent upon the insulation between
individual circuits, the insulation testing of all wiring and equipment associated with the
signalling installation shall be carried out prior to bringing into use any new work using
an approved insulation testing instrument with a voltage output of 500 volts D.C.

All individual wires run shall have their insulation resistance to the frame of the housing
or rack tested. The Testing Plan shall specify the minimum acceptable values of
insulation resistance. The use of a combined continuity and insulation resistance testing
device, which tests continuity at 500 volts above earth, will facilitate this requirement.

Insulation tests, as specified in Appendix B, shall be made on all lineside signalling

cables including local and power cables.

A5. INSULATION TESTS: CIRCUITS

When insulation testing circuits, it is desirable to test the complete circuit as a single test.

In approved cases, insulation testing of internal wiring may be done at the same time as
the bell continuity test, one wire at a time, using an approved combined bell
continuity/insulation tester.

When performed in conjunction with continuity tests, any insulation to earth defects in
plug-in relays and some other equipment will not be detected as these are removed for the
bell continuity tests. Similarly any insulation breakdown to the equipment case frame,
but not earth, will not be detected.

This needs to be covered by other means, e.g., earth leakage detection tests on busbars
during circuit function tests, individual equipment insulation tests, equipment acceptance
tests, or a later test of the complete circuit.

Testing of a complete circuit, with all other circuits connected and working, has the
added advantage of possibly detecting an insulation breakdown directly between circuits
and not via earth.

A5.1 Lightning Protection Devices

Prior to testing, all lightning protection devices must be removed or disconnected to

avoid incorrect or misleading readings.

A5.2 Removal of solid state devices

To avoid damage from the 500 volt output of the “Megger” all solid state devices
(electronic timers, flashing relays, rectifiers, etc.) must be disconnected or removed prior
to testing.

A5.3 Rotary Contacts

When testing circuits containing rotary contacts or other contacts with bridging segments,
the test must be made with the contact closed to ensure that the segment or bridging piece
is in the circuit.

A5.4 Equipment Case Earth.

Point mechanisms are mounted on sleepers and insulated from the rails and therefore
isolated from earth. All circuits passing through the points machine must therefore be
tested to the case of the machine as well as to earth. Circuits through Signal mechanisms,
Switch locks, rotary arm contacts, etc. must be similarly tested.

A5.5 Transformers

When testing circuits containing transformers the primary and secondary wiring must be
individually insulation tested.

A5.6 Use of common negatives and distributed supplies

Special attention is required in areas where common negatives are in use or where
supplies run for a considerable distance as an insulation fault in one of these circuits may
affect a number of signals or other equipment.

A5.7 ‘Megger’ Test Instrument

The insulation testing of all wiring and equipment associated with signalling installations
must be carried out prior to bring into use any new work and there after at regular
intervals with an approved ‘Megger’ Type tester with a voltage output of 500 volts D.C.
and a current output of no more than 3 milliamps. This can be a hand generator type or
an electronic version. Where an electronic version is used, it must be approved by the
Signal Systems Manager or the Maintenance Manager.

A5.8 Regularly check Insulation Test Equipment and Earth.

Test ‘Meggers’ to ensure correct operation and voltage and current output before
commencing the tests and at regular intervals during tests.

Test the test earth immediately prior to performing a series of tests and immediately after
the last of a series of tests. Retest if disturbed at any time.

Where a combined bell tester/insulation tester is approved regularly test the insulation
tester to ensure it detects an insulation resistance to earth below the stipulated value.

A5.9 Insulation Test Conditions

Insulation testing involving external wiring should be carried out in wet/damp conditions
wherever practical.

Record weather conditions at time and enter on test certificate.

A6. INSULATION TESTS: CABLES

A6.1 General

Cables are to be tested when terminated at both ends; it being of equal importance that
the terminals are free of earth faults, as is the cable.

In a section of open aerial wires, the cable connecting the locations to the aerial at each
end of the section, together with the aerials themselves may be treated as a continuous
cable.

Similarly, a series of power cables connecting several successive locations, may be

switched (or linked) through a location, and the continuity and insulation tests performed
as if the cables were one. On new or altered work the polarity shall be proved separately
at each location.

Minimum cable insulation values for new cables shall be: -

· 60 Megohm per km conductor to earth

· 5 Megohm per km sheath to earth

· 60 Megohm per km conductor to conductor.

Any failure to attain minimum values for new cables shall be regarded as a fault
condition.

Values for second-hand or used cable are to be as set out in the Contract Specification or
as agreed with the Signal systems Manager or Maintenance Manager.

The tests shall be carried out in the following order: -

¨ verify that any cables with metallic sheaths have their earthing or arrestors correctly
installed and removed prior to tests

¨ verify that the correct cable conductor size and cable insulation has been installed

¨ prove integrity of “earth test” (i.e. test equipment and test earth)

¨ test continuity of each conductor being insulation tested

¨ test insulation between each conductor and all other conductors

¨ where cables with metallic sheaths are used, test insulation between each conductor
and the cable sheath

¨ test Insulation between each conductor to earth

¨ test Insulation between sheath to earth

¨ check correct polarity of all power cable

A6.2 Continuity Test

Continuity must be checked before Insulation Testing to ensure that the correct wire or
cable is being tested, has been correctly terminated and to validate the results of the
Insulation Tests. If the continuity is not complete, then the insulation tests results will
not be correct.

When continuity tests are made on multicore cables, ensure that each cable is connected
to the correct termination by connecting cable core No 1 sequentially to every other cable
conductor at one end and similarly the continuity tester at the other end.

A low voltage continuity tester should be used for continuity tests instead of the ‘Megger’
type of insulation tester, because high resistance’s may not be detected by the Megger
insulation tester.

All details of tests are to be noted on the appropriate cable insulation test sheets and
signed by the Tester.

A6.3 Conductor Insulation Testing

With proper preparation, all insulation resistance measurements on a multicore cable can
be completed in a single series of tests, alternatively the tests may be carried out as
individual tests for each conductor core.

(a) Preparation required for a Single Series of tests:

- Ensure that the cable is terminated at both ends, on standard disconnect terminals,
and that all links are open at both ends

- Connect the earth terminals of the Megger tester to a suitable Test Earth

- At the end of the cable nearest the Test Earth, connect all conductors cores
together on the cable side of the termination links with, for example, a ‘daisy
chain’ of 4mm plugs looped together

- Prove the continuity of the daisy-chain by using the Megger to check that each
plug shows a short-circuit to the No 1 plug.

- Continue testing as described below for “Individual Tests”

(b)Alternatively the following tests may be carried out as individual tests for each
conductor core, without linking the cores i.e. Individual Tests:

¨ Prove integrity of Test Earth.

Connect the insulation tester, one leg to the Test Earth, the other leg to one
conductor, or to the conductors linked together.
At the remote end of the cable, apply a second earth to the same conductor or
conductors. A reading should be obtained.
Remove the remote earth.

¨ Insulation Test, Conductor to Earth.

Measure the insulation resistance between all conductors linked together and the
Test Earth. If the measured value is to low, Megger from each conductor
individually to the Test Earth, to identify any faulty conductor or terminal.
Record the value. This should be greater than 60 megohm per km.

¨ Insulation Test, Conductor to Sheath

Measure the insulation resistance between all conductors linked together and
metallic screen (sheath). If the measured value is to low, Megger from each
conductor individually to the sheath, to identify any faulty conductor. Record the
value. This should be greater than 60 Megohm per km.

¨ Insulation Test, Sheath to Earth.

Measure the insulation resistance between the cable sheath and the Test Earth.
Record the Value. This should be greater than 5 Megohm per km.

¨ Insulation Test between Conductors

Insulate each conductor in turn from the daisy-chain, and measure the insulation
resistance between it and all the other conductors linked together. Record the
resistance value. This should be greater than 60 megohm per km.

A7. INSULATION TESTING OF COMPLETE CIRCUITS

When testing, it is desirable to test the complete circuit in a single test. As an example,
the following procedure would be adopted:

¨ Test the ‘Megger’ when the handle is turned (or the button pushed on electronic
Meggers) with both leads together a zero reading should be obtained. When the
Megger is operated with the leads separated an infinity reading should be obtained.
Check the battery condition on electronic types

¨ Connect one lead of the Megger to a suitable known earth. The earth should be
tested by connecting the other lead to another earth and operating the Megger and
obtaining a zero reading. The second earth could be obtained by using screwdriver
pushed into the ground.

¨ Carry out the necessary safeworking requirements before interfering with the
signalling.

¨ Check the circuit is completely closed and that all parallel paths are closed.

¨ Remove the fuse and disconnect the negative/common from the Busbar.

¨ Test by immediately connecting the Megger lead to the active/positive end of the
circuit, operating the Megger and noting the reading.

¨ As a check to ensure that the circuit is complete, tap the negative/common onto a
suitable earth connection while operating the Megger. A zero reading will be
obtained

¨ Insulation test between the signal arm contacts and wiring and the signal arm case,
between the relay wiring and the relay racks, between points wiring and the points
mechanism case, between switch lock wiring and switch lock case, etc.

¨ If the test reading is below the minimum requirement then the circuit must be
broken up and each individual wire tested until the defect is located. To simplify the
testing the circuit could first be broken up into internal and external components.
When the defective part of the circuit has been found it is then only a matter of
breaking up that part of the circuit.

¨ Similarly, if it is not practical to close the complete circuit for testing, then the
circuit shall be wholly tested in separate parts.

¨ Circuits containing electronic equipment shall be isolated from insulation tests.

A8. TESTING BUSBAR VOLTAGE LEAKAGE TO EARTH

A Busbar voltage test to earth consists of measuring the voltage from each leg of a supply
bus, individually, to earth. Comparison of the result obtained with the nominal bus
voltage gives an indication of whether any leakage exists, and on which leg of the bus
(positive or negative, active or common) it is.

A significant reading obtained on one leg indicates an earth leakage fault on the opposite
leg. The magnitude of the Voltage reading, referred to the bus voltage, indicates the
degree of the earth leakage fault.

The accuracy of the equivalent earth leakage indicated by the test for each leg of the
supply Busbar relies on the other leg being at a high resistance to earth.

The measurement must be carried out with the earth test voltmeters built into the normal
relay room switchboards, or by using a high-impedance input digital multimeter with a 20
k-ohm test shunt in parallel with its input terminals. These provide a suitable reference
resistance against which any earth leakage is compared.

The use of a high-impedance input digital multimeter directly without the 20 k-ohm test
shunt, will lead to misleading results.

The test is also misleading if both legs of the Busbar have a lower resistance to earth than
the meter resistance.

The test will only indicate a leak to earth in circuit wiring and equipment that, at the time
of the test, is closed through to the Busbar.

If there are no discrete earth leakage points, voltage leak to earth readings would depend
on the amount and distribution of circuit wiring connected to each Busbar, with
alternating current circuits also reflecting captive coupling to earth.

Busbar voltage leak to earth tests are most useful where readings are taken and recorded
regularly and any significant change investigated. Maintenance documents should
stipulate required testing frequencies.

A8.1 LOCALISATION OF EARTH LEAKAGE FAULTS

When an earth leakage fault on a Busbar is detected isolate the circuits on the bus in turn,
until the fault clears, in order to find the faulty circuit. Then further isolate sections of
the faulty circuit to find the faulty component.

This method is time consuming, and involves serious disruptions to working circuits that
are in perfectly good order.

An alternative method involves the use of an approved earth ‘locator’. This injects a low
frequency signal between the faulty bus and earth without disruption of the working
equipment. A current clip ring, tuned to the injected frequency, is then used to track the
injected fault current from the bus to the earth fault point, without any circuit, even the
faulty one, being disconnected.

A8.2 TESTING EARTH LEAKAGE DETECTORS

Earth Leakage Detectors are fitted with a push button to provide a test to earth
connection.

To test the operation of the Earth Leakage Detector (ELD) itself, a resistance of value
equal to the sensitivity setting of an ELD can be temporarily connected between the
supply Busbar and the test earth, first one leg then the other.

A8.3 POWER SUPPLY ISOLATION TEST

Isolation between power supplies is checked by measuring for zero voltage between
power supplies using a 20k ohm per volt moving coil voltmeter or a high-impedance
input digital multimeter with a 20k ohm shunt. This is carried out separately for each
Busbar supply with the other busbars.

With the power supply disconnected, the Busbar isolation to earth is checked using an
ohm meter.

A9. CIRCUIT FUNCTION TESTS

A9.1 GENERAL

The Circuit Function Test is supplementary to the Bell Test and Wire Count and is
performed to verify that the fuses, links and controlling devices are effective in
controlling the circuit function.

Circuit Function Tests involve energisation of the circuit then energising or de-energising
(or removing and replacing) in turn each control device and observing the de-energisation
of the circuit function. Specific control contacts are not individually proved.

The fuses and links are also disconnected and reconnected and the circuit function
observed.

Part circuits in separate locations can be separately function tested using a voltmeter and
a Through Circuit Function Test performed when the parts are interconnected via external
cables.

With parallel paths, there can be several combinations of the minimum number of contact
closures needed to close the circuit, as well as several combinations of the minimum
number of contact openings needed to open the circuit. Rather than test every such
combination it is sufficient, in conjunction with a Wire Count, to function test the
controls in each and every series path with all other parallel paths open.

The Circuit Function Test will not, in itself, prove that a specific contact is actually in the
circuit, particularly if the controlling device has a second contact in another position in
the circuit (double switching) or if the controlling device also switches another device
which opens the circuit function under test.

A Bell Continuity Test and a Wire Count are therefore necessary to prove correspondence
to circuit wiring diagrams.

Even so, these tests will not necessarily prove that the control device contacts are the
correct type (back, front, normal, reverse, etc.) and will not necessarily prove that they are
not shorted out or qualified irregularly.

This additional verification shall be achieved by separately testing that the specific
control contacts are electrically opened and closed by operation of the control device and
by inspection that they are the correct type, e.g. plug-in relays tested in a relay test panel
and checked against the contact analysis sheets. This is called a Contact Proving Test.

Instead of a Circuit Function Test and separate Contact Proving Test, a Circuit Strap and
Function Test can be used to prove that the specific contacts of control devices are
effective in controlling the circuit function in accordance with the circuit wiring diagram.

Circuit Function tests, inclusive of Circuit Strap and Function tests, will not prove that
series contacts are wired in the correct sequence or the correct way around. The bell
continuity test is necessary for this.

The Circuit Function Test Procedure is the same as for the Circuit Strap and Function
Test, except that the specific control contacts are not proved by strapping or manual
disconnection.

A9.2 CIRCUIT FUNCTION TEST PROCEDURE

Connect a voltmeter across the end function, or the terminals of any outgoing "part
circuit".

Test with other circuits energised to provide a high probability of detecting the presence
of any false voltages in the circuit under test.

Apply voltage to the ends of the circuit either by inserting the relevant fuses and links or
by applying a fused false feed of the correct voltage to the terminals of an incoming "part
circuit". Records of any such false feed applied shall be kept by the person conducting
and certifying the tests.

Note:
If part of a circuit that does not include the circuit function, is being circuit function
tested then a through circuit test is also required to prove that "part circuit" is in the
circuit of the function concerned.

Make the circuit operative by energising or de-energising relevant relays and other
control devices to close the complete circuit over the specific contacts involved. This
may involve temporary false feeds to the control relays and these must be recorded and
strictly controlled.

Open and close in turn each fuse, link and control contact verifying the operation of the
circuit under test by observation of the voltmeter and, except for outgoing part circuits,
the end function.

De-energise (or energise for back contacts) the respective controlling device to open the
control contact and check that the end function de-energises and the voltmeter reading
drops to zero.

Where controls are wired in parallel, each and every series path through the complete
circuit shall be selected in turn and the contacts in that path tested with all alternative
paths broken. In each case the controlling contact, fuse or link on either side of the
parallel path shall be broken and proved.

Parallel paths may emanate from fuses, links or looping.

A10. CIRCUIT STRAP AND FUNCTION TEST

The Circuit Strap and Function Test is the same as the Circuit Function Test except that it
is extended to individually prove the specific contact of the control device is effective in
the circuit.

The strap and function test of a circuit assumes that the contacts and terminals shown are
the only ones in the circuit; it verifies the wiring arrangements of these contacts by:

¨ closing each full series path in turn through the circuit with all other contacts open, to
energise the function proving that none of the open contacts are in that series path.

¨ opening each contact in turn in the series path to de-energise the function proving that
the contact being opened is in the circuit and not in parallel with any other closed
contact in that series path.

If each and every other contact in the location were open during the strap and function
test of a circuit, or part of a circuit, than the tests would also verify that no other contacts
were in series within the circuit path being tested.

If each and every other contact in the location were closed during the strap and function
test of a circuit, or part of a circuit, than the tests would also verify that no other contacts
were in parallel with any contacts within the circuit path being tested.

The procedure sets out the preferred method of opening and closing each specific control
contact during function testing to the circuit wiring diagrams.

Where earth leakage detectors are available connect a temporary audible alarm for the
duration of the tests.

A10.1 CIRCUIT STRAP AND FUNCTION TEST PROCEDURE

Procedure

Carry out Safeworking regulations and procedures and ensure that any and all trackside
apparatus affected by the tests are out of use.

Connect a voltmeter across the end function, or the terminals of any outgoing "part
circuit".

Test with other circuits energised to provide a high probability of detecting the presence
of any false voltages in the circuit under test.

Note:
If part of a circuit, which does not include the circuit function, is being strap and function
tested then a through circuit test is also required to prove that "part circuit" is in the
circuit of the function concerned

Make the circuit operative by energising or de-energising relevant relays and other
control devices to close the complete circuit over the specific contacts involved. This
may involve temporary false feeds to control relays and these must be recorded and
strictly controlled.

Open and close in turn each fuse, link and control contact verifying the operation of the
circuit under test by observation of the voltmeter and, except for outgoing part circuits,
the end function.

De-energise (or energise for back contacts) the respective controlling device to open the
control contact and check that the end function de-energises and the voltmeter reading
drops to zero.

Bridge the specific control contact with a test strap to test the presence of that specific
contact in the circuit by observing the end function re-energise and the voltmeter reading
register the correct voltage.

Where controls are wired in parallel, each and every series path through the complete
circuit shall be selected in turn and the contacts in that path tested with all alternative
paths broken. In each case the controlling contact, fuse or link in series on each side of
the parallel path shall be broken and proved

Parallel paths may emanate from fuses, links or looping.

A10.2 MANUALLY OPENING CONTACTS

The seals of relays shall not be broken on site nor shall contact fingers be broken by
inserting an insulation piece, e.g. strip of paper or cardboard or a person's finger, within
the relay case.

In the case of accessible individual contacts (for example, rotary contacts, etc.) the tests
may be done by manually breaking the specific contact (for example, separating the
contact finger from the band) during the strap and function test.

Care must be taken to ensure that this action does not damage, introduce dirt or grease, or
upset the adjustment of the contact.

If this method of opening the contact is used it must be also be proved that the control
device when operated will electrically open and close the specific contact.

A10.3 DISCONNECTION OF WIRES

After certification bell continuity tests and wire counts, wires shall not be removed from
contact terminals for function testing except as absolutely necessary.

In such case removal, test and reconnection must be done one terminal at a time by the
person conducting and certifying the tests.

Wires shall be correctly labelled with the terminal number, etc., before removal.

A10.4 FALSE FEEDS

Where temporary false feeds have been applied to carry out this testing they shall be
removed at the conclusion of the test and signed for on the record of false feeds applied
(see Paragraph 6.1) by the person conducting and certifying the tests. Temporary wiring
shall be distinctly coloured and labelled.

When testing near working circuits, strict care must be taken to ensure that any false feed
cannot accidentally or inadvertently be applied to affect the working circuits. Where
practicable and relevant, additional security can be obtained using a false feed isolated
from any signalling supply in use through a separate transformer or transformer rectifier
unit.

Test Straps

¨ must be no less than 450mm long

¨ must have brightly coloured insulation, preferably orange

¨ must be numbered in sets

¨ must be kept in a locked box. The person conducting and certifying the tests must
ensure the safe custody of this box

¨ must be counted and recorded before the start and at the end of each day's testing
work to ensure that no straps have been inadvertently left in position.

A10.5 PLUG-IN RELAYS

With plug-in relays, if the relays are removed and straps placed in the relay base from the
front to bridge the control contact terminals, the circuit can be closed to energise the end
function.

If the straps are opened and closed in turn to correspondingly open and close the circuit
function then the contact terminals can be proved to be in circuit. (Proof of the contact
terminals would have been covered by the circuit bell continuity test.)

This test with straps in the front of the relay base is NOT a complete circuit strap and
function test, as the contact type (back or front) is not proved and it will not detect any
internally missing, wrong or short circuited contact.

The plug-in relay must therefore also be tested in a relay test panel to prove that it
electrically operates the contacts and that the specific contact concerned is the right type.
(Contact Proving Test),

Contact Proving Tests of plug-in relays also involve an inspection of the relay for any
signs of damage, foreign matter or defective operation. A signed and dated sticker
affixed to the relay case shall signify that the relay has been proved in the relay test panel.

A11. THROUGH FUNCTION TESTS

A11.1 GENERAL

Through function tests are carried out to prove correct correspondence where circuits
extend between locations.

The Through Circuit Function Test is carried out on circuits that operate between
locations to prove:

¨ The end function operates as intended through the complete circuit when the correct
voltage of the correct polarity is applied to the ends of the circuit.

¨ The circuit internal wiring has been correctly connected to the respective external
cables where both have been separately continuity tested, wire counted and insulation
tested.

¨ De-energisation of and zero residual voltage across the circuit function when the
circuit is opened in turn at the fuse, each link and at each intermediate relay. The test
is performed with as many other circuits energised as practicable to provide a high
probability of detecting the presence of any false voltages in the circuit.

¨ All repeat, indicating and intermediate relays correspond and operate correctly.

¨ Diagram indicators, repeaters and detectors respond correctly.

Through Function Tests of the System are also carried out to prove correspondence
from the operator's control to operation of the trackside apparatus and from the
operation of the trackside apparatus back to the operator's indicator panel.

¨ Through Circuit Function Test Procedure

After circuits internal to locations and the external interconnecting cables have been
separately tested, a through test shall be carried out on complete circuits, that is
circuits that operate between separate locations.

Where earth leakage detectors are available, temporarily connect an audible alarm for
the duration of the tests.

This test shall operate and verify the equipment and complete circuit from end to end
in a functional manner and shall be carried out for both control and indication circuits
as follows

¨ Energise the circuit to pick up the final control relay and any intermediate relays

¨ At all the locations involved, disconnect and replace in turn the feed fuse and every
link in the circuit, including at the power supply Busbar, observing that all relays in
the circuit and all indications respond in each case by correctly changing status.

Verify the wire count at the fuse and on each side of disconnection links and record
on the circuit diagrams.

¨ For polarised circuits the test shall be carried out for each polarity.

¨ Place a meter across the relay coils and observe correct working voltages. Investigate
any non zero voltage when the circuit is opened.

¨ Where circuits are in cascade (such as cut sections for AC traction immunisation or
for volt-drop purposes) the intermediate relay circuits must also be similarly tested,
the final relay under test being observed to respond.

¨ For FDM and TDM systems, prove that each output corresponds with its relevant
input.

¨ Where possible and relevant, carry out tests for each through circuit as a single
operation from the point of control to the point of operation and from the point of
operation to the point of indication.

A12. CHANGEOVER TESTS

On changeover, at the point of connection of new and existing circuits, the tester shall
undertake a wire count, continuity test and strap and function test inclusive of at least one
contact clear in all paths from the point of connection. The wire count shall include both
sides of each "clear" contact.

CABLE TESTS

B1. SCOPE

This Appendix describes the tests to satisfy the requirements for cabling testing contained
within Code of Practice W190-600-002.

B2. LOCATION EARTHS

All earthing grids/stakes installed at equipment box and relay/control room locations
shall conform to installation standards and be tested in accordance with Australian
Standard AS 1768 to give a resistance of not more than 5 ohms under all conditions of
weather. The integrity of the earth is essential for insulation resistance tests to be valid
and earth leakage tests to be effective.

An Earth Test Certificate shall be completed with the value measured and the nature of
soil condition at the time of test noted. Any location where it is anticipated that the
resistance may exceed 5 ohms with improvement in weather shall be listed for further
monitoring and test.

In principle, cable insulation tests shall not be commenced at any location where the earth
resistance of less than 5 ohms cannot be attained. Any exception to this rule shall be
subject to the Superintendent's or Signal Systems Manager’s approval.

B3. SIGNALLING AND POWER CABLES

B3.1 INSTALLATION CHECKS

The installation shall be inspected to ensure that it conforms to the relevant signalling
installation standards including that cables are correctly and securely terminated in the
correct core numbering sequence.

B3.2 ELECTRICAL TESTS

a) General - Continuity and insulation tests shall be made on all new through fireside
signalling, power distribution, data link, communication and local signalling
equipment cables after their permanent installation and termination has been
completed. Before cables are tested all apparatus shall be disconnected, all links
opened and all fuses removed.
b) Continuity - Each conductor in each multicore cable is to be tested for continuity, in
accordance with Appendix A section 2.

c) Insulation Resistance Tests - In signalling installations where safety integrity is

dependent upon the insulation between individual circuits insulation tests on multicore
and power cables shall be made after their permanent installation and termination has
been completed. For local cables in cases of difficulty (where equipment is not fitted
with plug couplers or isolation type terminals) the cable insulation resistance test may
be carried out with the cable in position but with the cable disconnected at the
equipment.
The tests to be made are for:-

i) insulation resistance between each core and earth

ii) insulation resistance between each core and all other cores in the cable

iii) insulation resistance between screen or drain wire and earth, where
applicable.

iv) insulation resistance between screen or drain wire and all other cores in the
cable, where applicable.

For each cable a Cable Test Certificate shall be completed and certified that the minimum
acceptable values of insulation resistance have been obtained. The minimum acceptable
values of insulation resistance for fully installed and terminated cables shall be the values
specified by the Superintendent.

If the applicable minimum values cannot be obtained the cable shall be regarded as
defective and shall not be commissioned.
a) Polarity Tests - Where polarity sensitive equipment is installed, all power
distribution and data link or circuit cable pair shall be tested for the correct
polarity using a DC power source connected to one end of the cable pair and a DC
voltmeter applied to the other end and at all intermediate terminations.

B3.3 DOCUMENTATION

The values of insulation resistance in each cable tested is to be recorded as a one line
entry on the Cable Test Certificate and be certified by the tester. If the cable fails the
above electrical tests, details of the failure(s) including the actual insulation resistance
values shall be reported to the Tester in Charge for further direction. A suggested format
for Cable Test Certificate is given in Appendix H.
APPENDIX C

APPARATUS TESTS

C1. SCOPE

This Appendix describes the required testing, installation checks and adjustments of
trackside signalling apparatus after they have been installed on site, to satisfy the
requirements of Code of Practice W190-600-002.

C2. SIGNALS

C2.1 SIGNAL INSTALLATION CHECKS

Inspections shall be conducted to ensure that the installation conforms to the relevant
signalling installation specifications particularly with respect to:-
a) Position - geographically located correctly to signalling plans and drawings and to
insulated or electronic rail joints, and lateral clearances to rolling stock and
overhead diagrams.
b) Signal Heads or Units - signalling light units fitted to posts agree with signalling
arrangement plan with correct lenses (colour/main/spreadlight/sector/phantom
inhibitor) and hoods fitted and correct identification number plate attached.
c) Cabling - all cables are correctly and securely terminated in the correct core
numbering sequence.
d) Telephone - installed where specified, and operational.
e) Earthing and Bonding - In electrified areas, traction safety bonding is correctly
installed and terminated.
f) Other requirements - as specified in the Testing Plan

C2.2 SIGNAL ADJUSTMENTS

Inspections shall be conducted to ensure that the installation conforms to the relevant
specifications particularly with respect to: -
a) Signal Lamps - ensure that lamps and 'filament failed' relays (if installed) are the
correct type for each aspect and the correct lamp is lit and lamp voltage is
correctly adjusted. Where multi- filament signal lamps and filament change-over
relays are fitted, the failure of each main filament should de-energise its filament
changeover relay to illuminate the auxiliary filament and operate the failure alarm
circuit.
b) Alignment and Focusing - ensure that each signal unit combination is focused for
long range viewing where applicable and that individual lenses or sectors are
adjusted for short range indication.
c) Sighting - view each signal and ensure that the minimum or better sighting
distance is achieved for all aspects and route indications and that there is no
ambiguity or conflict with other signals or extraneous lighting.

C2.3 OTHER SIGNAL TESTS

a) Wiring - carry out a wiring/cabling continuity test and wire count on all
terminations in the signal units.
b) Aspects - ensure that each aspect control relay/output correctly operates its
corresponding signal aspect. (For a searchlight mechanism, ensure correct
polarity and operation of the mechanism).
c) Flashing Rate - for flashing aspects, verify that the flash rate is acceptable and
where fitted flash proving works.
d) Route Indicators - prove all interlocking features including lamp proving are
effective.
e) Half Pilot Keys - where fitted prove interlocking effective with all signals entering
the single line section.
f) Lamp proving - prove lamp proving effective
g) Any specific test as detailed in the Testing Plan.

C2.4 SIGNAL DOCUMENTATION

Test certificates for each signal shall be completed and certified by the person conducting
the relevant tests. A suggested format for Test Certificates is given in Appendix H.

C2.5 PRECAUTIONS

When the door of a signal lamp unit is opened or the signal aspects are being adjusted or
tested, care shall be exercised by the tester to ensure that no false proceed signal aspect is
displayed to an approaching or standing train. The Testing Plan shall specify the method
to indicate signals that are not yet ready for service.

C3. TRACK CIRCUITS

C3.1 TRACK CIRCUIT INSTALLATION CHECKS

Inspections shall be conducted to ensure that the installation conforms to the relevant
signalling installation specifications particularly with respect to...
a) Geometry - the limits of each track circuit, positions of insulated or electronic rail
joints, provision of point and other insulations, mechanical rail joint bonding and
cross-bonding are in accordance with plans using bonding cable of the correct
size.
b) Type/Labelling - all lineside equipment is of the correct type, code, frequency and
correctly labelled.
c) Track Connections - the feed and relay leads of each track circuit are correctly
terminated on the respective track feed and track relays and of the correct polarity
designated by the track plan.
d) Traction Bonding - is in accordance with plans.
e) Points and apparatus insulation - is in accordance with plans.
APPENDIX C APPARATUS TESTS

f) Level crossing predictors (if applicable) – frequency, terminating shunts and

settings of level crossing predictor shunt are correctly installed and verified to be
for the approach section it is to define.

C3.2 TRACK CIRCUIT CHECKS AND ADJUSTMENTS

Inspections shall be conducted to ensure that the installation conforms to the relevant
signalling installation specifications particularly with respect to: -
a) Adjustment - adjust the feed/transmitter ends and relay/receiver ends of the track
circuit in accordance with the recommended practice for that type of track circuit
and record on the maintenance record card and the test certificate.
b) Shunt Test - apply the test shunt for the type of track circuit and confirm the result.
Test and record the drop away shunt and prevent shunt value.
c) Extraneous energy - With all adjacent track circuits energised remove the feed
links of the track circuit under test and check that only the correct relay responds
[Any adjacent unaltered track circuit shall be similarly tested]. Measure and
record any residual voltage on the track relay. Any voltage exceeding 30% [or
such lesser value specified in the instruction manual] of the track relay 'drop-away'
value is not permitted and the source of such an extraneous voltage shall be
identified and remedial action taken before commissioning.
d) Spark Gaps - check that connections between structures and traction rails are
correctly installed and effective, where applicable.
e) Insulations - prove that rail and point insulations are correctly installed and
effective.
f) Earths - check that rails are free from spurious bonds or earths.
g) Polarity - check polarity on feed and relay ends, and all other ends of the track
circuit.
h) Level crossing predictor (if applicable) - test and adjust level crossing predictor
approach sections in accordance with the recommended practice for that unit with
respect to extent and linearity.

C3.3 OTHER TRACK CIRCUIT TESTS

a) Track Circuit Parameters An inspection shall be conducted to ensure that:-

i) insulated rail joints and 'electronic' joints are in the correct position

ii) overlap tracks are the correct length

iii) clearance points –(i.e. extremities of track circuits which are clearance
points for release of locking) are located at physical clearance to other routes
which would be freed

iv) dead sections –do not exist (i.e. the track circuit configuration shall not
contain a section of track such that any one track circuit cannot detect at
least one axle of the vehicles expected to be detected)

v) polarities correspond to plans

APPENDIX C APPARATUS TESTS

vi) timing tracks are the correct length.

b) Shunting - ensure that the correct relay de-energises positively with a shunt applied
across the head of the rail at several points along the track circuit including all
extremities and at the extremity of each leg throughout points and crossings.
c) Correspondence - confirm that the physical shunt on each end of each track circuit de-
energises the correct track relay and track repeat relay and operates the corresponding
track indication light on the control diagram.
d) Shunting Zone - with electronic jointless track circuits confirm that there is no
shunting 'gap' (dead zone) where track circuits abut each other.
e) Level crossing predictor (if applicable) - confirm that the level crossing predictor
approach sections shunt in the way defined by the recommended checkout procedure
with respect to extent and linearity.

C3.4 TRACK CIRCUIT DOCUMENTATION

Appropriate test certificate(s) shall be completed and certified by the person responsible
for the relevant tests. A suggested format for Test Certificate for Tracks is given in
Appendix H.

C4. POINT MACHINES

C4.1 POINT MACHINE INSTALLATION CHECKS

Inspection shall be conducted to ensure that the installation conforms to the relevant
signalling installation specifications particularly with respect to: -
a) Type and Position - point equipment is of the correct type as specified and installed
on the correct side of the track as shown on the plan.
b) Labelling - The correct point identification number, including discrimination
between crossover ends, is on machine (or sleeper). Where required, the Normal
[N] and Reverse [R] closed blade position plates are correctly attached to the
sleepers or tie-plates.
c) Wiring - All cabling correctly is installed and securely terminated and internal
wiring complete.
d) Wire Count / Continuity / Insulation Resistance- carry out a wire count of all
terminations in the lineside point mechanism and detection units and continuity test
and insulation resistance test of all interconnecting cables.
e) Traction bonding of point machines in A.C. traction areas to the return rail is
correctly installed.

C4.2 POINT MACHINE CHECKS AND ADJUSTMENTS

Inspection shall be conducted to ensure that the installation conforms to the relevant
specifications particularly with respect to: -
APPENDIX C APPARATUS TESTS

a) Operation, locking and detection - Point mechanism correctly fixed to sleeper and
or rail, bolts correctly fitted and tightened, points operate easily, correct travel
applies, locking and detection adjustments comply with specified tolerances using
GO/NO GO gauges where specified, split pins in linkages are fitted and split, and
track alignment and geometry is correct.
b) For power operated points, ensure operating time and maximum current demand
(where applicable) do not exceed specified maximum values.
c) Microswitches - for systems employing microswitches each microswitch is to be
tested individually with a continuity tester to ensure that the contacts 'make' and
'break' at the correct position in the stroke, as described in the equipment manual.
d) Insulations - all insulations installed and effective in tie plates, spreaders, switch
extension pieces, point connections etc.
e) Additional drives and detectors- additional drives for high speed points or
catch/derails are correctly installed and detected where applicable.
f) Point Obstructions - ensure that in the event of a point obstruction the clutch
where provided slips at the required value and cut-off timers or overload devices
are effective within the specified time.

C4.3 OTHER POINT MACHINE TESTS

The following electrical tests are to be done to confirm correct operation of points.

Where the Testing Plan requires tests on point machines, earth leakage detectors with an
audible alarm are to be installed on point operating and detection power supplies and
shall remain connected for the duration of the tests.
a) Point Detection - operate the points normal and reverse confirming detection
locally and to the relay room and control room if possible. Ensure that the point
levers, all control and detection relays and the indications are in correspondence.
b) Individual Detection Contacts

i) Exposed contacts - break each contact in turn to ensure that the correct
detection relay de-energises for both normal and reverse positions.

ii) Sealed contacts - operate the respective microswitch / controller in turn and
strap, the individual contacts to confirm their presence.
In both cases above, each leg of the detection circuit shall be tested independently.
c) Correspondence - On track configurations utilising two point mechanisms
operating in unison (double-ended points) correspondence shall be proved as
follows: -

i) with all ends NORMAL, observe N detection and then disconnect one end
[point mechanism]

ii) operate REVERSE, and ensure 'out of correspondence' [i.e. no N or R

detection]
APPENDIX C APPARATUS TESTS

iii) manually operate the disconnected end to REVERSE and ensure that R
detection is obtained

iv) operate the points to NORMAL and ensure 'out of correspondence'

v) manually operate the disconnected end to NORMAL and ensure that N

detection is obtained.
Where three ends exist repeat the above procedure disconnecting ends as
appropriate for all possible permutations.
d) Emergency Manual Operation - prove that when the crank handle (where
applicable) is taken from the crank handle box, operation of power-operated
points at that location is disabled and that the power is isolated from the points
mechanisms.

C4.4 POINT MACHINE DOCUMENTATION

Test certificates shall be completed and certified by the person responsible for the
relevant tests. A suggested format for Test Certificate for Points is given in Appendix H.

C5. LEVEL CROSSING PROTECTION

C5.1 LEVEL CROSSING INSTALLATION CHECKS

Inspection shall be conducted to ensure that the installation conforms to the relevant
signalling installation specifications particularly with respect to: -
a) Layout - all site equipment is located in accordance with signalling drawings and
level crossing layout plans, including warning distances.
b) Clearance - all equipment is installed to specified rail and roadway clearance and
the elevated boom arm to overhead wire clearance.
c) Configuration / Signs - all flashing light, boom barrier and pedestrian gates are
equipped with the full complement of cross-arms, audible warning devices, level
crossing/stop on red/number of track signs and approach warning signs and
roadway markings are installed.
d) Wiring - all cabling installed and wiring securely terminated.
e) Wheel detector (if applicable) - type, position and setting of all treadles/wheel
detectors is correct.
f) Level crossing predictor (if applicable) - ensure that electronic equipment cards
are the correct type and are fully home in the card slots.
g) Earthing and Bonding - In electrified areas, traction safety bonding is correctly
installed and terminated.

C5.2 LEVEL CROSSING CHECKS AND ADJUSTMENTS

Inspection shall be conducted to ensure that the installation conforms to the relevant
specifications particularly with respect to :-
APPENDIX C APPARATUS TESTS

a) Lamp Units - ensure that all flashing light units are fitted with the specified lenses
backgrounds and lens hoods, lamp voltages are adjusted correctly and the units are
aligned in accordance with the approved diagram.
b) Bells - warning bells and other audible warning devices are correctly adjusted for
sound level and rate and correctly orientated.
c) Boom Mechanisms - are counterweighted correctly, control and indication
contacts adjusted correctly, the end of travel stops adjusted correctly, and the
boom clearance and lowering times within the recommended time settings.
d) Pedestrian Gates / Booms - adjusted correctly.
e) Power Supplies - are the correct voltage, automatic chargers are of the specified
capacity and batteries are the correct type and capacity and fully charged. Ale full
load is within the power supply capacity.
f) Level crossing predictors (if applicable) - are set to the correct frequency, warning
time, approach length, restart point and track drive.

C5.3 OTHER LEVEL CROSSING TESTS

a) bell and half-boom arm light circuits and half-boom barrier detection relays.
b) Minimum Clearance Time - confirm the minimum clearance time between
consecutive crossing operations is as specified in the design specifications.
c) Measurements - check and record boom mechanism and pedestrian gate drive
currents and no/full load voltages.
d) Failure Modes - test that:

i) half-booms lower, and pedestrian gates close and lock, in the absence of
power

ii) each half-boom arm lowering causes lights to flash

iii) test switch effective

iv) where applicable, lifting boom arm restores any interlocked signal to stop

v) correct operation of level crossing alarms

e) Simulation - test for correct operation of the boom barriers by simulation of both
'stopping' and 'express' train movements in all directions and any interlocking with
signals.
f) Road Traffic Signal Co-ordination - test for the correct operation of the outgoing
signals provided to associated road-traffic light system by simulation of all
conditions and the receipt of correct incoming signals from the associated road-
traffic lights.
g) Level crossing predictors (if applicable) - test for correct operation of constant
warning, motion detection, motion restart and freedom from tail flashing.
h) Emergency switches - test for correct operation of emergency switches, where
applicable.
APPENDIX C APPARATUS TESTS

i) Battery - Test and record battery voltages with the level crossing equipment
operating with the AC power supply disconnected.
j) Level crossing monitor - check operation, where applicable.
k) Speed boards - check installed track speed boards are in accordance with the level
crossing design speed criteria.
l) Operation Sequence - check directional stick circuits operate correctly.
m) Knock Down Timers - where fitted ensure that knock down timers operate
correctly.
n) Remote Monitoring – check that all inputs operate correctly and that the data
logger is correctly programmed and functioning.

C5.4 LEVEL CROSSING DOCUMENTATION

Test certificates shall be completed and certified by the person conducting the relevant
tests. A suggested format for Test Certificate for Level Crossings is given in Appendix
H.

C6. POWER SUPPLIES

C6.1 PRECAUTIONS

Before commencing work personnel are to ensure that all safety precautions have been -
taken and the rules and regulations relating to signal power supplies and distribution have
been strictly observed.

C6.2 POWER SUPPLY INSTALLATION CHECKS

Inspections shall be conducted to ensure that the installation conforms to the relevant
installation specifications particularly with respect to: -
a) Type and Positions - power supplies are the correct type as specified and installed
at the correct positions as shown on plans.
b) Workmanship and physical condition of the equipment and installation - are
suitable for safe reliable operation.
c) Power supply distributions

i) power cables tested for continuity, polarity and insulation resistance prior to
commissioning

ii) step down transformers checked for correct phasing and the secondary
adjusted to give rated voltage under anticipated load

iii) trip settings on automatic circuit breakers adjusted to the specified values

iv) indications - status indications and alarms be tested for correct operation.

After commissioning and full load distribution established, secondary voltages shall be
measured at each location in the distribution and adjusted if necessary.
APPENDIX C APPARATUS TESTS

Note: Adjustment of the power supply transformer output will require checking of
all previously set voltages.
d) Emergency Power Supplies - Check that emergency power supplies are of the
rated capacity and test that the main/standby changeover operates correctly with
appropriate alarms and indications.
e) Standby Batteries - Test that standby batteries operate correctly under power
failure conditions, secondary cells are correctly rated and terminated, and that
charging equipment is correctly adjusted.
f) Earth Leakage

i) Detectors - test earth leakage detectors and their associated alarms and
indications and adjust for sensitivity.

ii) Bus Bars - test bus-bars for earth leakage in accordance with instructions
and verify that there is no interconnection between bus-bars of different
supplies.

C6.3 POWER SUPPLY DOCUMENTATION

Test certificates shall be completed and certified by the person conducting the relevant
tests. A suggested format for Test Certificate for Power Supplies is given in Appendix H.

C7. EQUIPMENT HOUSINGS

C7.1 EQUIPMENT HOUSING INSTALLATION CHECKS

An inspection shall be conducted to ensure that the installation conforms to the relevant
signalling installation specifications particularly with respect to: -
a) Location - housing is installed with all positions of the hinged doors outside the
rolling stock clearance diagram with the front door on the side of the location as
shown on the signalling drawings, with cables properly clamped and wires
securely terminated.
b) Equipment - all the equipment specified to be in the housing are present.
c) Labelling - correct label on outside of housing and internal equipment relay bases,
terminations and bus-bars correctly labelled.
d) Signal Relays - When all through and local cabling has been installed, terminated
and tested, signal relays shall be installed in readiness for 'functional' testing.
Before each relay is inserted it is to be confirmed to be the correct type, the
pin/socket configuration matches the relay base and the relay is labelled to
correspond to the base into which it is to be inserted.
e) Earthing and Bonding - In electrified areas, traction safety bonding is correctly
installed and terminated.

Any timing relays are to be confirmed for accuracy of the time settings.
APPENDIX C APPARATUS TESTS

C7.2 OTHER EQUIPMENT HOUSING TESTS

a) Electrical Tests - following termination of through and local cables complete
insulation resistance, continuity and wire counting tests as specified for cables in
Appendix 2.
b) Outstanding Material - check that all outstanding material detailed on the
Location Test Certificate has been installed and all wiring completed. Check, test
and certify completeness on the Location Test Certificate.

C7.3 EQUIPMENT HOUSING DOCUMENTATION

Completion of all local testing is to be marked on the drawings pertaining to the housing
and test certificates shall be endorsed accordingly.

C8. EQUIPMENT AND CONTROL ROOMS

C8.1 EQUIPMENT AND CONTROL ROOM INSTALLATION CHECKS

Inspections shall be conducted to ensure that the installation conforms to the relevant
signalling installation specifications particularly with respect to: -
a) Equipment - check test certificates are supplied for all pre-wired signalling
equipment (track relay and equipment racks, relay racks, computer based
equipment, power supplies, maintenance diagram, track indication diagrams,
control consoles etc.) and check for any omissions listed on the test certificates,
confirm the need to rectify any deficiencies, complete testing and certify
accordingly.
b) Power Supplies - correct type, capacity, polarity and/or phasing installed to correct
standards, wired to power distribution plans and fitted with earth leakage detectors
and audible alarms fitted for the duration of the electrical tests. Fuses of the
correct type and rating installed. Appropriate labels installed where applicable,
e.g. "Danger High Voltage".
c) Relays - correct voltage, contact arrangement and registry coding installed
securely
d) Earthing and Bonding - In electrified areas, traction safety bonding is correctly
installed and terminated.

C8.2 OTHER RELAY AND CONTROL ROOM TESTS

a) Inter-cabling - ensure that all inter-cabling between equipment has been securely
terminated on fuses, busbars, terminals or plug couplers and tested in accordance
with the requirements of Appendix B.
b) Earthing - correctly installed, wired and tested as in Appendix B.
APPENDIX C APPARATUS TESTS

c) Simulation Test Rig - on new installations isolate all incoming and outgoing
circuits and temporarily wire to a simulation test rig to approved wiring diagrams.
This test set allows track circuit repeat relays to be dropped and energised
individually to simulate a train movement, and normal and reverse indication
relays for signals and points to respond to signal and point lever commands from
the control panel.
If a temporary test panel is used for simulation of some functions for control table
or principles testing, then a function test of the functions that were simulated shall
be carried out following the removal of the test panel and the connection of the
functions to the interlocking.
d) Internal Interlocking Test - using the simulation test rig confirm that

i) points can be set both ways and point indications respond and give correct
indications on diagrams,

ii) all signalling routes can be set from the control console and signal
indications are correctly displayed on the diagrams,

iii) all the interlocking requirements of the Control Table have been met.

C8.3 RELAY AND CONTROL ROOM DOCUMENTATION

Test certificates shall be completed and certified by the person conducting the relevant
tests. A suggested format for Test Certification for Relay/Control Rooms is given in
Appendix H.

C9. COMPUTER-BASED SYSTEMS

C9.1 FORMULATION OF TESTING PLANS

Processor based systems consist of three elements which shall be taken into account
when formulating a testing plan for new or modified processor based systems: -
a) The hardware configuration - this will determine the response to software
commands including error states and the capabilities of field modules.
b) The executive software version - this will determine approval compliance and
shall be validated as suitable for the hardware configuration to be used.
c) The approved version of the application data - this is to be the approved version
of application software which has been generated taking into account the
hardware configuration and executive software version to be employed.
d) The Testing Tools and Methodology – If testing tools or simulators are used as
part of the testing procedure then these must be certified for use on such systems
and be accepted by the Superintendent. They should also be supported by a safety
case as part of the testing plan.

C9.1.1 Testing Plan Content

The testing plan shall ensure that the following is taken into account:-
a) The system employed is approved for the use it is to be put to.
APPENDIX C APPARATUS TESTS

b) All functional operations, as detailed in the requirements specification for the job,
and/or as determined from the control tables are covered by tests in the testing
[Link] tests are performed in accordance with Code of Practice W190-
600-002.
c) The hardware is provided and installed as documented.
d) Correct versions of software are used and matched to the versions of other
software in use.
e) Where check sums are used to validate software versions, ensure that the software
check sums for each of the software items are correct and recorded.
f) If a software simulation test is undertaken, ensure that the simulator being used is
certified and accepted for the job. Ensure a safety case has been prepared for the
use of the simulator on the specific system.
g) If software test tools are used as part of the testing procedure, ensure that the tools
being used are certified and accepted for the job. Ensure a safety case has been
prepared for the use of the tools on the specific system.
h) If software simulation is undertaken or testing tools are used on code other than
the code to be commissioned the procedures to ensure that the installed code is
identical to the tested code have been followed.
i) The hardware configuration is validated as suitable for the purpose by reference to
the manufacturers documentation.
j) The system interfaces have been fully considered for testing criteria, including
failure modes.
k) Response time and performance criteria.

C9.2 COMPUTER-BASED SYSTEM HARDWARE CHECKS

The hardware shall be checked to ensure that:-

a) Correct boards are installed in card slots.
b) Correct power supplies are used.
c) Correct hardware set up of cards is employed.
d) Correct chassis or card addresses are set as applicable.

C9.3 DOCUMENTATION OF TESTS

Thorough recording of test results shall be made with traceability to the items in the
testing plan, which should in turn be traceable back to the requirements specification
and/or control tables. This is to facilitate auditing, to ensure that testing is complete and
not duplicated.

C9.4 TESTS OF MODIFIED INSTALLATIONS

When an installation is modified the entire system shall be re-tested or the rationale for
not doing so documented and approved by the Superintendent.
APPENDIX C APPARATUS TESTS

C10. MISCELLANEOUS EQUIPMENT

All other signalling equipment not specified is to be submitted to the same thorough and
exhaustive testing principles prescribed in this document with appropriate certification
developed to satisfy the quality assurance requirements for testing signalling safeworking
systems.

Such equipment includes but is not limited to the following systems or items

¨ Double Line Block Instruments

¨ Interlocked Gates

¨ Telemetry Systems

¨ Automatic Train Protection

¨ Automatic Warning System

¨ Self-Restoring Points
APPENDIX D

FUNCTION TESTING

D1. SCOPE

This Appendix describes function tests to satisfy the Function Testing requirements
contained within Code of Practice W190-600-002.

Each individual circuit shall be tested from its power supply fuse to its final controlled
function. At every intermediate location each link and relay function shall be verified as
effective and circuit polarities shall be correct.

D2. PROCEDURE

After circuits internal to locations and the external interconnecting cables have been
separately tested, tests shall be carried out on the complete circuits.

These tests shall operate and verify the equipment and complete circuit from end to end
in a functional manner and shall be carried out for both control and indication circuits as
follows:
a) Energise the circuit to pick up the final controlled function and any intermediate
relays connected to the same circuit.
b) At all the locations involved, disconnect and replace in turn the feed fuse and
every link in the circuit, including at the power supply busbar, observing that all
relays in the circuit and all indications respond in each case by correctly changing
status.
c) For polarised circuits the test shall be carried out for each polarity
d) Place a meter across the relay coils and verify correct working voltages.
Investigate any voltage when the circuit is opened.
e) For control and indication circuits, prove that each output corresponds with its
relevant input. A Function Test of the system shall ensure that when there is a
control operated at the control centre it is correctly relayed throughout the System
and operates the trackside apparatus, and when there is an indication from the
trackside apparatus that it is correctly relayed throughout the system to the control
centre. Each indication shall be observed to change status in correct
correspondence.

D3. DOCUMENTATION

A suggested method of indicating on the circuit diagrams that the circuit test has been
successfully completed at each fuse and disconnection link is shown in Appendix G.
APPENDIX E

TESTING TO CONTROL TABLES

E1. SCOPE

This Appendix describes the requirements for testing to Signalling Control Tables to
satisfy the requirements contained within Code of Practice W190-600-002.

Testing shall be conducted to ensure that the installation conforms to the interlocking
requirements detailed in the Control Tables.

Testing to control tables should be made only when the interlocking is operational,
detailed circuit and function testing have been completed.

To facilitate the testing, a simulator or a test rig may be used to simulate the expected
responses from external equipment.

Before testing commences ensure that points anti pre-select is disconnected, if fitted, and
ensure that no vital locking is masked by non vital controls

Testing to control tables will verify the following features

E2. SIGNAL CONTROLS

For each signal lever controlled route:-

a) verify that all locking and detection of points is present in the route by

i) in turn, set and lock each individual set of points in the route to conflict with
the route, and verify that the route will not set nor the signal clear.
Conversely with the route set and the signal clear prove that all the points
affected by the route are locked and detected in the correct position.

ii) set all points to conflict with the route to be tested and cancel each call
made, then call for the route and verify that the points to be set have moved
to the correct position as the routes sets for the signal to clear.
b) verify that all track circuits in the route, overlap and flank replace the signal to
danger.
c) verify that opposing signals lock each other initially and that opposing route
holding is held by simulating the movement of a train on each track circuit. Also
check that the route locking is not released until the specified release conditions
have been fulfilled.
d) verify that approach locking is initiated correctly for each of the possible
approaches, any timing is correct, all releasing conditions are applied correctly
and premature release is not possible under power interruptions.
e) verify that any 'lever stick' feature is effective and that any overriding controls
work correctly.

f) verify that any approach releasing feature operates only when the correct track
circuit or section is occupied and only after the specified time if time delayed.
g) verify conditional signal and aspect controls associated with level crossing
operations.
h) verify other requirements specified in the control tables.

E.3 POINT CONTROLS

For each set of points:-

a) verify that all track locking is present and that all signalled routes secure each set
of points in the correct position.
b) verify that route holding and sectional route releasing of points is operating
correctly by simulating the passage of a train through the route and by operating
the respective sets of points and proving that they are locked until the rear of the
train has passed the clearance point.

E4. LEVEL CROSSING

Test the operation of the level crossing warning devices by simulating train movements in
turn for both 'up' and 'down' directions for all routes and for both ‘express' and 'stopping'
conditions where provided. Prove the interlocking and/or key switch operation of any
signals, check any approach locking and releasing modes, check the timing of any
'delayed drop' circuits and confirm that minimum level crossing warning times are
achieved.

E5. OTHER REQUIREMENTS SPECIFIED IN THE CONTROL TABLES

Test the operation of other requirements specified in the control tables such as:
a) Bi-directional signalling
b) Automatic Warning System
c) Intermediate Train Stop
d) Gauge Discrimination

E6. DOCUMENTATION

The tests shall be recorded using standard marking on the test copy of the control tables.
Each page of the control table shall be signed off by the tester or the testers conducting
tests on that page.
APPENDIX F

ASPECT SEQUENCE TEST

F1. SCOPE

This Appendix describes the requirements for Aspect Sequence testing to satisfy the
requirements contained within Code of Practice W190-600-002.

F2. INTRODUCTION

Aspect Sequence Testing shall verify that only the correct aspect and route indication are
displayed to the driver of the train.

F3. PROCEDURE

This test shall be performed in accordance with the relevant track plans which provide
details of potential routes through the area of track under test, and with any special
Aspect Sequence Charts drawn up specifically for the test.

The complete aspect sequence should be simultaneously observed in its entirety. For
each route of the signal under test (the entrance signal), the exit signal(s) shall be cleared
to each attainable aspect. The entrance and exit signals and any repeater or co-acting
signals should be continually observed to ensure that only the correct aspect sequence is
displayed.

When testing an aspect sequence up to an exit signal at Red, the next signal(s) ahead of
the exit signal should be maintained at the least restrictive aspect. When testing the
straight, or turnout, sequence for a junction signal, the exit signals on the other route
should be cleared and cancelled to ensure the junction signal is unaffected.

Surveillance of maintained aspects shall be an integral part of the aspect sequence test.

Ensure that the lamp out in an aspect of a signal replaces the affected signal to restrictive
aspects, in accordance with WestNet Rail’s lamp proving requirements.

F4. DOCUMENTATION

The successful completion of each of the tests shall be recorded and signed by the person
conducting the test.
APPENDIX G

METHOD AND IDENTIFICATION OF CHECK MARKS

G1. SCOPE

This Appendix describes the requirements for testing to Signalling Control Tables to
satisfy the requirements contained within Code of Practice W190-600-002.

G2. TEST DOCUMENTATION

Each person responsible for testing against design drawings and tables shall be
designated a unique colour indelible marker, excluding colours reserved for design
changes.

The name, date, signature and colour shall be endorsed on each testing sheet when testing
is carried out. It shall be possible to clearly identify the person testing each element of a
circuit or part of a drawing. When a number of personnel are involved, each tester shall
sign off tests they have completed.

All inspections and tests shall be recorded as follows in Section 2.

G3. METHOD OF RECORDING TESTS ON DESIGN DRAWINGS

G3.1 RECORDING ON CIRCUIT BOOK / SHEET

Wire count denoted on the circuit diagram by small stroke across the wire next to each
terminal or contact.

Bell continuity test denoted on circuit diagram by small tick next to the wire.

Circuit strap and function test of a contact denoted on circuit diagrams by a large tick
through the contact.

Circuit strap and function test for more than one parallel path denoted by stroke across
large tick for each additional path.

Circuit function test of fuses and link terminals denoted on circuit diagrams by large tick
through fuse or terminal.

Correct busbar voltage denoted on circuit diagrams by small tick next to the supply
details.

Circuit function test of a relay denoted by a large tick through the relay.

Wire not terminated denoted by open circle.

Wire subsequently terminated denoted by tick Gross through circle.

G3.2 RECORDED ON ANALYSIS SHEETS

Relay type and pin code analysis check denoted on contact analysis sheet by large tick

Analysis check of each entry on the analysis sheet denoted by small tick on each and
every entry including spare contacts, wires and terminals (Null Count)

G3.3 RECORDED ON CONTROL TABLES

Function Test denoted by large tick

Through testing of contacts (e.g. tracks in auto signals ) denoted by a large tick.

Aspect check denoted by large tick.

G3.4 RECORDED ON CIRCUIT BOOK SHEETS

Sheet fully tested denoted by testers signature, name and date in the bottom right hand
corner.

G3.5 RECORDED ON TRACK PLANS

Inspection denoted by large tick against item checked.

APPENDIX H
SAMPLE FORMATS FOR TEST CERTIFICATION

(COMPANY NAME)
(Document Control Number)
MASTER TEST CERTIFICATE
PROJECT:..................
LOCATION: ..............
DESCRIPTION: .........
CUSTOMER: ............. WestNet Rail

Name Signature Date

DESIGN CLOSURE LIST REF.......................................
INSTALLATION COMPLETE .........................................
TESTING COMPLETE: CABLES ...............................
SIGNALS .............................
POINTS................................
TRACK CIRCUITS...............
ATS / ATP / AWS EQUIP ....
LOCATIONS ........................
RELAY ROOMS...................
CONTROL CENTRE ...........
LEVEL CROSSINGS ...........
FUNCTION TESTING..........
CONTROL TABLES.............
PRINCIPLES........................
ASPECT SEQUENCE .........
TEST LOG ACTIONS COMPLETE ................................

NOTE:Refer to the Summary Check List for the Testers' signatures and verification of individual tests.

ENDORSEMENTS:

I hereby certify that all equipment and systems relative to the signalling referred to and
described above has been tested against design details, customer specifications and AS 4292
(Part 1 and 4) and found to be correct in all respects subject to the endorsement noted above.

TESTER IN CHARGE: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)

CABLE TEST CERTIFICATE

PROJECT:
Section from....... to: ........
Cable ID .............
Cable Type ......... Numbeer of Cores....

Core To Screen / Drain To Earth Core To Screen / Drain To Earth

1 26
2 27
3 28
4 29
5 30
6 31
7 32
8 33
9 34
10 35
11 36
12 37
13 38
14 39
15 40
16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
24 49
25 50

Weather Conditions: Wet Damp Dry

Wire Count on each cable core termination correct YES NO

ENDORSEMENTS:

TESTER: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)
SIGNAL TEST CERTIFICATE

PROJECT:
LOCATION:
SIGNAL No ....... LOCATION No: ............

RECORD DETAILS OF ALL TESTS ON TEST COPY PLANS AND DIAGRAMS

YES NO REMARKS
Signal erected in conformity with sighting form,
structure gauge and Project Plan.........................................
Ready for testing .................................................................
Signal lenses/hoods/number plate correctly in place
Anti-phantom device correctly fitted ..................................
Cabling correct ....................................................................
Lamps and Filament failure relays correct..........................
Telephone installed and operational (where applicable) ....
Wire count and continuity test correct ................................
Filament failure test correct ................................................
Speed/Route Indicators test correct.....................................
Lamp Proving test correct ...................................................
Traction Safety Bonding and Earth Connections correct....
Functionally tested correct ..................................................
Ready for Commissioning...................................................
Final Sighting and Alignment .............................................

ENDORSEMENTS:

TESTER: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)
POINTS TEST CERTIFICATE

PROJECT:
LOCATION:
POINTS No: LOCATION No:

RECORD DETAILS OF ALL TESTS ON TEST COPY PLANS AND DIAGRAMS

YES NO REMARKS
Drive equipment installed and set up in
conformance with Project plan and mechanical
drawings and Ready for testing................................
Number Plate correctly fitted ...................................
Tail Cabling correct .................................................
Wire count and continuity test correct .....................
Traction and track circuit bonding correct...............
Point lock adjustment and correspondence correct
Detection contact adjustment and correspondence
correct.......................................................................
Point correspondence test correct ............................
Emergency Manual Operation correct .....................
Traction Safety Bonding and Earth connections
correct Functional test correct..................................
Ready for Commissioning........................................
Final Test correct .....................................................

ENDORSEMENTS:

TESTER: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)
TRACK CIRCUITS TEST CERTIFICATE

PROJECT:
LOCATION:

BONDING PLAN No: Sheet No:

RECORD DETAILS OF ALL TESTS ON TEST COPY PLANS AND DIAGRAMS AND ON INDIVIDUAL
TEST RECORD SHEETS OF TRACK CIRCUIT PARAMETER READINGS

TRACK CIRCUIT NUMBER....................................................

Track Circuit Type .....................................................................
Equipment Correct .....................................................................
Labelling Correct .......................................................................
Track Connections corrected as plans ........................................
Track Circuit Bonding installed correctly to plans.....................
Traction Bonding installed correctly to plans.............................
Spark Gaps installed correctly and tested...................................
Track length correct ...................................................................
Adjustment and shunt test correct ..............................................
insulated Rail Joints correctly installed......................................
Clearance Points correct.............................................................
Polarity/phasing correct..............................................................
Tested for extraneous voltage.....................................................
Dead Sections correct.................................................................
Level Crossing Predictor tested and adjusted.............................
Traction Safety Bonding and Earth Connection complete .........

Ready for Commissioning..........................................................

NOTE: Allowable markings are a "tick", "NO", or "N/A"

TESTER: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)

LEVEL CROSSING TEST CERTIFICATE

PROJECT:
LOCATION:

NAME OF CROSSING:

RECORD DETAILS OF ALL TESTS ON TEST COPY PLANS AND DIAGRAMS

Crossing Layout corrected as plans ...................................................................

Correct Clearance of equipment........................................................................
Road Signs and Markings as plans....................................................................
Lamp Units correctly installed and aligned .......................................................
Bell / Audible Warning Device correct orientation, sound level and rate .........
Boom Mechanisms correctly installed and adjusted..........................................
Correct Type of Power Supply, correctly installed and adjusted......................
Level Crossing Predictor correctly installed and adjusted.................................
Telephones correctly installed and operational .................................................
Local Circuit Test completed ............................................................................
Failure Mode Tests completed ..........................................................................
Correct Minimum Clearance Time as specified ................................................
Traction Safety Bonding and Earth Connection complete ................................
Ready for Commissioning.................................................................................
Correct Operation Sequence..............................................................................
Knock Down Timers .........................................................................................
Remote Monitoring ...........................................................................................

ENDORSEMENTS:

TESTER: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)

POWER SUPPLIES TEST CERTIFICATE

PROJECT:
LOCATION:

EQUIP. ROOM / LOCATION No:

RECORD DETAILS OF ALL TESTS ON TEST COPY PLANS AND DIAGRAMS

YES NO REMARKS
Equipment of correct type as specified .......................
Equipment correctly positioned and secured ..............
Equipment and installation suitable for safe and
reliable operation.........................................................
Cables tested for continuity, polarity and insulation
resistance .....................................................................
Correct Loading, Phasing and Polarity .......................
Correct trip settings of circuit breakers.......................
Correct operation of status indications and alarms .....
Correct operation of main/standby changeover ..........
Standby Batteries to correct specifications .................
Charging Equipment correctly adjusted......................
No interconnection between bus-bars .........................
Earth Leakage Detector correctly adjusted .................

Ready for Commissioning...........................................

ENDORSEMENTS:

TESTER: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)

LOCATION/ CASE RELAY-/CONTROL-ROOM TEST CERTIFICATE

PROJECT:
LOCATION:

ENCLOSURE IDENTITY:

RECORD DETAILS OF ALL TESTS ON TEST COPY PLANS AND DIAGRAMS

YES NO REMARKS
Equipment of correct number and type as
specified ...................................................
Equipment correctly installed ..................
Correct Relays Base Pin Codes / SSI.......
Polarising Pins..........................................
Power Supplies correctly installed...........
Labelling complete...................................
Cables secured..........................................
Earthing correctly installed ......................
Circuit Strap and Function tested.............
Internal Interlocking tested.......................
Traction Safety Bonding and Earth..........
Connections complete ..............................
Ready for Commissioning........................

ENDORSEMENTS:

TESTER: SIGNATURE: DATE:

APPENDIX H
Sample Formats For Test Certification

(COMPANY NAME)
(Document Control Number)

COMPUTER BASED INTERLOCKING SYSTEM TEST CERTIFICATE

PROJECT:
LOCATION:

SYSTEM IDENTITY:

RECORD DETAILS OF ALL TESTS ON TEST COPY PLANS AND DIAGRAMS

YES NO REMARKS
System Type Approved for intended use ...............
Documented Hardware is installed ........................
Software versions are correct .................................
All Checksums are correct .....................................
Software simulation test completed .......................
Installed software matches tested software............
All system interfaces tested....................................
Response time verified...........................................
Other Performance criteria verified .......................
Function tests complete..........................................

Ready for Commissioning......................................

ENDORSEMENTS:

TESTER: SIGNATURE: DATE:

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