Bo Peep and Ore 650v Signalling Power Upgrade

The challenge

Due to an unacceptable risk of electrocution posed by exposed conductors and compromised or inadequate earthing, Network Rail were obliged to ensure that all location cases between Bo Peep Junction and Ore on the south coast’s Hastings Line do not pose a risk of electrocution, replacing all equipment above 175v with cutting-edge class II 650v equivalents (including step down transformers/rectifiers) and placing those new components within their own separate enclosures.

The solution

Working directly for Network Rail and following a highly competitive tender process, Amaro was tasked with the procurement, installation, testing and commissioning works associated with the…

• Installation of 4 GRP class II full location cases (including bases)
• Installation of 11 GRP class II annexes on posts
• Installation of 2 powers pillars
• Installation of 4 15kva transformers

Essential for the upgrade of the area’s power feeders from 440v to 650v, these works also include a variety of alterations to 20 individual location cases, as well as the installation, termination and testing of 9,000m of 2c 650v power cable and the running in and termination of all 110v cable between the existing 440v location cases and the newly installed 650v power FSPs.

Following exchange of contract, and in part to identify any issues or technical queries, a comprehensive programme of surveys and inspections was instigated, including the following…

• A power pillar survey using EML (CAT and genny) equipment to locate radial feeds due to uncertainties surrounding the reliability of current power schematics
• A full survey of PSPs, DNOs, and feeders to educate the Form B design
• Fault finding to determine the scope of works for replacing end-of-life cables and equipment
• Cable route surveys to assess both condition and spare capacity
• Ecology surveys to identify any ecological constraints or concerns

With the surveys now complete, key members of Amaro’s supply chain carried out intensive vegetation clearance and refurbished the troughing route ready for the installation of the 650v and 110v cabling. With much of the troughing also having been deemed unfit for purpose, Amaro and its specialist partners were further asked to install approximately 1,700m of brand-new GRP Arco Type 1 troughing running though both Bo Peep and Hastings tunnels. Due to the need to work around other projects and contractors, however, this additional tranche of works will be completed towards the end of the programme.

Whilst this project is in its early stages, the civils design for the location case bases and new troughing routes has already been completed and submitted to Network Rail for AFC approval. Once sign-off has been achieved, however, the following steps will be carried out…

• Installation of concrete bases for location cases
• Installation of troughing within both tunnels over a number of 27h possessions
• Pulling in of all 650v cable, tucking it away neatly within the troughing
• Landing the FSPs trackside using an RRV followed by the termination and testing of all 650v cable
• Pulling in and terminating all 110v cable
• Carrying out alterations to existing location cases
• QA/QC including a comprehensive site walk out with the project’s CRE and construction manager, with each location being thoroughly inspected and the information recorded being fed into the inspection test plans
• Pre-testing to be carried out by Amaro’s specialist testing teams, ensuring all equipment has been installed in line with expectations and relevant standards
• Commissioning to be carried out over 2 distinct stages followed by the recovery of redundant cable and switchgear, and a final AMP walkout with the client prior to handover