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Sydney Light Rail - Moore Park West Substation and Moore Park Tunnel

Project Description

  • Construction of a new building, open cut tunnel and illumination of new tram tracks and surrounding public areas, including:
  • Electrical, Communications, HVAC, Dry Fire, Security, Earthing and Bonding, Public Illumination, Metering, infrastructure and pathways, traffic signage, systems automation (PLC), lighting automation (DALI) and systems integration (SCADA).
  • Tunnel:
    • All items installed in the tunnel are 3-hour fire rated to comply with Transport NSW
    • 6 Illuminated speed signs were mounted inside the tunnel and 2 non illuminated signs were installed. These signs had to meet strict font sizing, font styling and colour.
    • 5 x 4m long bi-directional project specific designed jet fans were mounted to the underside of the tunnel soffit to be used for emergency scenarios of fire and smoke.
    • Air Velocity Monitors were installed at both tunnel portals to monitor the direction and speed of air flow if there ever was an emergency within the tunnel and the jet fans needed to be used to assist with smoke flow.
    • A Linear Heat Detection fire detection fibre cable that is run in a continuous loop on the soffit from the substation along the down main track and then back via the upmain track into the substation. This system allows fast detection of any heat source and is an accurate measurement down to the metre along the 500m tunnel and can relay this information to the operation control command at Randwick stabling yard and the fire control room located within the substation.
    • The Jet fans can then be turned on remotely from the Operations and Control Centre (OCC) or locally in different directions to assist with the emergency situation via the PLC.
    • All metallic objects within the tunnel had to be electrically bonded using 70mm2 earth cable including each length of cable tray, jet fans, RTD and sump pump control panels, lighting and exits
    • The tunnel has a sump to discharge the water that collects from each portal. The pumps run and cycle automatically when the sump reaches a certain level all controlled by the PLC and if needed can be run from the OCC, manually from the substation or local controller inside the tunnel.
  • Substation:
    • The substation proved to be difficult and rewarding with a maze of cable tray in the basement to support the 11KV switchgear and HESOP equipment above.
    • HESOP (reversible direct current electric substation) allows for recovery of 99% of breaking energy, reducing environmental impact and number of substations by 20%.
    • The Low Voltage Main Switchboard (TMSB)required with street closures and specialised rigging to place the 7.8m long switchboard into place.
    • Installation of the board had to be done after the building works of the substation were complete and we had already installed the raised flooring in the LV switchroom.
    • The raised flooring was used to allow cable reticulation from the TMSB to the MSSB, FIP, Fire pump package, Computer room and to the equipment room basement and out into the tunnel cable tray system. The TMSB is fed by 2 different supplies, the normal supply directly from the Ausgrid’s HV transformer and the backup supply from the Alstom private HV network.
    • The complex PLC programming was very complex, impacting the works from 6 different contractors, all relying on Kerfoot to provide them solutions to the integration of all the systems in the substation and tunnel.
    • The large HVAC system consisted of 4 x CRAC units 2.5m long by 2m high and 2 x 3 fan dry coolers which all had to be lifted onto purpose-built platforms by crane.
    • The HVAC system is design for “off-line” operations, going into action only when temperatures exceed the predetermined thresholds.


  • Street Lighting:
    • This is a key area to ensure optimal illumination and maximum public safety to commuters, tram drivers and general public (pedestrians and drivers) in the vicinity of the light rail.
    • The optics for each luminaire were carefully designed and selected to ensure the light spreads in the correct direction and shape with specialised beam forming optics for minimum glare and optical safety.

Project Accolade

  • Substation: The systems integration and automation mean that all installed services can be monitored and controlled from the Operations Control Centre allowing the building to be unmanned.
  • Tunnel: spanning over 500m, with 180 light emergency and exit fittings it houses over 75 ton of steel, 65km of cable and over 50 ton of copper to integrate jet fans, lighting, hydraulic and essential services including a heat sensing fibre optical cable which triggers the fire systems response.
  • Street Lighting: optics plays a key role in implementing lighting with safety to pedestrians and drivers, 6 different combinations of optics were implemented to allow ideal illumination to each of the areas.
  • We at Kerfoot would be honoured to be recognised as winners, it reflects the commitment our team has to completion of projects exceeding client’s expectations on time, budget, quality, scope and safety.
  • Our ability to meet client’s needs on time and budget with high attention to innovation, safety, quality and the environment shows how well we adapted to the changing environment of today and over the past 47 years.
  • The implementation of little-known technologies such as the heat sensing fibre cable and the systems integration for remote operation and management of all services in the substation, tunnel and street lighting that are capable of operating with zero fault tolerance in a live environment where the safety of the light rail users is paramount is an unique accomplishment .

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