TCG 005005-1-2003 GUIDELINES FOR STREET LIGHTING OPERATION AND MAINTENANCE Issued: December 2003 Intelligent Transport Systems Group Traffic and Transport Integration Department 60 Denmark Street Kew 3101 Phone: (03) 9854 2111 Fax: (03) 9854 2319 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 PREFACE A. GENERAL This guideline has been developed by the VicRoads ‘Traffic and Transport Integration Department’ (herein called the “Department”). It is one of a number of technical guidelines designed to assist VicRoads Regional Offices and Project Groups when installing “on-road” ITS devices, traffic signal equipment and other electrical equipment and associated devices and control systems. This guideline, and any associated standard drawings, is intended for use in all relevant works undertaken by or on behalf of VicRoads. B. Electromagnetic Compatibility (EMC) All equipment covered by this guideline shall comply with all relevant requirements of the Australian Communications Authority (ACA) for EMC. All equipment covered by this guideline shall comply with the requirements of AS4251.1 Electromagnetic compatibility – Generic emission standard – Part 1: Residential, commercial and light industry. For equipment complying with the ACA’s ‘Level 1’ category a copy of a ‘Declaration of Conformity’ shall be supplied to VicRoads. For equipment complying with the ACA’s ‘Levels 2 and 3’ categories, a copy of a test report (from a NATA approved testing facility) showing compliance shall be supplied to VicRoads. Equipment falling into either of these two categories shall be labelled with a conforming ‘C-Tick’. C. Telecommunications Equipment All telecommunications equipment shall comply with relevant requirements of the ACA. Such equipment shall be labelled with an ACA issued ‘A-Tick’ . COPYRIGHT © Roads Corporation trading as VicRoads. All rights reserved. This document remains the property of VicRoads. No part of this document may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of VicRoads T&TI Department. © Roads Corporation trading as VicRoads. All rights reserved. Page 2 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 Contents 1 INTRODUCTION......................................................................................................................... 5 1.1 1.2 1.3 BACKGROUND ................................................................................................................... 5 REFERENCES ...................................................................................................................... 6 DEFINITIONS ......................................................................................................................... 8 1.4 ACCEPTANCE ..................................................................................................................... 9 1.4.1 Acceptance ........................................................................................................................ 9 1.4.2 Approved........................................................................................................................... 9 2 OPERATION OF LIGHTING SCHEMES ................................................................................ 9 2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.5 3 GENERAL MAINTENANCE REQUIREMENTS .................................................................. 13 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 4 SCOPE .................................................................................................................................. 9 MAINTENANCE ELEMENTS .......................................................................................... 10 LAMP REPLACEMENT OPTIONS................................................................................... 10 MAINTENANCE OPTIONS .............................................................................................. 11 Annual Tariff................................................................................................................... 11 Revised or Maintenance Only Tariff ............................................................................... 11 Maintenance Contract (Preffered).................................................................................. 11 Fee For Service .............................................................................................................. 12 IDENTIFICATION OF ASSETS ........................................................................................ 12 RESPONSE TIMES ............................................................................................................ 13 PERFORMANCE ............................................................................................................... 13 COMPLIANCE ................................................................................................................... 13 AUDIT ................................................................................................................................ 13 ELECTRICITY SUPPLY COMPANY REQUIREMENTS................................................ 13 ELECTRICAL CIRCUIT DESIGN PLANS ....................................................................... 13 JOINT USE POLES............................................................................................................. 14 FRANGIBLE POLES.......................................................................................................... 14 LUMINAIRES .................................................................................................................... 14 UNDERSTRUCTURE LIGHTING .................................................................................... 14 TUNNELS ........................................................................................................................... 14 PEDESTRIAN TUNNELS .................................................................................................. 15 NEAR AIRPORTS .............................................................................................................. 15 ROUTINE AND PERIODIC MAINTENANCE ...................................................................... 15 4.1 GENERAL .......................................................................................................................... 15 4.2 PATROLS ........................................................................................................................... 16 4.3 EQUIPMENT ...................................................................................................................... 16 4.3.1 Poles ............................................................................................................................... 16 Luminaires .................................................................................................................................... 16 4.3.3 Lamp Replacement ......................................................................................................... 17 4.3.4 Control Gear and Transformers ..................................................................................... 18 4.3.5 Photo Electric Equipment ............................................................................................... 18 4.3.6 Other Luminaire Components and Lighting Scheme Assets ........................................... 18 5 NON-ROUTINE MAINTENANCE AND REPAIRS .............................................................. 19 5.1 CALL-OUT AND FAULT ATTENDANCE ...................................................................... 19 5.2 FAILURE AND OUTAGE CORRECTION ....................................................................... 20 5.2.1 Repair of PE Cells and Contactors................................................................................. 20 5.2.2 Ad Hoc Replacement Of Lamps ...................................................................................... 20 5.2.3 Repair and Replacement Of Brackets ............................................................................. 20 © Roads Corporation trading as VicRoads. All rights reserved. Page 3 of 28 TTI – Intelligent Transport Systems Group 5.3 6 RE-INSTALLATION OF RIGID AND FRANGIBLE POLES .......................................... 21 CONTRACTOR WARRANTY AND RESOURCES .............................................................. 21 6.1 6.2 6.3 7 Guideline No.: TCG 005-1-2003 WARRANTY ...................................................................................................................... 21 RESOURCES ...................................................................................................................... 22 PENALTIES........................................................................................................................ 22 INVENTORY AND SURVEYS ................................................................................................. 22 7.1 INVENTORY...................................................................................................................... 22 7.2 SURVEYS ........................................................................................................................... 23 SUGGESTED MAINTENANCE REGIME ...................................................................................... 24 APPENDIX B ........................................................................................................................................ 26 BULK REPLACEMENT V BURN TO EXTINCTION ..................................................................... 26 APPENDIX C ....................................................................................................................................... 28 CALL OUT AND FAULT ATTENDANCE TIME ........................................................................... 28 INSPECTION FREQUENCY .................................................................................................................... 28 END OF LIFE / PREDICTED LIFE SPANS ..................................................................................... 28 © Roads Corporation trading as VicRoads. All rights reserved. Page 4 of 28 TTI – Intelligent Transport Systems Group 1 INTRODUCTION 1.1 BACKGROUND Guideline No.: TCG 005-1-2003 As part of the deregulation of the electricity supply industry, from 1 January 2001 VicRoads and Municipalities are now able to design, install, own, operate, maintain, and repair street lighting schemes. To maximise the benefits that flow from deregulation, some changes have been made to the way in which street lighting schemes have been designed, installed and maintained in the past. Wherever possible, schemes shall be installed as “stand alone”, that is, using dedicated lighting poles rather than power distribution poles, with minimal points of supply, and metered. This enables the operation and maintenance of these schemes to be competitively tendered and to be to VicRoads standards. Where it is not practicable for a scheme to be installed as a “stand alone” scheme, the mounting of luminaires on Distribution Company (Dist Co) poles with supply via the local distribution network may be necessary, and the operation and maintenance of such schemes will remain with the relevant Dist Co. The purpose of this guideline is to provide assistance to Regions for the management of the operation and maintenance of new stand-alone street lighting schemes on declared roads; being freeways, State highways, main roads, and tourists' roads. Schemes should, as far as practicable, be operated and maintained in accordance with this guideline and with the associated standards and documents listed herein. The contents of this guideline include general maintenance considerations, requirements for the maintenance of specific equipment, and repair of crash damage. In accordance with general practice all VicRoads electrical installations shall be maintained to fully conform to the requirements of Australian Standard AS/NZS 3000:2000 Australian/New Zealand Wiring Rules. It should be noted that the electrical industry is now deregulated in respect of street lighting, for new and replacement street lighting schemes installed on roads under the care and management of VicRoads. Thus, no agreement which transfers ownership, or which could be interpreted as transferring ownership, away from VicRoads shall be made. All lighting installations need electrical power. This requires coordination with an electric utility to obtain and maintain the necessary voltage at the designed point of delivery. Proper maintenance of the lighting system is essential. It must produce the type of results that were contemplated in the system design. Over time, light output from lamps diminishes and dirt accumulates on the luminaire. Brackets and poles suffer corrosion. Pits and conduits may suffer damage. © Roads Corporation trading as VicRoads. All rights reserved. Page 5 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 These require a restoration process. Maintenance intervals and the extent of maintenance need to be set up so as to guarantee proper operation of the system to within the parameters set out in the Australian Standard. 1.2 REFERENCES The following standards, codes, specifications, procedures, guides and related documents shall be adhered to in the operation and maintenance of street lighting schemes on VicRoads’ declared road network, and in the design and fabrication/manufacture of the various replacement component parts. • AS 1052, "Electromagnetic measuring methods"; interference measuring apparatus and • AS/NZS 1158, "Road lighting"; • AS 1158.4, SAA Public Lighting Code, "Supplementary Lighting at Pedestrian Crossings"; • AS 1170.2, "Wind Loads"; • AS 1204, "Weldable Steels or AS1594-1981 Hot Rolled Low Carbon Steel Plate, Sheet and Strip"; • AS 1468, "Ballasts for high pressure mercury vapour and low pressure sodium discharge lamps"; • AS 1554.1, "Welding of steel structures"; • AS 1650, "Hot-dipped galvanised coatings on ferrous articles"; • AS 1897, "Electroplated coatings on threaded components"; • AS 1939, "Degrees of Protection provided by Enclosures for Electrical Protection"; • AS 2053.1, "Conduits and Fittings for Electrical Devices General requirements"; • AS 2053.2, "Conduits and Fittings for Electrical Installations Rigid plain conduits and fittings of insulating materials"; • AS 2344, "Limits of electromagnetic interference from overhead a.c. power lines"; • AS 2644, "Capacitors for use in discharge lamp circuits"; • AS/NZS 3000, Electrical Installations (known as the Australian/New Zealand Wiring Rules); © Roads Corporation trading as VicRoads. All rights reserved. Page 6 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 • AS 3008.1, "Electrical Installations - Selection of Cables"; • AS 3100, "Approval and test specification for definitions and general requirements for electrical materials and equipment"; • AS 3108, "Approval and test specification - Particular requirements for isolating transformers and safety isolating transformers" (i.e. control gear); • AS 3678, "Structural steel - Hot-Rolled plates, floor plates and slabs"; • AS 3679.1, "Hot-rolled bars and sections"; • AS 3771, "Road Lighting Luminaires with Integral Control Gear"; • AS/NZS 3947, "Low-voltage switchgear and controlgear"; • AS 4100, "Steel structures"; • AS 9000 series, "Quality Systems" as applicable; • Standards Australia - Communications Cabling Manual; and • International Commission on Illumination (CIE) Publication CIE 88 - 1990, Guide for the Lighting of Road Tunnels and Underpasses. • VicRoads Standard Specifications For Roadworks And Bridgeworks and associated standard drawings; • VicRoads and T&TI standard drawings; • VicRoads Specification for the Supply of Joint Use Poles, Joint Use Mast Arms, Mast Arms, and Rigid Street Lighting Poles, numbered TCS001; • VicRoads Specification for the Supply of Luminaires for High Pressure Sodium Lamps, numbered TCS012; • VicRoads Specification for the Installation and Remodel of Traffic Signals, numbered TCS013; • VicRoads Specification for the Supply of Frangible Street Lighting Poles, numbered TCS014; • VicRoads Specification for the Supply of Distribution Box for Street Lighting Power Supply, numbered TCS043; • VicRoads Specification for the Supply of Lamps for High Pressure Sodium Luminaires, numbered TCS044; © Roads Corporation trading as VicRoads. All rights reserved. Page 7 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 • VicRoads Specification for the Fabrication and Supply of Street Lighting Brackets, numbered TCS050; • VicRoads Procedure for “Plant Operation in Proximity to Overhead Powerlines”; • VicRoads Traffic Engineering Manual Volume 1, Chapter 6, Lighting of Roads, where applicable; • Guide to Traffic Engineering Practice, Part 12, AUSTROADS (formerly NAASRA) 1988, Roadway Lighting, where applicable; • current Dist Co VESI wiring rules and standard drawings, where applicable; • draft ESAA/AUSTROADS document entitled "Guidelines for the Use and Placement of Rigid and Frangible Street Lighting Columns on Traffic Routes" October 1990 where not in conflict with any VicRoads or Dist Co document; and • AUSTRALIAN Bridge Design Code. • Office of the Chief Electrical Inspector, Rules for Operating Near Overhead Power Lines for Cranes, Concrete Placing Booms and Excavating Equipment. • Office of the Chief Electrical Inspector, Rules for Operating Elevating Work Platforms Near Overhead Power Lines. • Office of the Chief Electrical Inspector, Rules for Erecting Scaffolding Near Overhead Power Lines. 1.3 DEFINITIONS For the purposes of this document, the following definitions apply: "Distribution Company" and "Dist Co" have the same meaning as "distribution company" in the Electricity Industry Act 1993, No. 130/1993 and CitiPower, TXU, AGL, PowerCor, United Energy or other distributor as appropriate wherever used throughout this document. "lamp" or "globe" or "bulb" or "tube" - the man made source of light contained or fitted within the luminaire. "luminaire" or "lantern" or "light" - the apparatus which distributes, filters or transforms the light transmitted from one or more lamps and which includes, except for the lamps themselves, all the parts necessary for fixing and protecting the lamps and, where necessary, circuit auxiliaries together with the means for connecting them to the electric supply. © Roads Corporation trading as VicRoads. All rights reserved. Page 8 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 "Pre-qualified contractor" - a contractor registered with VicRoads to undertake the necessary on road electrical work for VicRoads. The contractor shall also be a “Registered Electrical contractor” registered in accordance with Part 3 of the Electricity Safety Act 1998 and the Electricity Safety (Installations) Regulations 1999 contractors. "SECV" - the former State Electricity Commission of Victoria where appropriate or else means the relevant Dist Co as appropriate. "T&TI" - Traffic and Transport Integration Department of VicRoads. "VESI" - Victorian Electricity Supply Industry as used in the term VESI standard. 1.4 ACCEPTANCE 1.4.1 Acceptance All street lighting parts and equipment supplied by the contractor or installed at the work site shall conform to a sample previously supplied to and formally accepted by the VicRoads Traffic & Transport Integration Department. Such acceptance is subject to the T&TI procedure for Product Evaluation, which requires samples to be submitted by the supplier for evaluation and acceptance. Acceptance of the submitted product is acknowledged by the issue of a notification of "Certificate of Type approval". 1.4.2 Approved References to "approved" within this document shall mean acceptance by T&TI of individual components, processes or methods for like or similar applications and purposes. 2 OPERATION OF LIGHTING SCHEMES 2.1 SCOPE VicRoads shall undertake the operation and maintenance of: (a) existing and future lighting schemes on all freeways; and (b) post 2000 stand-alone cost shared lighting schemes on declared roads under VicRoads’ care and management. Any new street lighting operation and maintenance systems instituted by VicRoads should: (c) be under VicRoads control and to VicRoads standards; (d) be Region wide and merged with any Regional freeway lighting operation and maintenance systems; © Roads Corporation trading as VicRoads. All rights reserved. Page 9 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 (e) be immediately responsive to failures and crash damage; (f) deliver the lowest cost operation and maintenance whilst maintaining the light technical parameter values; and (g) avoid being locked into any one service provider. 2.2 MAINTENANCE ELEMENTS The elements of an effective operation and maintenance regime shall include: (a) an up-to-date inventory of equipment (b) good condition monitoring and effective fault detection through day and/or night patrols, or by remote monitoring (if available) (c) a prompt fault and damage repair response, within specified time frames (d) an established cyclic maintenance programme with regular cleaning (e) an electrical testing schedule (f) a programme for risk assessment and structural testing of columns and brackets. 2.3 LAMP REPLACEMENT OPTIONS Lamps may be either “bulk replaced” at the end of their ‘useful service life’ (see section 4.3.3), or may be “burnt to extinction” to maximise their life. The former, results in lighting levels meeting the designer’s intentions. The latter results in every scheme not meeting these requirements for the later part of its life. All lamps need to be cleaned to maintain an acceptable light output. There are three basic lamp maintenance replacement strategies: (a) bulk relamping plus spot relamping and bulk cleaning (b) spot relamping and bulk cleaning (c) spot relamping and spot cleaning. If instituted effectively, option (a) above is the strategy most likely to result in proper observance of the light technical parameters for the lighting scheme. Options (b) and (c) guarantee that every luminaire will be visited on an individual ad hoc basis as it fails; which maximises maintenance trips and costs, and results in poor observance of the light technical parameters. See also Appendix B. © Roads Corporation trading as VicRoads. All rights reserved. Page 10 of 28 TTI – Intelligent Transport Systems Group 2.4 Guideline No.: TCG 005-1-2003 MAINTENANCE OPTIONS Maintenance of VicRoads owned and operated lighting schemes may be undertaken in a number of ways. Examples of maintenance options are given below. NB. Dist Co interest to any of these maintenance options has not been investigated. See Appendix A for the T&TI preferred maintenance practices. (Power supply companies are required to provide street lighting services, including maintenance, in accordance with the “Public Lighting Code” which can be obtained on-line from the Essential Services Commission at http://reggen.vic.gov (formerly the Office of the Regulator General – ORG)). 2.4.1 Annual Tariff An annual tariff is paid to the local Dist Co. The tariff comprises a power supply component, a maintenance component, and a 20 year capital replacement component. In this instance, Region's involvement is solely to pay the annual tariff when billed, the Dist Co does the rest on VicRoads behalf. The distribution box and meter are not required, but if deleted or not installed there are few options if the Dist Co is unable or unwilling to continue the maintenance for the whole of the life of the installation. Based on this guideline, basic ground rules will need to be set. The current maintenance provided by the Dist Co under the tariff system is considered to be not sufficiently complete. This option does not apply to the maintenance of lighting schemes on the State's freeways. It is not known whether any Dist Co would be prepared to maintain a VicRoads owned scheme, or a stand-alone metered scheme installed to AS/NZS3000. 2.4.2 Revised or Maintenance Only Tariff Separate or unbundle power supply and capital replacement from the annual tariff, and pay only the maintenance component. It is not known whether any Dist Co would agree to such an option. 2.4.3 Maintenance Contract (Preffered) VicRoads may arrange maintenance by letting a maintenance contract of duration (say) one to four years to a Pre-qualified contractor following a public competitive tendering process. The contract would be based on a lump sum amount for the contract period with specified duties and performance criteria listed. Repair of crash damage would be as for 2.4.4 below. © Roads Corporation trading as VicRoads. All rights reserved. Page 11 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 VicRoads shall maintain adequate records to ensure lamp changes (bulk changes and ad hoc changes) are made in good time. 2.4.4 Fee For Service VicRoads may arrange maintenance by engaging a Pre-qualified contractor, perhaps on a retainer, or on an ad hoc basis, or “as needed” with a “fee-forservice” payment, or on a “recoverable works” basis with payment made as replacements or repairs are undertaken. Where the local Dist Co is able to maintain the lighting scheme, this may be undertaken on a full recoverable works basis (see Section 8.1.1 of the SECV Public Lighting Manual). VicRoads shall maintain adequate records to ensure lamp changes are made in good time. 2.5 IDENTIFICATION OF ASSETS Public identification of the VicRoads owned and maintained lighting assets as distinct from the Council, and/or the Dist Co owned and maintained lighting assets may present difficulties several years into the future, particularly as the proportion of VicRoads owned and maintained schemes increase. Accurate records need to be kept up to date by VicRoads Regions, Councils, and by the Dist Cos. Several measures may be taken to reduce confusion between VicRoads owned assets and Dist Co controlled assets, including: (a) an identification plate or printed sticker could be attached to each VicRoads owned pole; (b) the use of VicRoads straight style brackets for future schemes will aid maintenance personnel; and (c) luminaires should be clearly identified as belonging to VicRoads by stencilling "VicRoads" on both the underside and the left hand side of the luminaire. However, the public may telephone any one of VicRoads, the local Council, or the local Dist Co to report lighting faults. Once some experience has been gained with this perceived difficulty, rectification procedures should be put in place by Region if found to be necessary. Cooperation will be required from the local Dist Co, and perhaps some fee for service arrangement could be considered. © Roads Corporation trading as VicRoads. All rights reserved. Page 12 of 28 TTI – Intelligent Transport Systems Group 3 GENERAL MAINTENANCE REQUIREMENTS 3.1 RESPONSE TIMES Guideline No.: TCG 005-1-2003 Contractor response times, from the date of fault notification, should be in accordance with the requirements of section 5.1 and Appendix C, Table C1. 3.2 PERFORMANCE The maintenance performance criteria for public lighting relates to the number of non-functional luminaires at any time and the length of time each luminaire is non-functional before repair. Defects, breakages and losses should be rectified within the required times. 3.3 COMPLIANCE Where a maintenance contractor has failed to satisfy the performance criteria on (say) ten separate instances throughout the term of the maintenance contract, the Superintendent may determine whether the contract is to be terminated. The maintenance contract could be set up in the first instance to require such termination. 3.4 AUDIT Region could consider scheduling (say) four audits of the contractor's maintenance performance during the life of a four year contract. The audit would involve a night inspection to determine which lights were out, followed by a formal written notification to the maintenance contractor, with a follow up night inspection at the end of the repair period. 3.5 ELECTRICITY SUPPLY COMPANY REQUIREMENTS All maintenance of the power source shall be undertaken in accordance with the requirements of the relevant Dist Co, including the currently approved VESI wiring regulations and VESI standard drawings. The contractor shall liaise with the relevant Dist Co in all matters regarding power supply from the point of supply to the distribution box. 3.6 ELECTRICAL CIRCUIT DESIGN PLANS Where available, the Superintendent should provide the contractor (and the relevant Dist Co, if required) with the plans for the electrical design for those lighting installations to be maintained by the contractor. All electrical works from the distribution box outwards must fully conform to the requirements of AS/NZS 3000, Australia New Zealand Wiring Rules. In stand-alone schemes, independent electrical circuits have been provided to cater for all of the VicRoads lighting. The electricity supply may be metered to the VicRoads electrical circuit(s). The electrical design includes a switch © Roads Corporation trading as VicRoads. All rights reserved. Page 13 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 located in the distribution box to enable the VicRoads lights to be turned on/off independently of all other lighting. A photoelectric (PE) cell and back-up is located near the distribution box for each VicRoads lighting circuit; thus the luminaires used on the VicRoads circuits shall not need PE cells connected as an integral part of the luminaire. 3.7 JOINT USE POLES The maintenance of street lighting on VicRoads joint-use poles (JUPs) and joint-use mast arms (JUMAs) etc. shall be part of the contractor's responsibilities. This does not apply to existing VESI schemes where the Dist Co is responsible for maintaining the lighting. 3.8 FRANGIBLE POLES The maintenance of frangible poles (both slip-base and impact absorbing) within the lighting scheme should be part of the contractor's responsibilities. 3.9 LUMINAIRES All replacement luminaires shall be high pressure sodium (HPS). Only those luminaires type approved in accordance with the VicRoads luminaire specification TCS012 may be used in VicRoads street lighting schemes. The relevant Dist Co should also approve the luminaires where the luminaires are to be owned and/or operated by the Dist Co. Luminaires supplied by the contractor shall have a life span of not less than 20 years from new and are to meet the requirements of AS3771. 3.10 UNDERSTRUCTURE LIGHTING Under structure, (soffit) mounted lighting is usually 150w HPS luminaires. The switching of under structure luminaires may be connected in with the freeway interchange lighting. Thus, no PE cell equipment may be required for under structure lights. 3.11 TUNNELS There is no current Australian Standard for the lighting of major road tunnels, as there are few tunnels of note in this country. Tunnel lighting is generally designed to ease the transition between the light outside and the entry zone just within the tunnel. Thus tunnel lighting is based upon daylight contrasts far more than upon lighting for the hours of darkness. Where tunnel lighting is to be maintained the contractor shall rigorously maintain the luminaires, particularly those located in the tunnel entrance zones. © Roads Corporation trading as VicRoads. All rights reserved. Page 14 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 It is usual to bulk replace tunnel lighting lamps as many of them burn continuously which results in lamp life being achieved earlier than for lamps used for normal road lighting. Bulk replacement of tunnel lamps limits the amount of time the tunnel is affected by repair crews. 3.12 PEDESTRIAN TUNNELS Effective pedestrian tunnel lighting is perceived as a personal safety issue for users, and the lighting fixtures are susceptible to vandalism. The maintenance programme will have to centre on regular inspections at intervals to be fixed based on local knowledge, but not exceeding twelve months. 3.13 NEAR AIRPORTS For lighting installations in the vicinity of airports, any existing HPS aeroscreen type luminaires shall be replaced as necessary by equivalent aeroscreen type luminaires. 4 ROUTINE AND PERIODIC MAINTENANCE 4.1 GENERAL Subject to the following, the contractor’s maintenance regime should fully conform to the requirements of Section 14 of AS/NZS1158.1.3:1997, and to Appendix C The maintenance performance criteria for street lighting relates to the number of non-functional luminaires at any time and the length of time each luminaire is non-functional before repair. No more than 5% of luminaires and no more than two adjoining luminaires shall be permitted to be non-functional at any time. New and/or replacement parts and equipment for street lighting purposes shall be type approved and conform to VicRoads' drawings and specifications, eg luminaires and components, lamps, brackets, frangible and rigid poles, pits, cables, conduits, etc. The maintenance contractor shall maintain comprehensive maintenance records for each pole, bracket, luminaire, and distribution box, along with the maintenance history for the wiring, conduits and pits for each scheme. Such maintenance records shall be provided to the Superintendent or his authorised representative at regular intervals, not exceeding six months. Where major routine periodic maintenance is to be carried out the contractor shall advise the Superintendent two weeks before commencement. © Roads Corporation trading as VicRoads. All rights reserved. Page 15 of 28 TTI – Intelligent Transport Systems Group 4.2 Guideline No.: TCG 005-1-2003 PATROLS The contractor shall carry out a regular night time patrol not less than once every second month in order to detect luminaires cycling or not operating, to detect poles down, and to detect other factors adversely affecting the amount of light on the road. The contractor shall carry out a regular daytime fault inspection patrol at intervals not exceeding six (6) months in order to detect obvious visual faults with any components of all kinds. 4.3 EQUIPMENT For the full period of the maintenance contract, the contractor shall maintain (ie. inspect, test, repair, replace) all the various parts and equipment of the street lighting scheme in accordance with the following: 4.3.1 Poles All lighting poles shall be inspected at least once every twelve months to ensure they are correctly installed, vertical, safe, corrosion free, and undamaged. The access opening cover shall be inspected and the bolts retightened or replaced as necessary. The holding down bolts shall be examined and re-tightened, repaired or replaced as necessary. In order to ensure that slip base poles are correctly tensioned they shall be inspected and re-tensioned in accordance with Section 14.5.6 of AS/NZS1158.1.3:1997 and at least once every twelve months. 4.3.2 Luminaires Every 12 months, the luminaires should be inspected to ensure: (a) the luminaire is kept clean and free of moisture, mud, dust and debris; (b) the luminaire Ingress Protection (IP) Rating is maintained; (c) the luminaire bowl is kept clean, intact, undamaged and free of moisture, mud, dust and debris at all times. Where a luminaire bowl is missing or hanging loose it is determined to have failed and the luminaire bowl should be either repaired or replaced within seven days of the fault being discovered; (d) the seal gasket is kept intact and free of damage. Where any part of a seal gasket is missing or hanging loose it is determined to have failed and the seal gasket should be either repaired or replaced within seven days of the fault being discovered; (e) the luminaire electronic equipment tray and cover is operational; © Roads Corporation trading as VicRoads. All rights reserved. Page 16 of 28 TTI – Intelligent Transport Systems Group (f) Guideline No.: TCG 005-1-2003 the luminaire mounting height, tilt angle, spin angle, and orientation are preserved at all times. Where any of these luminaire mounting parameters no longer meet the specified requirements, the luminaire attitude should be corrected within seven days of the fault being discovered. 4.3.3 Lamp Replacement It is required that proper procedures and programs be instituted to minimise the incidence and duration of outages and burnouts, and to maintain the output of the lamp at no less than the output levels that ensure compliance with Table 2.1 of AS/NZS1158.1.1:1997. The code permits lamp output to fall to 70% of new. “Bulk replacement” of all lamps is sought. The alternative practice of "burn to extinction" will result in the requirements of AS/NZS1158 NOT being met. This is not acceptable to T&TI. See also Appendix B. Twin arc externally ignited HPS lamps shall be replaced no later than four (4) years after their installation or last replacement date, and single arc HPS lamps every three (3) years. Replacement lamps to be used for future VicRoads schemes shall be the twin arc externally ignited HPS type conforming to VicRoads specification TCS044. Single arc externally ignited or single arc internally ignited HPS lamps shall not be used for VicRoads purposes, as they have a 10% failure rate after six months and they only have a useful service life of three years. Whereas the twin arc tube type is the more reliable at only a marginally higher cost with a 33% longer service life before replacement. The new internally ignited type lamps shall not be used at this stage, as there is only the one supplier in Australia. Once a luminaire is modified to suit the internally ignited type (ie. the external igniter is removed) a return to the former type can only be achieved at the cost of replacing the previously removed external igniter. Mercury Vapour lamps shall be bulk replaced every two (2) years as they rapidly drop below the 70% output requirement after that period, but may continue to burn for up to another 15 years. (As a stopgap measure only, special purpose HPS lamps may be used to replace existing mercury vapour lamps. These special HPS lamps are expensive and only a temporary expedient until such time as the complete luminaire can be changed over). Metal Halide lamps shall be bulk replaced every three (3) years. Testing is to be done as routine during bulk lamp changing to avoid costly call backs. © Roads Corporation trading as VicRoads. All rights reserved. Page 17 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 Six months after bulk replacement of lamps, an inspection should be carried out to identify and rectify lamp failures. Individual lamp failures not replaced within two weeks of failure may result in the consequential burnout of either the igniter or the ballast within the luminaire. 4.3.4 Control Gear and Transformers The contractor shall use luminaire control gear and/or transformers conforming to AS3108. Control gear and transformers shall be replaced as necessary within three days of the fault being reported. 4.3.5 Photo Electric Equipment The contractor is to supply and install replacement electronic photo electric (PE cell) equipment, or lumatrols, with a minimum in-service life of eight (8) years. The lumatrol is mounted in the distribution box behind a clear weatherproof and vandalproof cover, and operates a contactor switch, which controls the power supply to the luminaires. One maintenance strategy is for a spare lumatrol to be kept in the distribution box for emergency repairs in the event of failure of the primary lumatrol. The spare is then installed at each eight year changeover, and a new replacement spare stored in the cabinet. Replacement All lumatrols and contactors should be regularly replaced no later than eight years after their installation or last replacement date. Lumatrols and contactors shall be replaced as necessary within three days of a fault being reported. For VicRoads circuits with lumatrol control from the distribution box, where the luminaires are the type with an integral PE cell and the luminaires have had these PE cells disconnected there is no requirement to maintain those PE cells in the luminaires. 4.3.6 Other Luminaire Components and Lighting Scheme Assets In order to ensure correct operation of the lighting scheme all other components of the scheme, such as luminaire igniters, ballasts and power supplies, earth stakes, pits, cabling, conduits, distribution box, brackets, etc., are to be inspected at least once every twelve months and repaired or replaced as necessary. © Roads Corporation trading as VicRoads. All rights reserved. Page 18 of 28 TTI – Intelligent Transport Systems Group 5 Guideline No.: TCG 005-1-2003 NON-ROUTINE MAINTENANCE AND REPAIRS Street lighting schemes may suffer crash damage, or other non-programmed outages. contractor response times, from the date of verbal or written fault notification from any source, should be a maximum of one (1) hour for urgent response, one (1) day for non-urgent site attendance, seven (7) calendar days for luminaire replacement, and ten (10) calendar days for pole replacement. Defects, crash damage, breakages and losses should be rectified within these required times, and as detailed below. 5.1 CALL-OUT AND FAULT ATTENDANCE Purpose: To respond to faults and crashes as advised. Frequency: Unless otherwise determined by the Superintendent Make safe Site Attendance Repair/Replace < 1 hour for urgent response, < 1 day for non-urgent response, < 3 days for lumatrols and PE cells, < 3 days for contactors, igniters, & ballasts, < 3 days for control gear and transformers, < 3 days for lamps, < 7 days for replacement luminaires, < 7 days for brackets, and < 10 days for poles. When directed by the Superintendent to carry out Non-Routine Maintenance, the contractor should mobilise a technician to attend the nominated site of the incident as soon as possible within the required times for the purpose of identifying and rectifying the fault. Unless otherwise instructed by the Superintendent, the maximum time between issue of the authorisation to attend and the contractor's initial attendance at the nominated site should not exceed one (1) day. Upon initial attendance, the contractor should identify the fault, ascertain the cause, make safe any damaged equipment, and rectify same as soon as practicable within the relevant time frames. Where the fault cannot be immediately rectified the contractor should ensure that all available processes are set in place such that public safety (either direct or indirect) is maintained and that all VicRoads property is secure and safe from further damage or loss. In accordance with the contract, where required, the contractor should notify the Superintendent immediately of the situation and seek agreement to the ongoing actions where rectification works will require: © Roads Corporation trading as VicRoads. All rights reserved. Page 19 of 28 TTI – Intelligent Transport Systems Group (a) (b) (c) (d) Guideline No.: TCG 005-1-2003 additional equipment and/or personnel; a second visit to the site; major works extending to greater than two (2) days; or the site being left in an operational mode other than normal for a period greater than two (2) days. Upon satisfactory completion of repair works the contractor should immediately advise the Superintendent of the site status and action taken, and shall return the site to normal operation. 5.2 FAILURE AND OUTAGE CORRECTION 5.2.1 Repair of PE Cells and Contactors Non-routine correction of malfunctioning PE cells and/or contactors shall be deemed as urgent and a maximum restoration time of three (3) days, or as directed by the Superintendent, shall apply. Note that VicRoads PE cells are required to fail in the "power on" condition in order to ensure continuing operation of the lighting installation. Thus the luminaires in a VicRoads lighting scheme remaining lit 24 hours per day is indicative of a PE cell malfunction resulting in a live power circuit. 5.2.2 Ad Hoc Replacement Of Lamps Non-routine correction of malfunctioning individual luminaires shall be deemed as non-urgent and a maximum restoration time of seven (7) days, or as directed by the Superintendent where the luminaire is situated at a critical location, shall apply. Any failure of an individual luminaire should in the first instance be assumed to be a lamp failure. This should be verified by testing after the lamp change. Any broken lamps shall be replaced only after the luminaire has been disconnected from the electricity supply. If the lamp has failed the igniter will constantly arc in order to re-ignite the failed lamp. Igniter and/or ballast failure can then be expected after about two weeks. Delays in correcting failures may result in subsequent failure of, or damage to, the igniter and/or the ballast. Where delay has occurred in correcting luminaire failure, the contractor shall test for igniter and ballast damage and replace as necessary. 5.2.3 Repair and Replacement Of Brackets Those brackets exhibiting drooping of the bracket outreach arm such that the luminaire has a downward angle exceeding 10 degrees to the horizontal shall be considered to have failed and shall be repaired or replaced within seven (7) days. © Roads Corporation trading as VicRoads. All rights reserved. Page 20 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 In a VicRoads owned scheme, replacement brackets shall be of the VicRoads straight (freeway) style. 5.3 RE-INSTALLATION OF RIGID AND FRANGIBLE POLES Where a VicRoads owned rigid or frangible (slip base or impact absorbing) street lighting pole has suffered crash or other damage, and is considered by the Superintendent to be beyond repair, VicRoads shall be liable for the capital cost of purchasing a replacement pole and for its delivery on-site. With the exception of VicRoads traffic signal poles, the contractor shall be fully responsible for the erection of the replacement pole. The contractor shall be fully responsible for the remounting of the bracket and luminaire(s) on all pole types. The contractor shall do everything necessary to re-commission the lighting installation within ten (10) days of notification of failure, and remove all redundant materials. The pole (including bracket and luminaires) shall be re-instated in accordance with: (a) AS/NZS 3000. (b) Specification TCS051, Street Lighting, Design and Installation. (c) Relevant Dist Co requirements, where applicable. 6 CONTRACTOR WARRANTY AND RESOURCES 6.1 WARRANTY For all routine and non-routine repair and maintenance works conducted by the contractor on a nominated maintenance site, the contractor should provide a warranty on all workmanship and materials associated with such work in accordance with the following: (a) (b) (c) (d) (e) (f) (g) lumatrol contactor control gear luminaires lamps brackets poles 1 year 1 year 1 year 1 year 1 year 4 years 1 year For all non-routine repair and maintenance works carried out by the contractor on a nominated maintenance site, the contractor should provide a ninety (90) day warranty on all workmanship and materials associated with such work. © Roads Corporation trading as VicRoads. All rights reserved. Page 21 of 28 TTI – Intelligent Transport Systems Group 6.2 Guideline No.: TCG 005-1-2003 RESOURCES The contractor should maintain and operate twenty four (24) hours per day, seven (7) days per week (including public holidays) a sufficient number of suitably qualified personnel and vehicles and the necessary tools and equipment to carry out routine and non-routine maintenance of VicRoads' street lighting schemes. The contractor's field personnel, or their on-site supervisor, shall be a Registered Electrical contractor, being registered in accordance with Part 3 of the Electricity Safety Act 1998, and with the Electricity Safety (Installations) Regulations 1999 contractors. The contractor should ensure that all technical works associated with routine service and non-routine service fault attendance are undertaken by technically competent persons with a sound knowledge of VicRoads stand-alone street lighting schemes constructed in accordance with AS/NZS3000. All vehicles should, as a minimum, be suitably equipped to undertake the requirements of routine maintenance outlined herein. The contractor shall provide a manned telephone service for the purpose of receiving and relaying fault calls 24 hours per day. 6.3 PENALTIES The maintenance contract could include penalties, perhaps based on the following: During instances of prolonged outages, or in the event of non-conformance, the contractor may be liable in the amount of $10 per luminaire per day for each and every non-functioning luminaire for whatever reason. This clause may be waived or varied on the written notification of the Superintendent. 7 INVENTORY AND SURVEYS 7.1 INVENTORY An accurate inventory of lighting equipment is essential to efficient system operation. Reliable records of routine maintenance and repairs require that an up-to-date inventory of field installations be kept. The proper use of computerised data base programs permits instantaneous review of system performance. Programs have been developed overseas that provide current information on each luminaire such as when it was re-lamped, repaired, replaced or cleaned. © Roads Corporation trading as VicRoads. All rights reserved. Page 22 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 The maintainer can then analyse the incidence of various equipment needs and take appropriate action. This requires an accurate field reporting system. Field maintenance personnel should record and transmit information as to the required and/or effected maintenance at each field installation in order that the data is kept current. For uniformity and compatibility, Region is advised to base their system on current power company systems such as are being used by AGL, PowerCor, etc. These systems are map based, using the Land Victoria mapping system, are GIS compliant, and can be accessed online and via the internet. Standard symbols are used for each luminaire and a service history can be accessed. The AGL system is kept updated by “Small World P/L”, and AGL (for instance) have expertise that can be accessed by VicRoads at a price. 7.2 SURVEYS All of the street lighting system components are perishable over time. Regular survey of components and equipment is necessary for preventative maintenance to reduce or eliminate the potential for costly failures or for untoward incidents. For instance, frangible steel poles have now been in use for up to fifteen years. All steel poles are liable to corrosion damage in the base section, especially in the region of ground level down to about 450mm below ground level. The failure of a steel pole (or a steel bracket) could have adverse safety effects. Regular steel component inspection is to be designed and intended to detect evidence of impending failure and collapse. As field surveys cannot accurately measure luminaire output, the effective lamp life is usually determined from manufacturer’s data, which then feeds in to a bulk replacement regime. © Roads Corporation trading as VicRoads. All rights reserved. Page 23 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 APPENDIX A SUGGESTED MAINTENANCE REGIME See sections 2.4 and 4.3.3 for details. The T&TI preferred maintenance option (non-mandatory) includes: (a) VicRoads is to engage only pre-qualified contractors. (b) Engagement may be made by competitive tender for the maintenance of VicRoads owned freeway schemes and declared road stand-alone metered schemes. (c) As used by VicRoads, twin arc externally ignited HPS lamps output sufficient light to meet code requirements for up to 4 years, and thus require replacement after 4 years, and lumatrols (PE cells) are generally effective for up to 8 years. (d) It is envisaged that the maintenance contract would be a multiple of these figures, ie 4 years. The following contract would similarly be of 4 years duration with the addition that any lumatrols would also be replaced on commencement of this contract. (e) On commencement, the contractor would be required to bulk replace all lamps, service all luminaires, and check all poles, fittings and equipment, and would then maintain that street lighting installation to the required performance levels for the next 4 years. To minimise downstream costs, it is in the contractor’s interest to use good quality components at the start of each contract. (f) An adverse effect of the suggested regime would be uneven funding over the four years. The first year would be expensive with the next three being of lesser cost. (It might be possible to smooth out expenditure if the Region was able to let several staggered maintenance contracts (for different areas).) (g) Suggested Scope The maintenance contractor should investigate, supply and replace, install, test, commission and warrant the repair and/or replacement of malfunctioning lighting equipment, including electrical services, for the VicRoads owned lighting scheme and at the emergency telephone bays as required as shown on the relevant VicRoads drawings. The maintenance shall be in accordance with the relevant specification. The cost of maintenance for all lighting shown on the specified drawings should be deemed to be included in the Contract Sum. © Roads Corporation trading as VicRoads. All rights reserved. Page 24 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 The contractor should be fully responsible for the supply and maintenance of replacement components. The contractor should supply replacement poles (with the exception of joint-use poles), pole foundations, brackets, luminaires, lamps, PE cells, ballasts, igniters, capacitors, conduits, pits, cables, fittings, and all things necessary to maintain the street lighting installation in a fully functioning manner. The contractor should be responsible for maintaining power supply connection points, meters, distribution boxes and integral equipment, and for obtaining all necessary approvals and assistance from the relevant power supply company. © Roads Corporation trading as VicRoads. All rights reserved. Page 25 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 APPENDIX B BULK REPLACEMENT V BURN TO EXTINCTION Bulk Replacement: (a) (b) (c) (d) (e) (f) (g) timely replacement of used up lamps minimises outages and thus ad hoc replacements all lamps operate to similar output levels results in an even lighting scheme high cash flow year 1, reduced cash flow subsequently minimises costs permits bulk purchase of lamps Burn to Extinction: (a) (b) (c) (d) (e) maximises lamp life maximises outages and ad hoc replacements after several years no two lamps will be at the same point in their life cycle results in an uneven lighting scheme even cash flow from one year to the next Notes: (a) See sections 2.3 and 4.3.3 (b) The literature of overseas experience (England) seems to be coming down heavily in favour of bulk lamp changing (c) In general the most significant component of cost in the routine replacement of a failed lamp in a luminaire is the labour cost not only to do the job but also the travelling time between jobs. It is therefore important to reduce or minimise this non-productive time by preventative maintenance by bulk lamp changing. (d) Bulk lamp changing is based on having reliable data on the hours of operation of the lamps, the life of the lamps, and the date of the last bulk lamp change. (e) Street lighting hours of operation average out at 11.5 hours per day or 4200 hours per year. Seasonal variations, however, produce fluctuations from 9 hours per night at mid summer to about 13.5 hours in mid winter. In practice seasonal variations have little or no influence on the maintenance cycle; however the lamp life does. (f) Lamp life is expressed in terms of hours of operation before the lamp output falls below the minimum levels required to meet the requirements of AS/NZS1158. © Roads Corporation trading as VicRoads. All rights reserved. Page 26 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 (g) Keeping adequate records of when the previous bulk lamp change took place will assist to manage assets and thus avoid too low a lamp output rate. If the maintenance contractor does not bulk change lamps at the appropriate time the lighting scheme will no longer meet the requirements of AS/NZS1158 and may leave VicRoads open to adverse legal action. (h) Consequently, lamps should be replaced so as to ensure luminaire output is held at or above the levels required to confirm that the street lighting scheme meets the minimum maintained values of the light technical parameters as required by AS/NZS1158.1.1:1997. This is achieved by the bulk replacement of lamps at suitable intervals. (i) Consequently, the maintenance contractor should bulk replace all lamps. All bulk replacement lamps to be used for future VicRoads schemes shall be of the twin arc externally ignited high pressure sodium (HPS) type with a minimum service life of four years before unacceptable deterioration of the lamp output. These lamps have a 1% failure rate after six months and generally retain more than 70% of code output for the life of the lamp. © Roads Corporation trading as VicRoads. All rights reserved. Page 27 of 28 TTI – Intelligent Transport Systems Group Guideline No.: TCG 005-1-2003 APPENDIX C CALL OUT AND FAULT ATTENDANCE TIME INSPECTION FREQUENCY END OF LIFE / PREDICTED LIFE SPANS Table C1 -Call out and fault attendance response times – refer section 5 Callout & Fault Attendance Make safe Maximum Response Time 1 Hour Site Attendance 1 Day Repairs/Replace: lumatrols and PE cells contactors, igniters, & ballasts, control gear and transformers, lamps, replacement luminaires, brackets poles. 3 days 3 days 3 days 3 days 7 days 7 days 10 days Table C3 –Inspection Frequency Refer section 4.2 and 4.3 for details of activities to be completed during inspections Inspection 1. Night patrol 2. Day time inspection 3. Pole 4. Luminaires Frequency Bi monthly Every 6 months Every 12 months Every 12 Months Table C2 - End of Life / Predicted Life Spans for common items Refer section 4.3 for details and other components End of life 1. Luminaires 2. Poles 3. Lumatrols 4. Globes Years 20 30 8 4 - Twin arc externally ignited HPS 3 - Single arc externally ignited HPS (note these globes are not to be used as replacement globes) © Roads Corporation trading as VicRoads. All rights reserved. Page 28 of 28