PACKAGE B - SIGNALLING & COMMUNICATION WORKSTECHNICAL SPECIFICATION - SECTION A

1.0 PRACTICES AND STANDARDS

1.1 In this section (Section A – Technical Specifications), the Jabatan Keretapi

Negeri Sabah shall be referred to or abbreviated as JKNS.

1.2 The works shall be implemented in accordance with recognised national and
international railway practice.

1.3 Except where otherwise stated, the Works shall comply with the relevant
standards, regulations, codes of practice, recommendations etc. of the following
organisations:-

a) Technical Standards and Procedures of JKNS & KTMB.

b) Malaysian Standards Specification (MSS)
c) The International Organisation for Standardisation (ISO)
d) The International Electrotechnical Commission (IEC)
e) The International Telephone and Telegraph Consultative Committee (CCITT)
f) The European Committee for Electrotechnical Standardisation (CENELEC)
g) International Union of Railways (UIC)
h) British Standards Institution (BSI)
i) Institution of Electrical Engineers (IEE)
j) International Telecommunication Union – Telecommunication Standardisation
Sector (ITU-T)
k) European Telecommunication Standardisation Institute (ETSI)

1.4 The National or International Standards referred to above represent the minimum
requirements which shall be met. The Contractor is free to adopt other standards,
provided always that such other standards are equivalent to, or superior to, those
stated above. The use of alternative standards shall be subject to the specific
approval of the Engineer.

1.5 The Contractor shall maintain consistency in the adoption of, and conformance
to, any of the standards chosen.

1.6 In cases where the Contractor is required to change from one standard to
another or where any conflict exists between provisions of two (or more)
applicable standards, the matter shall be referred to the Engineer for
determination.

1.7 Works shall conform to manufacturers published instructions, safety

requirements, procedures etc. including use of personnel safetyware and
protection requirements.

1.8 Metric standards and SI units shall be utilised unless otherwise approved.

2.0 COMPATIBILITY

2.1 It is the Contractor’s responsibility to provide systems, plant and equipment such
as to ensure that the Works are fully compatible within themselves and also that
the Works are fully compatible with Associated Works and adjacent JKNS and
3rd Party Systems, plant and equipment.

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2.2 Accordingly it is the Contractor’s responsibility to ensure that all matters of

interfacing, immunity and interference are satisfactorily addressed and resolved
in respect of the Works and such Associated Works and adjacent JKNS and 3rd
Party Systems, plant and equipment taking into account normal and abnormal
operation and fault conditions.

2.3 In respect of the Works, associated Works and 3rd Parties, it is the Contractor’s
responsibility to conduct such negotiations, dialogue, discussions etc. As are
necessary and to exchange such information as is necessary to ensure the
successful implementation of the Works.

3.0 PROVEN SYSTEMS

3.1 All systems, plant and equipment provided under the contract shall be proven
and fully tried and tested in the service of a recognised railway organisation and
shall have a substantial satisfactory service history. Full and complete technical
and operational information and details shall be included in the Tender for all
major components together with full service history and performance details,
number of units in use etc. for reference purposes.

3.2 All equipment offered shall be new, of proven design, in current production and
shall be designed for continuous duty service under the prevailing environmental
conditions.

3.3 The materials and furnishes used shall conform to recognised relevant
international standards in addition to any specific requirements described in this
tender document.

3.4 The equipment shall be of modular design for easy installation, future upgrading
and maintenance.

3.5 The Tenderer shall furnish all description and design details of the offered
equipment and other characteristics that may not have been specifically
mentioned in this specification.

4.0 SYSTEM ARCHITECTURE AND PERFORMANCE

4.1 Reliability

4.1.1 The Works shall be designed and constructed so as to achieve a high level of
availability and fault tolerance. Reliability data including MTBF figures shall be
given in the Tender for main components and system performance.

4.1.2 Condition monitoring techniques shall be employed, where possible, such that
degradation of system performance shall be detected before system failure
occurs.

4.1.3 Integrated system diagnostics shall be incorporated to continuosly check the

condition of hardware, data links etc. Failure of diagnostics shall not affect
system operation.

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4.1.4 Multiplicated system architecture shall be employed for microprocessor based

and solid state system etc. utilising fully updated standby systems, redundant
data links, etc. and automatic changeover facilities. Changeover between such
systems shall be fully automatic requiring no manual actions whatsoever.

Changeover between systems shall have no effect whatsoever on system

operation or the status of controls or indications etc. and shall be imperceptible to
operators. Such facilities shall be provided in respect of, but not limited to the
following systems:-

a) Signalling telemetry systems

b) Microprocessor interlockings
c) Transmission Multiplexing Systems
d) Computerised Train Dispatching and Radio Block Signalling System
e) Power Supply Systems – N + 1 configuration

4.1.5 Standby systems, data links etc. shall be continuously monitored and semiurgent
alarms given immediately on loss of such systems.

4.2 Alterability

4.2.1 Hardware shall be inherently alterable such that JKNS, within its own resources,
shall be able to implement engineering modifications to accommodate associated
system changes etc.

4.3 Operational Performance

4.3.1 Systems shall perform at high speed such that there is no perceptible delay in
system response to operators. System reaction to operator interfaces shall
appear as virtually instantaneous to operators.

4.4 Safety Requirements

4.4.1 Adequately safety precautions to protect maintenance personnel against

dangerous voltages, exposure to intense radiation and / or any form of hazard
shall be incorporated in the equipment to be supplied. These precautions shall
include the display of warning notices, shrouding of terminals and fitting of
interlock devices where necessary.

5.0 SPARE CAPACITY

5.1 Spare capacity shall be included in systems and equipment to facilitate future
changes to the railway network. The precise nature of such spare capacity will be
dependent on the types of systems and equipment supplied.

5.2 Unless otherwise specified, a minimum of 10% increase in trackwork, signalling,

communication and associated facilities shall be allowed for.

5.3 Unless otherwise specified, cables shall have a minimum of 25% spare cores or
pairs subject to a minimum of 2 cores / pairs, whichever is higher. This shall
include power cables.

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5.4 Power Supplies and Transmission Multiplexing Systems shall have minimum
spare capacity of 25 %, unless otherwise specified.

5.5 It is anticipated that spare capacity shall be included in, but not limited to the
following:-

a) cabling
b) transmission multiplexing systems
c) power supplies
d) microprocessor systems
e) equipment housings and racks

6.0 SPECIAL TOOLS AND TEST EQUIPMENT

6.1 The Contractor shall provide special tools and test equipment for JKNS to be able
to monitor, fault-find, repair, upgrade, reconfigure & reset and other aspects of
maintenance of the systems to be installed under the Contract.

6.2 The requirement of the special tools and test equipment shall include, but not
limited to the following:-

1) Copper cable system – Insulation Resistance Tester (Megger), digital

multimeter.

2) Optical Cable System – Fusion Splicer, Optical Time Domain Reflectometer

(OTDR), Optical Power Meter, Mechanical Splicer & accessories

3) Digital Transmission System – Portable Service Terminals (PDH), Digital

Communication Analyser, laptop computers for node / NE management,
Network Tester (SDH Version), PCM Tester

4) Train Radio System – Spectrum Analyser, Portable Frequency Counter,

Portable Digital Transmission Set, Base Station & Radio Terminal Set, Radio
Network Prediction Tool

5) Others – earth tester, terminal punchers

A minimum of 2 (two) units / sets of the above items shall be supplied by the
Contractor, except for Digital Multimeter (5 units shall be supplied) and also for
mechanical splicer & accessories and terminal punchers where reasonable
quantities shall supplied. The Contractor shall also proposed any other special
tools and test equipment that are deemed very necessary to operate and
maintain the system. Sufficient training shall also be provided on special tools
and test equipment supplied.

7.0 DOCUMENTATION AND DRAWINGS

7.1 Documentation and drawings shall consist a series of diagrams, schematics,

drawings. layouts. plan, tables, methods statements, handbooks manuals etc.
which together shall comprehensively describe and detail the whole of the Works
in every respect.

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7.2 Copies of all such designs, documentation and drawings shall be submitted to the
Engineer in accordance with the approved programme. Such submissions shall
be for the sole benefit and information of the Engineer. Notwithstanding such
submissions, or any comments that may subsequently arise therefrom, the
Contractor shall be, and shall remain, wholly and solely responsible and liable for
any non-conformances, discrepancies, errors or omissions etc. contained in any
designs, documentation and drawings.

7.3 Such documentation and drawings shall contain sufficient information and details
so as to facilitate provision of the Works and to permit JKNS to eventually
maintain, operate and carry out engineering modification to the Works.

7.4 Maintenance documentation shall be structured and presented in such a manner

as to facilitate a 1st, 2nd and 3rd Level Maintenance hierarchy.

7.5 With the exception of established proprietary documentation, all documents and
drawings shall be produced by the following processes:-

Test : WINWORD - Latest Version

Drawings : AUTOCAD - Latest Version

and shall be issued in hard copies and on computer diskettes or CD ROMs.

The Contractor shall also provide 1 nos of a licensed AUTOCAD software come
complete with recovery discs and license disc plate together with software lock.

7.6 Hard copies of documentation shall be presented and bound in a fashion which
will allow easy use, maintenance and updating and will be hard wearing such that
it shall last for the lifetime of the system. Books of design details shall be of
maximum A3 size unless otherwise approved by the Engineer. Prints of drawings
shall be substantially mounted in hard covers in such a manner as to readily
permit insertion and removal of individual drawings.

7.7 All documentation shall be clearly legible, comprehensively indexed, fully cross
referenced, set out logically and consistent in the use of symbols, texts, layouts,
title boxes etc.

7.8 Each and every sheet of documentation shall contain the following :-

(a) Main Title

(b) Sheet Number
(c) Sheet Title
(d) Issue Type e.g. Preliminary, Inspection, Approval, Construction, Testing, As-
Built etc.
(e) Modification Status
(f) Revision No. & Date
(g) Signatures in respect of preparation, checking and approval.

7.9 Each and every sheet of documentation which is in circulation shall be endorsed
with its current status.

7.10 Unless otherwise specified, numbers of copies of documentation and drawings to

be submitted to the Engineer shall be as follows :-

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Issue Nos of Copies

Inspection/Approval 2
Testing Records 1
Commissioning Maintenance Copies 2
Final As-Built Records 4 (plus 1 diskette or CD ROM)
Final Manuals, Handbooks etc. 10 (plus 1 diskette or CD ROM)
(including operational manuals)

7.11 Software licensing fee must be included in the offer inclusive of software
integration whenever required.

8.0 ENVIRONMENTAL CONDITIONS AND ASSOCIATED REQUIREMENTS

8.1 General

The works shall operate satisfactorily and fully in accordance with the
specification under all environmental conditions experienced in Malaysia. For
each of the environmental conditions specified the Tender shall state the range,
intensity, level etc. over, or at, which systems and equipment will :-

(a) function normally in accordance with the specification.

(b) not suffer any permanent degradation or damage.

8.2 Tropicalisation

All equipment shall be fully tropicalised.

8.3 Temperature and Humidity

8.3.1 Systems and equipment shall operate correctly under all temperature and
humidity conditions.

8.3.2 Account shall be taken of condensation which may occur under a combination of
temperature and humidity conditions.

8.3.3 When considering heating effects account shall be taken of outside ambient
temperatures together with the accumulated effects of solar radiation and heat
generated within enclosures.

8.3.4 Trackside equipment cases shall be designed particularly to limit internal

temperature rise and shall include the necessary features to maintain adequate
ventilation. They may require extra panels to act as sunshades.

8.4 Pollution

8.4.1 Systems and equipment will be in contact with the atmosphere which will
generally be polluted. Pollutants may be either chemically active or inert such as
dust.

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8.4.2 All systems and equipment shall operate correctly in a polluted dust laden
atmosphere. Means shall be provided to prevent, either ingress of pollutants or
the direct, or indirect, effects of pollutants, causing incorrect operation or
permanent damage during operation, transport or storage.

8.4.3 Chemically active pollutants may occur in the atmosphere near sea water or in
industrial areas. In the latter case gases may dissolve in condensation or
themselves condense in or on equipment. Equipment shall be protected against
the effects of such corrosive substances.

8.4.4 Equipment exposed to the weather shall be resistant to attack by detergents,

sewage, toxic substances such as weed killer and lubricating and fuel oils.

8.5 Solar Radiation

8.5.1 Systems and equipment shall be impervious to and shall not deteriorate or
discolour under the effects of direct solar radiation.

8.6 Electromagnetic Effects

8.6.1 All equipment and system which are susceptible to electromagnetic effects shall
be suitably protected with electromagnetic noise free screened enclosures to
ensure correct operation and avoid permanent degradation.

8.7 Electromagnetic Radiation

8.7.1 The Tenderer shall state the electromagnetic radiation from the offered
equipment, referred to a distance of 3 metres and measured according to IEC
publication 106 latest edition.

8.8 Lightning

8.8.1 As the state of Sabah is a region of high incidence of thunderstorms with very
severe lightning, adequate protection against damage or malfunctioning of
systems, plant and equipment, entire cable plant, etc. due to high voltage or
current transients shall be incorporated. Equipment to be connected to the mains
power supply and items to be connected to or mounted close to the railway track
should receive special attention. The importance of providing adequate
safeguards for prevention of damage by lightning must be strongly emphasized;
details of high voltage surge arrestors, fuses, chokes, etc. being provided for this
purpose must be included in the tender.

8.8.2 It shall be the Contractor’s responsibility to ensure that all systems and
equipment supplied and installed under the contract incorporate adequate
measures to prevent damage and system failures due to high transient voltages
and currents resulting from lightning strikes. The specific requirements mentioned
in the following paragraph shall be regarded as only the minimum requirements
which may not be necessarily adequate in particular situation.

8.8.3 For protection against transient high voltages and currents introduced via the
mains power supply, the minimum protection shall be a Surge Reduction Filter
(S.R.F) of appropriate size fitted to the incoming supply lines and having the

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following features:

(i) Mains type rated for operation at 240V 50Hz single phase.

(ii) Provide protection against both differentials and common mode transients
from the supply lines.

(iii) Incorporate high energy clamping devices and filtering components with low
frequency (low pass) characteristics. Inductors shall be air-core (non-
saturable) and capacitors shall be of ‘self-healing’ type.

(iv) The neutral conductor shall not be bonded to earth (ground), but it shall be
so protected that any surge arriving via the neutral conductor will also be
diverted to earth.

8.8.4 For protection against transient high voltages and currents surges introduced via
the data lines, and other lines connected to equipment having electronic
components, the minimum protection shall be a Transient Protection Units
(T.P.U) of appropriate size fitted to the external lines and having the following
features:

(i) Two stages of protection shall been incorporated in each T.P.U, with separate
modules being used for the primary and secondary protection so as to
facilitate testing and replacement, and the two modules securely connected
together with high grade connectors.

(ii) The secondary protection module shall include a matching attenuator or filter
and high energy clamping devices (with a response time less than 100
picoseconds). Such clamping devices shall be effective against surge
voltages of either polarity appearing between the lines or between either lines
and earth (ground).

(iii) The T.P.U shall be designed to allow easy installation and connection of the
incoming and outgoing lines to primary protection module. Removal and
insertion of the secondary protection module should be possible without
having to disconnect the lines.

8.8.5 For protection against transient high voltage and high current surges introduced
from the railway track via the track circuit connections or any other connections,
the minimum protection shall be appropriate Transient Protection Units (T.P.U.)
fitted to the external lines and having the following features:

(i) Provide protection against transient voltages between the lines and between
each line and earth (ground).

(ii) One or more stages of protection incorporated in each T.P.U. according to the
requirements of the particular track circuit equipment. Electronic equipment
(for example, jointless track circuits) require more than one stage. Each stage
shall be a separate module so as to facilitate testing and replacement.

(iii) Connection pins and terminals shall have adequate current carrying capacity
to withstand the high transient currents in addition to the normal current.

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(iv) The T.P.U. shall be designed to allow easy installation and connection.
Removal and insertion of the protection modules should be possible without
having to disconnect the lines.

8.9 Vibration

All systems and equipment shall be capable of satisfactory operation and

permanent storage without deterioration or damage in vibration conditions which
are consistent with the passage of trains.

8.10 Waterproofing

8.10.1 The project area is a region which experiences severe tropical rainstorms.

8.10.2 All equipment external to permanent buildings must be proofed against ingress of
water caused by such rainstorms or other liquids not only in the vertical plane but
in any other direction.

8.11 Wind

Systems and equipment shall be able to withstand, and shall operate correctly
under, the most onerous wind conditions. Wind effects shall be suitably factorised
to take account of ground topography and exposed areas.

8.12 Vandalism

The works shall include protective measures to counter either accidental or

malicious damage by vandalism particular attention shall be paid to:-

(a) Cables
(b) Equipment Housing
(c) Outdoor boxes or cases
(d) Outdoor equipment
(e) Graffiti Resistant Finishes

8.13 Reptile, Insect and Rodent Protection

8.13.1 Materials, cables, installations and equipment shall be designed and constructed
to be unattractive to, and to be resistant to, reptiles, insects and rodents etc.

8.13.2 In respect of equipment and operational rooms, termination boxes, outdoor

shelves etc. cable entries, ducting etc. shall be sealed and cables shall enter
through close fitting cable glands to prevent ingress of reptiles, insects and
rodents.

8.14 Environmental Conditioning

8.14.1 It is preferred that all systems and equipment shall operate and perform
satisfactory in accordance with the specification without any reliance on
environmental conditioning.
8.14.2 Any cases where environmental conditioning is necessary or recommended in
respect of systems and equipment performance shall be fully detailed in the

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Tender. Provision of any such environmental conditioning shall be responsibility

of the Contractor where equipment rooms are provide under the Contract.

8.14.3 The works shall include the provision of environmental conditioning for personnel
purposes in operational and equipment rooms where such rooms are provided
under the contract.

8.14.4 Where accommodation is provided by others, or is in situ, and environmental

conditioning is required, the contractor is responsible for satisfying himself and
providing confirmation as to the adequacy of provision of such environmental
conditioning by others.

8.14.5 The Tender shall identify any spares which are required to be stored in a
conditioned environment together with details of the conditioning required.

8.15 Painting Protection and Finishes

8.15.1 Painting, protection and finishes shall be suitable for the environmental conditions
and shall also take due regard of the following:-

(a) whole life durability

(b) protection against fungi, corrosion, electrolytic corrosion etc.
(c) resistance to accidental damage and vandalism
(d) colour schemes
(e) maintenance and cleaning
(f) resistance to deterioration due to touch
(g) staff safety

8.15.2 Consideration shall be given to provision of stainless steel where possible for
metalwork exposed to the atmosphere. Outdoor stainless steel equipment cases,
distribution boxes etc. shall be painted.

8.15.3 All nuts, bolts,fittings, washer etc. utilised in outdoor locations shall be of a non-
corroding material or shall have suitable means of protection such as nickel
plating, galvanising etc.

8.15.4 Where paint or other finishes are damaged during delivery or installation etc. they
shall not be patched finished. They shall be properly prepared such that the
original protection shall be restored in full including preparation, undercoating and
top finishes as required.

8.16 Fire Resistant

All materials shall be chosen to minimise the risk of fire. Materials which are used
in large quantities shall have an oxygen index higher than 21 % measured
according to ASTM D 2863 “Standard Method of Test For Flammability of Plastic
Using the Oxygen Index Method”. Other equivalent or higher standards are also
acceptable.

8.17 Electrostatic Discharge

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The equipment shall fulfill the Electrostatic Discharge (ESD) requirements stated
in the EMC Directive of the European Communities (89/336/EEC) and in the
following standards :
• IEC: IEC 61000-4-2 and IEC 801-2
• CENELEC: EN 61000-4-2
• ETSI: EN 300 386-2 and ETS 300 386-1

8.18 Mechanical Construction

8.18.1 Tenderer shall provide details on the construction and dimension of equipment
offered. The equipment and rack offered should not be more than 2750mm in
height. Rack of 2100mm height shall also be offered. The equipment offered shall
be mounted on a 19 and / or 23 inches wide rack. The racks shall be fully
covered, well ventilated and with front (see through) and rear access doors.

8.18.2 The required form of construction shall be plug in modules, readily removables
from the front of the rack.

8.18.3 The grouping of instruments, and adjustment controls shall be such that any
operation or adjustment of the equipment shall be simple and involving the
minimum possibility for access to dangerous voltages.

8.18.4 The equipment design shall be that replacement of consumable components

such as fuses, LEDs / indication lamps, etc., can be made without risk of
accidental contact with high voltages. High voltage components shall be mounted
in enclosures and labeled for safety reasons.

8.18.5 Wiring and cabling shall be colour coded or provided with other means of
identification to facilitate maintenance. The colour code or other means of
identification, subject to the approval of the Engineer, shall be documented.

8.18.6 Switches and controls shall be placed or constructed such that the risk of
accidental or unauthorised operation is minimized.

9.0 MAINTENANCE REQUIREMENTS

9.1 The Works shall be designed and constructed so as to be wholly maintainable.

Attention shall be given to adequate equipment spacing, working environment,
accessibility of components, plugs, sockets, terminations etc. adequacy of
lightning etc.

9.2 Systems, plant and equipment together with documentation, drawings, manuals
etc. shall be structured so as to be maintainable by the following general
maintenance hierarchy :-

(a) First Level Maintenance

Technician Level maintenance comprising routine periodic activities and

rectification of failure or potential failures which can be remedied by use of
diagnostics and module replacement.
(b) Second Level Maintenance

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Investigation and rectification, with the use of special test equipment as

necessary, of such failures or potential failures, with respect to on-line or
standby systems etc., that the 1st Level Maintenance procedures have been
unable to cope with.

(c) Third Level Maintenance

Off-site diagnosis and repair of modules which have been removed and
replaced under 1st level or 2nd level maintenance.

9.3 Equipment shall be laid out in equipment rooms, compounds and other housings
in a logical and consistent manner. The spacing between equipment, equipment
modules, cable terminations, plug/sockets etc. shall be such as to allow easy
access for maintenance purposes and shall be subject to an absolute minimum of
:-

a) 800 mm working clearance between equipment, mounted on the floor, wall,

adjacent racks etc. where maintenance work is carried out.

b) 600 mm passing clearance at ends of racks etc. where walkways only are
involved.

9.4 Comprehensive maintenance, diagnostic and fault finding facilities shall be

provided with clear and concise status and failure indication etc. System
performance/fault logging storage, display and hard copy printing facilities shall
be provided for microprocessor and solid state systems.

9.5 To minimise Mean Time to Rectification and simplify procedures for maintenance
staff, all systems and equipment shall be installed on a modular basis.
Preference will be given to systems utilising a “plug-in” method of connecting
modules.

9.6 The number of different types of module in the system shall be kept to a
minimum. Maximum use shall be made of interchangeability of modules.

9.7 There shall be mechanism which physically prevents insertion of an incorrect

module into a location.

9.8 Where adjacent cable plug/socket terminations are utilised, physical means shall
be provided to prevent cables from being erroneously interchanged.

9.9 Where a module requires replacement, an indication system must make it easily
and immediately apparent to the maintainer which module should be replaced.

9.10 All modules shall be capable of being fitted and removed by one person.
Preferably, the maximum weight of each item shall not exceed 15 kg and the
weight shall be evenly distributed.

9.11 Where appropriate equipment modules shall be fitted with handles by which they
can be removed from the equipment rack and carried.

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9.12 All modules shall be indelibly marked with both a unique serial number and a
version number/modification status code. The marking shall be so located that it
can be easily seen and read.

9.13 Full, complete and up-to-date sets of Commissioning Maintenance

Documentation and Drawings shall be available at each stage commissioning of
the Works.

10.0 POWER SUPPLY

10.1 A single phase mains power supply of 240Vac 50 Hz will be available at most
railway stations, except at Pangi and Rayoh stations. The Contractor shall be
responsible for the connection of mains power supply to Pangi and Rayoh
stations.

10.1.1 For the connection of mains power supply at Rayoh and Pangi stations, the
Tenderer shall, before submitting his Tender, communicate and arrange with
SESB to jointly undertake a thorough study and site investigation to ascertain the
availability of the nearest SESB mains power supply lines, with respect to these
stations . If the connection to the nearest available SESB mains power supply
line is not possible due to excessive voltage drop (very far from the station), a
power sub-station shall be provided. All costs pertaining to the connection of
mains power supply to these stations shall be included in the Tender, including
deposits, fees, building cost, materials and installation costs and all other costs
imposed by SESB.

10.1.2 The Tenderer shall submit a detailed proposal on the provision of mains power
supply at Rayoh and Pangi stations in his Tender, including drawings, layouts,
etc.

10.2 The Contractor shall be responsible for the necessary connections and wiring
from the suitable mains power supply points in the station building to equipment
room / cabin and also to train radio cabin, if the latter is located closed to a radio
tower due to site constraints, but still within the station area. This shall include
any necessary modification / upgrading of switchboard, fuse box, circuit breakers,
etc., and the provision of additional power points, ELCB and MCCB.

10.3 In the event of train radio equipment room / cabin (for both radio base station
and repeater station) is located far away from the station area, the mains power
supply shall be arranged by the Contractor to be connected to the cabin /
equipment room. All facilities including electrical wiring, switchboard, fuse box,
ARCB, ELCB, MCCB, power points, fans, twin air conditioning units (with
automatic changeover unit), etc., shall be provided by the Contractor. All costs
pertaining to connection of mains power supply to train radio cabin shall be borne
by the Contractor, including all deposits, materials costs and other costs imposed
by SESB.

10.4 The Contractor shall state the electrical loading for the systems to be supplied
under the contract , as follows:-

(a) estimated maximum continuous load

(b) estimated maximum peak load and duration

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These values shall be ascertained by the Contractor at systems design stage.

10.5 The necessary equipment, wiring and cable distribution network shall be provided
for the connection / distribution of power to digital transmission equipment, PABX,
train radio equipment, train dispatching equipment, block & station signalling
equipment, level crossing protection equipment, etc., which to be installed under
this Contract. This shall include, but not be limited to the following:-

a) equipment room / cabin, train radio cabin

b) centrallised traffic control room, operational room
c) lineside equipment rooms and cases
d) gate hut

10.6 Power supply equipment to be provided shall include any special power
conditioning units, filters, regulators, etc. as are necessary for reliable operation
of the Works taking into consideration voltage fluctuations, interruptions, and
other disturbances which may occur.

10.7 All circuits shall be protected against damage from excessive currents by means
of adequate safety fuses (cartridge type) and/or circuit breakers, which shall be
distributed so as to limit and localise failure of equipment resulting from the
operation of protection devices.

10.8 Work and equipment associated with mains power supply points and all work
carried out on power cables and circuits (including wiring, power connection
works etc.) shall only be carried out by personnel properly licensed and
registered with Jabatan Bekalan Elektrik (JBE). All such work shall be carried out
in compliance with the Electricity Supply Act and Regulations.

10.9 Power cables shall be rated such that the maximum voltage drop from the supply
point to the furthest point on any power supply feeder shall not exceed 10 % of
the supply voltage under maximum loading conditions.

10.10 Fuses or single pole switches shall not be connected in series with the neutral
connection of the mains power supply.

10.11 For Digital Transmission System (DTS) installed in the equipment room alone
(without train radio system), a Switch Mode Rectifier system (SMR) shall be
provided. The rectifier modules shall be in N + 1 configuration. The batteries shall
have sufficient capacity for DTS system to operate at least 10 (ten) hours during
mains power failure and be float-charged on automatically regulated constant
potential charging system. The SMR shall be capable of displaying all alarms and
indications.

10.12 For all equipment in Centralised Traffic Control (CTC) room at Tg. Aru, including
central equipment for train radio, radio block equipment, computerised train
distpatching equipment, PABX, digital voice logging equipment, etc., the standby
power supply shall be in the form of Uninterruptible Power Supply (UPS) and
stanby generator set of sufficient capacity with additional spare capacity of 25%
as per Clause 5.4 of this Section.

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10.12.1 The UPS system shall include storage batteries, provision for battery charging,
invertors, automatic control and switching facilities, including automatic and
manual bypass in the event of failure of UPS system.

10.12.2 The storage battery used for UPS system shall be an industrial grade
maintenance free type stationary battery and be installed in a ventilated room
(battery room). A twin units of ventilation fan shall be provided working
alternately by means of automatic changeover unit. The battery charging system
shall operate from the mains supply and also from the standby generator set, so
that under normal conditions the battery shall be maintained in a fully charged
state.

10.12.3 The UPS system shall have sufficient capacity to supply power for all equipment
and systems in the CTC room for a duration of not less than four (4) hour.

10.13 For train radio system (radio base station and repeater station equipment
installed in train radio cabin), the standby power supply shall be a Switch Mode
Rectifier system (SMR) and standby generator set. The rectifier modules shall be
in N + 1 configuration. The batteries shall have sufficient capacity for train radio
system to operate at least 4 (four) hours during failures of both mains power
supply and standby generator set, and shall be float-charged on automatically
regulated constant potential charging system. The SMR shall be capable of
displaying all alarms and indications. In the event of failure of mains power
supply, the changeover to standby generator set shall be automatic, taking into
account the time delay for the power generator to stabilise. The standby
generator set to be provided shall have sufficient capacity with additional spare
capacity of 25 % as per Clause 5.4 of this Section.

10.14 For the equipment room that housed both DTS and train radio system, the
standby power supply requirement shall be as per Clause 10.13.

10.15 The Contractor shall also supply and install Automatic Recovery Circuit Breakers
(ARCB) in the equipment room, train radio cabin and gate hut for the incoming
240Vac supply to the SMR, battery chargers or to power supply system. The
ARCB shall be able to detect earth leakage, surges from lightning, overvoltage /
overcurrent and conductor faults. The details of ARCB shall be provided,
including the number of tripping before ARCB locks, i.e. whether factory
configured or user configurable, tripping counter, resetting of counter, etc. For
equipment room having train radio equipment installed or for train radio cabin, the
ARCB shall be installed after changeover unit of mains supply / standby
generator set.

10.16 Failure of mains power supply incoming to SMR / chargers shall be indicated at
CTC in Tanjung Aru. This may be done via dry contact provided in SMR /
chargers, if available, or else to be provided by the Contractor, and be sent
through E&M channel of the digital transmission system. The indication may be in
the form of lighting of LED to denote the failure of mains power supply at
particular location and a panel / board to house a group of indication LEDs from
various locations shall be provided in the CTC.

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11.0 EARTHING SYSTEM

11.1 All apparatus must be immune from stray currents and be effectively earthed.
Terminals for earth connections shall be provided on all apparatus as required.

11.2 Earth leakage detection and warning devices must be included for the electrical
circuits.

11.3 The earth resistance shall be sufficiently low to ensure adequate protection to
personnel and proper operation of equipment and systems including
surge/lightning devices. In any case, unless otherwise specified, earth resistance
shall not exceed 3 ohms.

11.4 Lightning protection earths shall be fast transient earths connected to various
equipment with cabling which is as short as possible, contains the minimum
number of bends and is free of coiling.

11.5 A flat hard drawn copper strip (copper tape) of suitable type and size shall be
utilised for earth connections and shall be rated to accommodate the highest
value of earth fault current to be expected, due regard being given to the
operation of surge/ lightning protection devices.

11.6 The preferred method of making an earth connection is to use “Copperweld”

earth rods approximately 13mm in diameter couple together as required and
driven vertically into the ground, selecting a damp area for this purpose where
possible. Longer rods or additional rods, earth farm arrangements etc. Shall be
used to obtain the necessary low earth resistance. If a different method is to be
used, prior approval shall be obtained from the Engineer.

11.7 Earth rods shall be driven into the ground such that the top end of the rod is
approximately 15 cm below ground level and enclosed by a suitable concrete
enclosure (earth chamber) provided with an inspection cover (at ground level) to
mark the location. The enclosure cover shall be easily removed for inspection
and earth testing purposes.

11.8 Copper tapes of suitable type and size shall be utilised for the connection from
one earth chamber to the others, and from the first earth chamber to earth
busbar.

11.9 Earthing copper tapes shall be connected to the earth rods using thermic welded
bonds.

11.10 It is preferable to have earth rods to be installed in star configuration to minimize

the overall impedance of the earthing system. These earth rods shall also be
installed as close as possible to earth busbar to minimise the length of copper
tape.

11.11 For the purpose of ground equipotential, all other earth busbars in the station, if
available, shall be linked together, or if direct link is not possible, transient earth
clamp (TEC) shall be install in between.

11.12 A complete earthing and protection schemes shall be proposed in detail in the
method statement which to be submitted in the Tender.

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12.0 OUTDOOR EQUIPMENT CASES AND DISCONNECTION BOXES

12.1 All electrical components such as transformers, relays, fuses, power supplies
etc., if so required to be installed outdoor, shall be mounted inside weatherproof
equipment cases or cabinets for outdoor installation. Such cases shall be
supplied pre-wired as far as possible.

12.2 Out-door equipment cases and disconnection boxes shall be fabricated from high
quality stainless steel.

12.3 Such equipment cases and cable disconnection boxes (referred to as ‘boxes’ in
the remainder of this section) shall be strong, weatherproof, resistant to damage
by vandals, and fabricated from good quality stainless steel. Entry of insects and
vermin shall also be prevented.

12.4 Boxes shall also have good accessibility for maintenance inside. Equipment
cases shall normally be provided with large front and rear doors for this purpose,
but for cable disconnection boxes, a single cover or door may be adequate.
Provision shall also be made for boxes to be securely locked by padlocks (which
can be opened using a common key).

12.5 The boxes shall be mounted on a heavy concrete base such that the lowest part
of the box will not be less than 40 cm above the ground level. A layer of soft and
durable plastic materials shall be provided between the bottom of the box and the
upper surface of the concrete base. The upper surface of the concrete base (onto
which the box will be bolted) shall be slope away from the base of the box, so
that any rain water flowing down the side of the box will flow off away from the
box.

12.6 All bolts and nuts used for the assembly and installation of the box, including the
installation of the box onto the concrete base, shall be galvanised or plated to
resist corrosion.

12.7 The entry of cables into the box shall be concealed and protected by passing the
cable from below through one or more opening (or ducts) within the concrete
base and into the box. The holes through which the cables enter the box shall be
effectively sealed against entry of insects and lined with soft materials to avoid
damage to the cable sheath. Proprietary cable gland usually satisfy these
requirements.

12.8 An earth terminal, shall be fitted on the inside of every box, at a place with good
access and preferably near the cable entry area, to enable a good electrical
connection to be made to the box.

12.9 As there could be a substantial temperature rise within a box due to heat from the
equipment within, as well as solar radiation effects, the design of the box shall
include the necessary features for maintaining temperature within acceptable
limits. Holes for ventilation, where provided, shall be protected against entry of
insects, vermin, and rain water. The box may also be provided with extra panels
functioning as sun shades to limit the temperature rise.

12.10 The equipment cases and disconnection boxes shall be painted with an
appropriate primer and at least two finishing coats in grey colour.

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12.11 The actual location at which a box has to be installed shall be selected based not
only upon the equipment or conditions such as ground stability and drainage.
Places which are prone to flash floods during heavy rain shall be avoided.

12.12 Every equipment case or disconnection box shall be distinctively identified by

number or code which shall be clearly stenciled onto the box with white paint.
The same number or code shall be used in the drawings to refer to the box.

13.0 EQUIPMENT ROOMS

13.1 An equipment room and a back-up power supply room (standby generator set &
battery room) will not be available at all relevant railway stations. At location
where digital transmission equipment (DTS) and train radio equipment (and also
the DTS, train radio, radio-based block signalling, PABX equipment, etc., at CTC
in Tg Aru) are to be installed, an equipment room / cabin of the dimension of not
less than 30’ x 10’ x 8.5’ (L x W x H) shall be provided. The Contractor shall also
provide the cabin for back-up power supply system of the dimension of not less
than 20’ x 10’ x 8.5’. The Contractor shall install all the equipment to be supplied
under the Contract in respective rooms.

13.2 However, if due to site constraints and / or due to the technical requirement of
train radio system which require the radio tower to be installed away from the
station, the train radio equipment room / cabin shall be provided by the
Contractor closed to radio tower (away from the main equipment room / cabin).
The dimension of train radio cabin shall not be less than 20’ x 10’ x 8.5’ (L x W x
H) and the dimension of the main equipment room (without train radio equipment)
at station shall be reduced to 20’ x 10’ x 8.5’. The Contractor shall also provide
the cabin for back-up power supply system of the dimension of not less than 20’ x
10’ x 8.5’. The Contractor shall install all the equipment to be supplied under the
Contract in respective rooms.

13.3 All equipment rooms / cabins (including train radio cabin) shall be equipped with
twin air-conditioning units, working alternately by means of automatic changeover
unit.

13.4 All equipment shall be install in this room / cabin. For train radio system, the
equipment room shall be as close as possible to the radio tower. However if due
to site constraints the radio tower is unable to be installed closed to designated
equipment room, a separate equipment room / cabin of the dimensions as per
Clause 13.2 shall be provided by the Contractor closed to radio tower. A cabin
shall also be provided to house the standby generator set, UPS / SMR / charger
unit and back-up batteries, and shall be well ventilated with twin units of
ventilation fan operated via automatic changeover unit. An unauthorised entrance
/ breakage of equipment room’s door and fire alarm shall be detected, and be
indicated at CTC in Tg Aru. The burglar alarm shall also be installed at all
equipment room and train radio cabin.

13.5 The Contractor shall also provide perimeter fencing which will fence up main
equipment cabin / train radio cabin, back-up power supply cabin and radio tower.
The fence shall be of a heavy duty chain-linked type and the height shall not be
less than 2 metres and with 3 layers of barb wires at the top portion. The chain
link fence shall come with a fence gate of approximately 2 meter wide.

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13.6 Mains power supply shall be connected to respective equipment rooms installed
(main equipment cabin / train radio cabin), with the required mains power supply
facilities including Automatic Recovery Circuit Breakers (ARCB), lightning /
overvoltage & overcurrent protection, power points, lighting, twin air-conditioning
units (with automatic changeover unit) etc.,

13.7 The Contractor shall make a joint investigation and survey with JKNS as to
ascertain the suitable locations for the equipment cabins within JKNS reserve
land.

13.8 The general requirements of equipment cabin / train radio cabin shall be as per
Appendix T9.

14.0 CABLE ROUTES AND CABLING

14.1 The Contractor shall perform all works related to installation of the cables
including trenching, passage of cables under railway tracks and roads, crossing
of bridges and culverts, backfilling and compacting as well as any other ancillary
operation of cabling. The Contractor shall be responsible for the correct execution
as well as operational safety in carrying out these works.

14.2 The cable route shall be within the railway reserve land and as near to the track
as the local conditions will permit, complying with the requirements of stability of
the track bed and of cable installation. Cable trenches on the face of the slopes
beside the railway track will not be permitted. If there is insufficient level ground
beside the track , the cable route must be diverted away from the track until level
ground is reached. In exceptional circumstances other means of installing the
cable may be permitted subject to the approval of the Employer.

14.3 The cable route shall run, as far as possible, in a straight line parallel to the track.
Track shall be crossed only at the right angle. Crossing the track within the
turnout areas shall not be permitted. Disturbance of existing earth drains, cables,
pipes and other services shall be avoided as far as possible.

14.4 Digging of cable trenches and construction of manholes shall always be carried
out under the supervision of the Engineer or his authorised representation.

14.5 Prior to starting any cable laying works, the Contractor must ensure that sufficient
labourers, machines and tools as well as all specialised materials and equipment
required are available at site, so that the cables can be laid immediately after
the trench has been prepared.

14.6 Existing cables and other underground equipments shall be taken into
consideration when digging the trench and laying the cable.

14.7 The earth dug must be placed clear of the track and drains. Every care shall be
taken to avoid any damage or disturbance to the track and its drainage system.

14.8 Cable trenches shall be kept open for a minimum period to avoid possible
accidents and unintended backfilling of trenches before the cable are laid.

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14.9 Trenching shall be carried out by cable-trenching machines or excavators as far

as the soil and site conditions permit.

14.10 The cables trenches shall be of such that buried cables shall be not less than
0.80m deep below ground level. The trenches shall not be more than 0.20m
wide. In rocky ground, the cables may be buried at 0.60m depth, but over a short
distance only. The trench bottom shall be of soft soil or sand with a maximum
grain size of 5.00mm. If the bottom is rocky, a layer of sieved soil or sand shall
be put in before laying the cable.

14.11 If the required minimum depth below ground level cannot be obtained without
incurring unduly high cost due to hard rocks or other obstructions, the cable may
be installed in galvanised mild steel pipes of suitable sizes, either buried or
otherwise fixed in placed by suitable means. Such works shall require prior
approval from the Engineer and all additional expenses incurred will be the
responsibility of the Contractor.

14.12 Where the cable route has to cross the railway track or a road, the cables must
be protected by passing them through galvanised mild steel pipes of suitable
sizes buried not less than 1.20m below cess level. Similarly where cable has to
be run along bridges or in other outdoor situations, where the cables would be
otherwise exposed, they shall be protected by galvanised mild steel pipes or
metal ducts clamped to the bridge or other structure in a satisfactory manner.

14.13 Digging across the railway tracks shall be avoided. The galvanised mild steel
pipes used for protection of cables shall be install under the track by jacking or by
boring from one side to the other, so that the ballast is not disturb, and
disturbance of the ground under the track is minimised. For the purpose, pits of
suitable depth shall be dug on either side as required, and later backfilled and
compacted. However, in particular situations where this method of pipe
installation is considered to be impractical or not desirable, other method such as
horizontal direct drilling (HDD), etc., may be authorised by the Engineer.

14.14 The method to be adopted for installing the galvanised mild steel pipes under a
road shall be subject to approval by the relevant party or public authority which is
responsible for the road.

14.15 Cable laying in the trench and drawing the cables into pipes, conduit, tubes etc.
may be done from railway wagons or trucks. If the area permit, the cable can also
be rolled out alongside the trench and then laid into the trench. Cable jacks,
rollers and all other necessary equipments shall be provided by the Contractor.
The use of railway wagons shall be permitted only if the track sections are not
block for train movements and requires approval from the railway officials
concerned. The relevant operating procedures and regulations shall always be
strictly complied.

14.16 All fibre optic cables shall be pulled through in the Hard Drawn Polyethylene
Pipes (HDPE pipe) and direct buried at depth of 800mm of the open trenching
work.

14.17 The soil filled in above laid cable shall be compacted and a durable plastic tape
(yellow colour) at least 40mm wide and 0.1mm thick shall be laid at a depth of
0.30m to 0.40m above the laid cable. The warning tape shall bear the inscription

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“Kabel Semboyan & Komunikasi Jabatan Keretapi Negeri Sabah” in black colour
continuously throughout its length.

14.18 Apart from laying of cables, the Contractor is required to carry out all cable
related operations such as terminating the cables, providing cable joints where
necessary, installing cable junction boxes, cable disconnection boxes, cabinets
and shelves as well as connecting up all equipment components.

14.19 All incoming cables into equipments rooms, outdoor equipment cases and
disconnection boxes shall be directly connected to screw-type terminals with
spring loaded and isolating links type or Insulation Displacement Connection
type with isolating links on terminal banks in a cable rack or frame. It must be
possible to easily isolate the external cables without having actually remove the
cable from the terminals. This shall apply to all copper cables.

14.20 Cable cores shall be designated at the terminals by different markings.

14.21 Every out-door cable shall terminate at each end within an equipment case,
junction box, disconnection box, or equipment such as a signal head, barrier
machines and the like or otherwise within the relay room. Intermediate joints
within a section of cable shall be avoided by laying the cables in full lengths.

14.22 The use of buried cable joints shall not be permitted, except for the optical fibre
cable. All cable ends shall be terminated and linked through the disconnection
boxes.

14.23 Contaminated ballast due to trenching shall be cleaned at the Contractor’s

expense. At all locations where ballast is missing due to reasons of trenching and
cabling it shall be replaced at the Contractor’s expense. Any damage to existing
drains, cables, pipes or other services shall be repaired at Contractor’s expense.

14.24 All cable routes shall be marked with cable markers. The markers shall be placed
at intervals of 50m and at all points where the cable route changes direction.

14.25 For optical fibre cable, all cable joints shall be marked with cable joint markers.

15.0 LOCKS AND KEYS

15.1 The Contractor shall supply and install high quality special type safety padlocks
required for all outdoor installations, such as cabinets, disconnection boxes,
barrier machines, signal heads etc., to prevent interference by unauthorised
personnel.

15.2 It is preferable that such padlocks and keys are of a type already used by the
Railway.

15.3 All locks must be suitable for use with the same standard key.

16.0 LABELLING

16.1 All equipment shall be clearly and permanently labelled.

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16.2 Labelling shall be provided in respect of:-

(a) identification
(b) safety and warning aspects
(c) operation

16.3 Labels shall be of engraved material which shall be screwed or riveted in

position. Printed labels suitably sleeve or varnished may be provided on
equipment or cables when wear is likely to be minimal.

16.4 All labels shall be made and fixed by a method that will ensure they remain
legible and in position for the life of the equipment.

16.5 All labels shall be clearly visible when the equipment is fixed into its working
position. They shall also correspond to the naming of equipment on drawings and
documentation. Minimum text height on any label shall be easily seen.

16.6 Labelling in respect of pluggable modules, printed circuit cards etc. shall be
suitably applied to both the module, card etc. itself and also to its respective
position on the equipment rack.

16.7 Each type of pluggable module, printed circuit card etc. shall be given a unique
unit number which shall include the modification state. This number shall be
engraved on the unit’s handle and on the cabinet label associated with the
normal unit position.

16.8 Where identical units have their function changed by program the unit handle
shall carry a different number.

16.9 The rack label shall carry the same number plus additional classification for the
equipment state required for that slot.

16.10 Where a unit’s function is determined by subsidiary pluggable components, the

pluggable components shall carry a label that corresponds to the additional
classification given on the rack label.

16.11 Where more than one but not all units in one housing form a working group, the
group and its function shall be identified on the rack label.

16.12 Cables shall be identified individually by labels which shall identify the location of
the far end. Where any confusion may exist, they shall also identify the near end
plug or socket to which they should be connected.

16.13 Individual cable conductors shall be identified with their individual termination
point by the fitting of suitable inscribed cable tags or markers.

16.14 Distinctive earthing cables terminated on racks and equipment etc., where they
are obvious, shall not be labelled. However earth cables terminated on earth
busbars shall be individually labelled with the far end identification.

16.15 Labelling shall conform to the same number/character/number scheme as is

utilised in associated diagrams and drawings to identify equipment.

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16.16 Label types, letter sizes, affixation etc., shall be applied consistently.

17.0 RECOVERIES

17.1 All redundant materials and equipment dismantled and recovered shall be
removed from site and disposed of in accordance with the following :-

(a) Cables and Overhead Pole Route Wires

Wire and cables shall be recovered, coiled, delivered to a Depot to be

designated by JKNS within the Works site area and unloaded and stacked
neatly in a place designated by JKNS.

(b) Reusable Items

Reusable items shall be carefully recovered, suitably packed, delivered to a

Depot to be designated by JKNS within the Works site area and unloaded
and stacked neatly by type in places designated by JKNS.

(c) Scrap Items

Scrap items shall be delivered to a Depot to be designated by JKNS within

the Works site area.

17.2 Auditable records shall be kept for the recovery process including the following :-

(a) Recovery Schedule containing a list of all items to be recovered by above

category.

(b) Certification Document verifying receipt of all items at the JKNS receiving
depot including correlation, with the Recovery Schedule.

17.3 Before recovering any items the contractor shall obtain the Engineers approval to
the Recovery Schedule.

18.0 TRAINING

18.1 The contractor shall provide full and comprehensive training for JKNS staff. The
aims of the training shall be such as to ensure that JKNS staff shall be capable
and fully competent to maintain, rectify, operate and modify the particular
systems provided.
Training courses shall cover, but not be limited to the following :-

(a) Concepts, design and engineering.

(b) Testing and Commissioning
(c) 1st, 2nd, and 3rd. Level Maintenance
(d) Emergency maintenance
(e) System alterability
(f) Operational interfaces
(g) Software

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18.2 Training courses shall include and emphasise safety matters appropriate to the
exposure of the staff concerned.

18.3 Training shall cover the whole range of JKNS staff including, but not limited to :-

(a) Training Instructors

(b) Technicians and Supervisors
(c) Technical and Engineering Staff
(d) Operation Staff

18.4 Training shall include the training of the JKNS’s own training staff. Such training
shall ensure the ability for JKNS to continue their own ongoing training
programmes.

18.5 Training shall include both theoretical and practical experience. Practical training
shall be integrated into project design, construction, testing, commissioning and
maintenance activities whenever possible.

18.6 For each courses the contractor shall define the following :-

(a) Syllabus
(b) Course Objectives
(c) Trainee Entrance Criteria
(d) Instructor/Trainee Ratio
(e) Maximum Number of Trainees
(f) Location
(g) Accommodation Arrangement

18.7 All training courses shall incorporate formal trainee assessment, reporting and
certification.

18.8 The contractor shall provide all training aids, films, materials, parts, tools,
manuals and other documentation required for training purposes.

18.9 The Tender shall include outline course syllabuses and outline training
programme together with details of the location of training including :-

(a) training on JKNS’s premises

(b) training on the contractor’s premises in Malaysia

18.10 The Tender shall clearly set out any facilities, requirements or obligations placed
on JKNS in respect of provision of training.

19.0 QUALITY ASSURANCE

19.1 General

19.1.1 The contractor shall operate a quality assurance (QA) system in accordance with
the requirements of the ISO 9000 series of specifications which shall provide
documented evidence of quality system compliance and ensure that all activities
related to quality of items and workmanship shall be in accordance with the
contract requirements.

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19.1.2 A quality assurance manual shall be provided and submitted to the Engineer for
approval. Such a manual shall fully describe methods, procedures and processes
which form the QA system.

19.2 System Implementation

19.2.1 The Contractor shall provide and maintain a QA programme to regulate methods,
procedures and processes as shown in the QA plan. The QA plan shall also
clearly identify the QA organisation.

19.2.2 The Contractor shall implement written procedures, including at least the
following, copies of which shall be issued to the Engineer.

(a) Control of Sub-Contractor

(b) Control of Suppliers
(c) Receiving, First Article, In-Progress and Final Inspection
(d) Production and Process Control
(e) Functional Test
(f) Control of Non-Conformances and Corrective Action
(g) Calibration of Test and Measuring Equipment
(h) Design Control
(i) Document and Drawing Control
(j) QA Records
(k) Quality Audit

19.3 Certificates of Compliance

19.3.1 When approved by the Engineer, certificates of compliance for equipment,

materials and products may be accepted in lieu of the specified sampling and
testing procedures.

19.3.2 Certificates of compliance shall include as a minimum,

(a) The batch, lot or serial number to provide traceability

(b) Test results including dates
(c) Name and address of test organisation
(d) Specification requirements
(e) Quantity tested

19.4 Design and Proposals

The contractor shall implement QA methods for control of production, checking,

approval and amendments for designs proposals. Arrangements for review by the
Engineer of project designs and proposals shall include, but not be limited to,
submission, by the contractor, of the following :-
(a) project programme
(b) specifications and standards
(c) method statements
(d) design principles
(e) detailed designs
(f) construction drawings
(g) samples
(h) testing/commissioning and as-built drawings

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PACKAGE B - SIGNALLING & COMMUNICATION WORKSTECHNICAL SPECIFICATION - SECTION A

19.5 Inspection and Testing Programme

19.5.1 The contractor’s inspection and testing programme should as a minimum include
the physical inspection and testing of items in the process of manufacture,
delivered items and construction works.

19.5.2 The contractor shall ensure that inspections and acceptance tests are based
upon the latest revision or change to drawings and specifications.

19.5.3 Request by the Contractor for attendance by the Engineer at inspections and
tests shall be in writing or by telephone notification, followed by written
confirmation, with a minimum of 14 days for local inspection and testing prior to
the event. Except as otherwise agreed, inspections and tests to be witnessed
shall be performed during regular business hours.

19.5.8 Certificates of compliance or formal test reports shall be provided for completed
work.

19.5.9 Inspection shall occur at appropriate points in the manufacturing and installation
sequence to ensure compliance with drawings, test specifications, process
specifications, and quality standards.

19.5.10 The Engineer may designate inspection hold points in manufacturing,

installation and testing processes.

19.5.11 Whenever modifications, repairs or replacements are required the Contractor

shall reinspect the affected characteristics and re-submit specified results.

19.5.12 Final inspection shall be based on completion of inspections and/or tests, as

appropriate. Verification of final inspections and tests will be subject to review by
the Engineer at his convenience.

19.5.13 Testing of construction works shall apply to each phase of the works. The
contractor shall submit and execute comprehensive testing proposals which shall
include, but shall not be limited to :-

(a) testing standards, regulations, codes etc.

(b) performance requirement
(c) unit testing
(d) system testing
(e) commissioning testing
(f) final acceptance testing

19.6 QA Records

19.6.1 The contractor shall maintain QA records in a retrievable manner to provide

documented evidence of quality and accountability.

19.6.2 QA records shall include, but not be limited to the following :-

(a) results of inspections and tests

(b) process controls
(c) certification of processes and personnel

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(d) nonconforming materials (including records of disposition)

(e) other quality requirements defined in the Contract

19.6.3 As a minimum, the contractor shall indicate the following on inspection records :-

(a) inspection instructions reference

(b) nature of the observation
(c) number of observation made
(d) number and types on non-conformances found
(e) specified requirements
(f) acceptability of work or products
(g) action taken in connection with the correction or disposition of non-
conformances

19.7 Verification

19.7.1 The QA operations of the Contractor and any sub-contractors shall be subject to
verification by Engineer at any time.

19.7.2 Verification will include, but not be limited to :-

(a) surveillance of the operations to determine that practices, methods and

procedures of the QA programme are being properly applied.

(b) inspection to measure quality of items to be offered for acceptance.

(c) inspection of items awaiting release for shipment

(d) Audit to ensure compliance

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