CHAPTER I

MANAGEMENT OF AC TRACTION
1. HEADQUARTERS OFFICE

PARA NO. SUBJECT

10100 Introduction
10101 Chief Electrical Engineer(CEE)-Zonal Railway
10102 Control Over Division
10103 Duties of Administrative Officers
10104 Stores procurement
10105 Standard Drawings and Specifications

II. DIVISIONAL ORGANIZATION

10106 Divisional Railway Manager (DRM)

10107 Duties of Traction Distribution (TRD) Officers
10108 Duties of Rolling Stock (RS) Officers
10109 Duties of Rolling Stock Operation Officers
10110 Duties of Principal, Training School
10111 Budget Estimates for Electric Traction
10112 Electrical Department- Budget Demands

INDIAN RAILWAYS AC TRACTION MANUAL- VOLUME 1 [2]

 CHAPTER I
MANAGEMENT OF AC TRACTION
I. HEADQUARTERS OFFICE
10100 Introduction
Electrification on Indian Railways remained mainly confined to following sections, till early fifties, at
1500 V dc:-
1. Suburban Railways in Bombay
i) Central Railway
a) Bombay VT -Kalyan (main line)
b) Bombay VT-Kurla (Harbour Branch)
ii) Western Railway
a) Churchgate-Virar
2. Ghat Sections of Central Railway)
i) Kalyan-Pune
ii) Kalyan-Igatpuri

3. MG Suburban Sections of Madras

i) Madras Egmore-Tambaram section of Southern Railway.

Before large scale electrification was thought of on Eastern Railway, the suburban section of
Howrah-Burdwan was electrified at 3000 V dc.

In the meantime SNCF (Socieite National Chemin de Fer Francais, i.e., French National Railways)
had gone ahead with large scale main line electrification on their system with 25 kV, 50 Hz, ac,
SNCF, who worked as Technical Consultants to Indian Railways for adopting a system of
electrification on main line, recommended 25 kV, 50 Hz system as technically viable and
economical for Indian Railways. Since then the entire electrification on Indian Railways has been
carried out on 25 kV, 50 Hz, ac only. The first electrification on 25 kV, 50 Hz ac was taken up on
South Eastern Railway between Rajkharaswan and Dongaposi. Even the Howrah-Burdwan section
on Eastern Railway and Madras - Tambaram section on Southern Railway were later on converted
to 25 kV, 50 HZ ac system. As on 31.3.94, a total of 11793 Route Kilometer have been electrified on
25 kV, 50 Hz ac single phase system.

1500 V dc system is, however, retained on Central and Western Railways, even though further
electrification on these two Railways was done on 25 kV, 50 Hz, ac single phase system primarily
because of problems of clearances in tunnels and interference with telecommunication lines in the
suburban section. The system compatibility was obtained by providing either dual system yard with
neutral sections at either end (as in Central Railway) or by using dual voltage locomotives (as in
Western Railway).

10101 Chief Electrical Engineer (CEE)-Zonal Railway

CEE is the Administrative Head of the Electrical Department, with overall responsibility for efficient
working of the department. He is responsible to the General Manager in all matters pertaining to
Electric Traction and Electrical General Services. On behalf of the General Manager, he directs and
supervises all electrical works related to Railway, whether executed by Divisional Officer or by
independent organisation. He oversees the budget of the Electrical Department and is also
responsible for works to be executed by the department.

CEE also functions as Electrical Inspector to the Government as defined in Section 36(1) of Indian
Electricity Act- 1910, in respect of all high voltage electrical installations and equipment owned by
the Railways. This includes all high voltage electrical installations in the Railway including
transmission lines, 25 kV feeder lines, sub-stations, switching stations which although running
outside Railway premises, are, nevertheless, owned by the Railway. He is responsible for
administration of the Electricity Rules in the Railway.
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In regard to electric traction installations, in his capacity as Electrical Inspector, CEE is chiefly responsible for
the following: -

1. Scrutiny and approval of the layout and designs for sub-stations, OHE and other installations for
compliance with the Indian Electricity Act and Rules;

2. Inspection of the completed installations, either personally or by deputing his officers, for compliance
with the safety requirements;

3. Approval for the energization of the Installations;

4. Statutory inspection of the installations periodically under Rule 46 of the Indian Electricity Rules;

5. Investigation of electrical accidents and Issuing directives to prevent their recurrence; and

6. Submission of annual report to Central Electricity Authority.

10102 Control Over Division

In all technical matters, the Senior Divisional Electrical Engineers (Sr. DEEs) in the Division are
answerable to CEE.

10103 Duties of Administrative Officers

CEE is assisted by one or more officers of Senior Administrative rank, who will be responsible to CEE for the
proper working of the department, the area of responsibility of each will be defined by CEE.

Administrative Officers will :

a) Normally deal with all correspondence except those involving important policy matters and expression of
opinion on behalf of the Railway on major matters of policy;

b) On behalf of CEE, exercise administrative and technical control for the efficient planning, design,
construction, commissioning, safe and economic operation and effective periodic maintenance of electric
traction services, Train Lighting, Air Conditioning on Coaches, General Power Services in Railway premises
and equipment owned by the Railway and to achieve this, carry out purposeful periodic inspection of
installations;

c) In the event of major breakdowns/accidents, take prompt and energetic action to restore normal services at
the earliest possible time and subsequently take follow-up action to investigate the cause of failure and initiate
measures to prevent recurrence;
d) Co-ordinate effectively with Administrative Officers of operating and other departments on the Railway and
also their counterparts in other Railways in regard to items of common interest;

e) Maintain liaison with the Power-Supply Authorities at Headquarters level In regard to continuity of supply,
tariff and policy matters;
f) Keep a close watch over the day-to-day performance of traction services and tighten up preventive
maintenance where required;

g) Investigate equipment failures, particularly of recurring nature, initiate appropriate remedial steps to modify
the design wherever required In consultation with the Research, Designs and Standards Organisation
(RDSO), Locomotive manufacturers; also take follow-up action to ensure prompt completion of modifications
ordered on all equipment held by the Railway;

h) Plan and review the organizational set-up required for satisfactory maintenance and operation of the
electric traction services;
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME I (4)
i)Plan the recruitment and training of staff for maintenance and operation;

j) Exercise effective technical scrutiny over items for inclusion in the M&P, Works and Rolling Stock
Programmes and progress items approved in the programmes;
k) Plan in advance the procurement of vital stores required for maintenance and operation of electric
traction services and maintain effective liaison with the Stores Department at Headquarters level for
prompt procurement and adequate stocking of such stores;
l) Arrange for standardization of stores as required and preparation of drawings and specifications to
facilitate procurement;

m) Study and analyze the periodic statistical returns on electric traction and initiate appropriate
remedial measures as required to improve efficiency;

n) Monitor energy consumption, power factor and Maximum Demand at various traction sub-stations
on the Railway and initiate appropriate measures to ensure efficient utilization of energy and to
contain the energy bill;

o) Ensure the prompt submission of periodical returns to the Railway Board and RDSO;

p) Budgeting and control over expenditure, particularly in regard to repair costs, energy bills and
maximum demand charges;
q) Carry out studies regarding the feasibility and economics of electrification of additional sections In
consultation with the Operating and Accounts Departments and submission of proposals to the
Board where found justifiable;
r) Keep in touch with modern technical developments with a view to identify applicability in railway
installations to reduce operation and maintenance cost;

s) Maintain liaison with the Railways for quick return of overdue locomotives;

t) Maintain close co-ordination with production units and POH workshops for supply of shop
manufac- tured items, reducing POH time and improving reliability.
10104 Stores Procurement

An important responsibility on the Headquarters and Divisional Offices is to ensure by timely action
that sufficient stocks of stores and spares are actually held not only for meeting the day-to-day
needs of maintenance and repair, but also for any emergency such as thefts of overhead
conductors, uprooting of OHE masts on account of accidents, or to meet urgent operational
requirements such as wiring of additional lines in a yard.

Number of component parts involved in rolling stock and OHE maintenance is quite large and each
of them should comply with rigid specifications, being of special nature. Reliable sources of supply
are also limited. Taking all these factors into account, it is essential to
take advance action to make a realistic assessment of the requirements for the whole Railway and
take timely procurement action through the Stores Department. Machinery should exist on each
Railway to review periodically the supply position jointly with the Stores Department so that prompt
corrective action may be taken for items which are likely to be in short supply.

Consolidation and scrutiny of requirements for the whole Railway, follow-up action in regard to the
release of foreign exchange for imported items and correspondence with the Railway Board as well
as with procurement agencies is the responsibility of the Headquarters Office.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I (5)

10105 Standard Drawings and Specifications

Indian Railway Standard (IRS) drawings and specifications for electric traction spare parts and
stores required will be issued by Chief Electrical Engineer. Drawings and specifications to be issued
will keep in view the drawings and standards issued by RDSO and manufacturers and experience
of Railways etc.

II. DIVISIONAL ORGANIZATION

10106 Divisional Railway Manager (DRM)

For administrative purposes, the DRM functions under direct control of the General Manager but is
responsible to CEE for efficient functioning of electric traction and electrical general services under
his direct administrative control.
10107 Duties of Traction Distribution (TrD) Officers

1.Duties of Senior Divisional Electrical Engineer (TrD)

Sr. DEE/DEE(TrD) is the officer in immediate charge of the Traction Distribution section in a
Division, responsible for all technical and organizational matters connected with the efficient
maintenance and operation of the power supply installations, OHE and RC equipment. He should
be intimately acquainted with the technical details, performance rating and operating and
maintenance problems of the installations under his charge. His chief duties will be as under :-

a) General planning and supervision to ensure efficient and safe maintenance and operation of the
installations under his charge in accordance with prescribed schedules and regulations;

b) Study of the day-to-day technical and organizational problems of operation and maintenance and
initiation of appropriate measures to deal with these;

c) Man-power planning for effective maintenance at minimum cost;

d) Careful statistical analysis and compilation of details of all defects and failures occurring and
initiation of appropriate remedial steps if these are attributable to inadequate or improper operation
or maintenance or mismanagement by staff. Where defects are attributable to improper design or
manufacture, or where modifications or proposed remedial measures require CEE's approval,
prompt submission of detailed analysis together with recommendations, seeking such approval;

e) Watch on the progress and completion of all approved modifications as well as the efficacy of
such modifications;

f)Watch on the availability of spare parts and stores required for maintenance and initiation of stores
action well in advance for procurement of items involving prolonged delivery and effective follow-up
action to ensure timely procurement. Also watch the behaviour of equipment to assess their
anticipated life and timely programming of replacements;

g)Overall co-ordination at the divisional level with the operating and other departments to plan
power blocks required for maintenance of OHE and careful planning of maintenance work to make
the best use of such blocks;

h) Inspection of his jurisdiction as under-

1. Detailed visual inspection of the OHE by push trolley, motor trolley or OHE Inspection Car as
often as possible;
2. . Detailed inspection of traction sub-stations, switching stations and other power supply and RC
installations, in particular protective gear, once in six months,

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME I [6]

3. Frequent surprise checks of maintenance gangs at works including gangs working at night. At
least one night inspection and one day inspection will be carried out by him;

4. General inspection of all subordinate offices under him once a year, including test check of
stores and tools and plant items;

5. At least one current collection test in a year throughout his jurisdiction on main lines;
i) Liaison with power supply authorities in regard to important matters that cannot be dealt with at
lower levels;

j)Preparation of plans and estimates for works involving the traction distribution system and
scrutiny of plans and estimates for works of other departments affecting the traction
distribution system. For minor works such as small changes in the layout of lines in yards or
alignments, provision of OHE for one or two additional loops, cross-overs etc. designs will
be worked out at the divisional level in accordance with approved standards and approval
of CEE obtained before the works are executed. Designs for major works will however, be
worked out in CEE's office;
k)Arrange adequate training of staff under him in the correct methods of maintenance and
operation;

l) Careful preparation of the budget for traction distribution section and control over expenditure for
operation and maintenance. In addition to scrutiny and passing of power supply bills, study of the
energy consumption and maximum demand figures and liaison with the operating department and
Rolling Stock section to keep expenditure for these under effective control;

m) Special watch on the adequacy and alertness of the organization for dealing with failures and
break- downs, personal supervision of operations in the event of major failures affecting train
services or involving outage of essential equipment, so as to effect quick restoration ;

n) Close association with tests and trials in the area under his jurisdiction and submission of
prescribed reports;

o) Ensuring by periodical and surprise inspections that rules and procedures laid down in the
General and Subsidiary Rules, Manual of AC Traction, department codes and orders and circulars
issued from time to time are being complied with by all staff under him and that they are Performing
their allotted duties efficiently.

2. Duties of Divisional / Assistant Electrical Engineer (TrD)

DEE/AEE(TrD) is the officer in immediate charge of the maintenance, operation and safety of all
power supply installations, overhead equipment (OHE) and RC equipment in his jurisdiction and is
answerable to Sr. DEE(TRD) in all matters connected therewith. In addition to assisting
Sr.DEE(TrD) in his duties, his chief duties will be as under :-

a) Efficient and safe upkeep and operation of the installations under his charge in accordance with
the prescribed schedules including detailed planning of all maintenance works;

b) He should ensure that Traction Power Controller (TPC) takes effective and prompt action to
restore services in the event of power supply interruptions or other failures of the distribution system
affecting train services;

c) Close liaison with power supply authorities to ensure continuity of power supply;

d) Careful and prompt investigation of all recurring or major power supply interruptions and
equipment failures and initiation of appropriate remedial measures;

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME I (7)

e) Preparation of preliminary plans and estimates called for by Sr.DEE(TrD) for works involving the
traction distribution system, and scrutiny as called for by Sr.DEE(TrD) of plans and estimates for
works of other departments in the section so far as they affect the system;

f) Personal and periodical checking of the break-down organization to ensure that it is in good fettle
to deal with all break-downs ;

g) Prompt implementation of instructions received from time to time including those contained in
Inspection Notes of superior officers and keeping record of action taken against each item;

h) Careful scrutiny of statistical and other periodical returns before submission to Sr.DEE(TrD) and
taking appropriate corrective action;
i) Effective co-ordination with officers and staff of other departments in matters that warrant joint
action and similar co-ordination with officers of contiguous sections;

j) Inspection of his jurisdiction as under :-

1.Detailed visual inspection of the OHE in his section from observation dome/roof of OHE Inspection
Car once in six months. Similarly inspection from cab of locomotives shall also be carried out:

2.Detailed inspection of traction sub-stations, switching stations and other power supply
installations, in particular, protective gear, once in 3 months;

3 Frequent surprise checks of maintenance gangs at work including gangs working at night. The
musters for casual staff, if any, should be checked and initialled;

4. Random check of the procedure followed for imposition of power blocks to verify that all
prescribed safety rules are being rigidly followed;

5. Periodic inspection of subordinate offices, including stores, at least once in six months;

6.Current Collection Test over his entire jurisdiction at least once in six months.

10108 Duties of Rolling Stock (RS) Officers

1 Duties of Senior Divisional Electrical Engineer (RS)

He is the officer in immediate charge of an Electric Loco or EMU Shed and responsible for all
technical and organizational matters connected with the efficient maintenance of the Electric Locos
based in the shed. He should be well acquainted with the mechanical and electrical design details,
performance data and operating and maintenance problems of locos under his charge. His chief
duties will be as under :-

a) Manage the working of the shed to make the best use of manpower and facilities
provided. Study the need for additional facilities and manpower to deal with existing and
anticipated workload and formulate proposals for such additional requirements;

b) Keep in touch with the day-to-day problems of the shed and take appropriate measures to deal
with these;

c) Make a careful statistical analysis of all defects and failures occurring and take appropriate steps
if they are attributable to inadequate or improper attention in the shed. In the case of type defects
due to improper design or manufacturing defects, furnish full analysis to CEE for taking up the
matter with RDSO and the manufacturers;

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d) Keep a watch on the progressing of modifications approved and Special Maintenance
Instructions (SMIs) as well as the efficacy of such modifications/SMIs;

e) Keep a careful watch on the availability of spare parts and stores required for maintenance of
the locos/ EMUs and initiate action well in advance for procurement of items involving prolonged
delivery and take effective follow-up action to ensure timely procurement also watch the
behaviour of equipment to assess their anticipated life and programme procurement of
replacements well in time;
f) Through the Planning and Progress Organization (PPO) watch that maintenance is being
carried out in accordance with prescribed schedules and carry out frequent test checks to
ensure required standard of maintenance;
g) Keep effective liaison with Sr.DEE(OP) in regard to operating problems, particularly
shortcomings of the shed affecting optimum utilization of the locos/EMUs. Failures involving
special or unusual features should be jointly investigated with Sr.DEE(OP);

h) Careful study of the prescribed statistical returns before submission to CEE, RDSO etc. and
initiation of appropriate steps in case of departure from accepted norms;

i) Arrange adequate training of the staff under him in the correct methods of maintenance and
operation;

j) Ensure by periodical inspection that rules and procedures laid down in the General and
Subsidiary Rules, Manual of ac Traction, departmental codes and orders and circulars issued from
time to time are being complied with by all staff under him and that they are performing their allotted
duties efficiently ;

k) Ensure safety of stock, security of assets and staff in the shed;

l.) Prepare the Works Programme, Rolling Stock Programme, M & P Programme and Budget and
ensure expenditure control.

2. Duties of Divisional /Assistant Electrical Engineer (RS)

The duties of DEE/ AEE(RS) will be similar to those for the Sr.DEE(RS) in respect of all works under
his direct charge. He shall work directly under the control of Sr. DEE(RS) and be fully responsible
for the proper and efficient functioning of all equipment under his control, and the standard of
workmanship of repair and maintenance work carried out. Periodic inspection of subordinate offices
including, stores at least once in six months.

10109 Duties of Rolling Stock Operation Officers

1. Duties of Senior Divisional Electrical Engineer (OP)
Sr. DEE(OP) is the officer in immediate charge of the maintenance & operation of electric
locomotives and electric multiple unit (EMU) stocks outside the electric loco shed. Sr. DEE(OP) is
also responsible for dealing, on behalf of the Electrical Department, with all technical and
organizational matters connected with the operation of electric rolling-stock. His chief duties will be
as under : -

a) Plan the requirements of locos and EMUs to meet traffic requirements and preparation of
loco/EMU links to suit traffic requirements;

b) Plan/review of the requirement of crew every six months;

c) Maintain close liaison with the Operating Department officials and keeping himself fully
conversant with operating problems and evolving counter measures to get over them so far as
electric stock is concerned. Ensure maximum utilization of locos by watching detentions, taking on
additional services, improving the engine links etc.;
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I (9)
d) Make available locos and EMUs as well as running staff as required for traffic and keeping a
watch over train operations and making suggestions for better utilization of available stock.

e) Keep himself fully posted with the technical details of the electrical equipment on rolling-stock so
as to give guidance to the Drivers of locos in case of failures of equipment to give first aid attention,
and arranging relief when required, so that normal working may be restored with the least possible
delay;

f) Ensure by periodical and surprise inspections that rules and procedures laid down in the General
and Subsidiary Rules, Manual of AC Traction, departmental codes and orders and circulars issued
from time to time are being complied with by all staff under him and that they are performing their
allotted duties efficiently;

g) Ensure efficient and safe operation and running maintenance of the rolling-stock under his
charge in accordance with the prescribed rules;

h) Prompt and careful investigation of electrical rolling-stock failures and furnishing of necessary
details to the maintenance shed for taking remedial action. Failures causing detention of more than
30 minutes or other unusual occurrences shall be investigated jointly with Sr.DEE(RS) in-charge of
the loco shed. Appropriate remedial action should be taken by Sr.DEE(OP) himself if the failure is
attributable to lapses of running maintenance or defective operation;

i) Organize, in co-operation with the Operating Department, the timely withdrawal of electric rolling-
stock for maintenance attention in accordance with prescribed maintenance schedules. Liaison with
the PPO of the shed for this purpose;

j) Compile prescribed statistical information on electric rolling-stock, performance and utilization

and their timely submission, after proper scrutiny, to CEE and other concerned officers;

k) Maintain watch over the punctual running of electrically hauled trains and report of serious
lapses to the Divisional Railway Manager;

l) Study the pattern of energy consumption and maximum demand figures in relation to the traffic
handled and initiation of appropriate measures;

m) Give requisite technical guidance to Operating Department officers and staff in regard to the
special techniques involved in the operation of electric rolling-stock;

n) Train and examine for competency of electric running staff, watch over their performance and
arranging refresher courses for such staff;

o) Arrange the rosters for electric running staff;

p) Issue of trouble-shooting, standing and other instructions required for the guidance and
education of running staff. Arrange notification in the Working Time Table of instructions
specially applicable to Electric Running Staff;

q) Supervise restoration work personally or through DEE(OP), AEE(OP) when electric rolling-
stock is involved in accidents and arranging representation of Electrical Department at joint
inquiries;

r) Foot-plate inspection of train working so as to cover the entire division at least once in 3
months, when he should pay special attention to -
i) Punctuality of trains in accordance with the time-table and allotted paths;

(ii) Observance of safety rules by Drivers and other operating staff;

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME (10)

iii) Correct observance of the prescribed rules of driving including, the best use of coasting and
gradients for conservation of energy;
iv) Proper functioning of loco/EMU equipment;

v) Observance of speed restriction;

vi) Scrutiny of loco log books and test check of locomotives and EMU stock as often as feasible
for compliance with prescribed safety regulations and for efficient upkeep; by frequent
surprise checks and questioning of electrical running staff. He will observe their alertness on
duty, knowledge of and observance of rules and carrying of prescribed equipment;

(vii) Look for reasons of poor signal visibility, train parting, stalling and other irregularities in the
section where such things are reported;

s) Periodic inspection of booking points, running rooms at least once in two months and at least
one night inspection in a month.

t) Ensure that speedometer charts are regularly scrutinized through Senior Divisional
Inspectors (TELOC) having suitable cell. Duration for which charts are to be preserved, may
be fixed by Division.

2. Duties of DEEIAEE((OP)
The duties of DEE (OP) /AEE (OP) will be similar to those for the Sr. DEE (OP) in respect of all
works under his direct charge. He shall work directly under the control of Sr. DEE (OP).

10110 Duties of Principal, Training School

He is incharge of Training School of Zonal Railway for training of electric traction, maintenance and
operating staff.

The Principal, Training School/Senior DEE(Trg) shall be responsible for :-

1. Estimation of current training needs for maintenance and operating staff of the Railway;

2. Organising and imparting stipulated training for the maintenance and operating staff of the
Railway;

3. Planning for future- training needs keeping in view the expansions, increase in traffic,
induction of newer technology and to keep the senior personnel of the maintenance shops
abreast with the new technology;

4 He will be responsible for equipping the training school with modern aids of teachings and
learning and for this he will be assisted by a Vice-Principal and a team of instructors.
Training being such an activity, assistance of non-Railway organisations is imperative. He
will, therefore, be equipped to draft such assistance as and when required;

5. Up-keep of the training school and its environment in keeping. With the atmosphere required
for learning.
10111 Budget Estimates for Electric Traction
The following special points shall be kept in mind when preparing the Budget estimate for electric
traction :-
a) Energy consumption and maximum demand for goods and passenger services should be
estimated based on an assessment of traffic expected during the next financial year obtained from
the Operating Department. This is particularly important for sections where electric traction is likely
to be introduced for the first time during the new year. Based on this, necessary provision should be
made for energy

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME [11]

Consumption and other charges. The additional energy consumption may be computed on the basis
of the specific energy consumption actually obtained for different services on the Railway during the
previous six months. Where maximum demand payment is involved, the additional maximum
demand for budgetting purposes may be assumed to be in proportion to the anticipated additional
energy consumption if the pattern of train working remains unchanged. If there is material change in
the pattern of train working, detailed calculation of maximum demand will have to be made from the
proposed Graphic Train Charts for the period of the day when the traffic is heaviest;

b) Anticipated changes in tariff and possibility of application of such changes with retrospective
effect;

c) Assessment of additional requirements of operating staff based on the traffic expected;

d) Provision for training of additional staff based on anticipated expansion of services;

e) Careful assessment of the cost of special procurement of stores for normal maintenance and
heavy repairs;

f) Provision for clearing backlog of repairs, if any.

10112 Electrical Department -- Budget Demands

The demands and the main heads pertaining to the Electrical Department are as under -

Demand No. 3 -- General Superintendence and Services of Railways Main Head 700
Electrical Management

Demand No. 5 -- Repairs and Maintenance of Motive Power Main Head 500 Electric
Locomotives

Demand No. 6 -- Repairs and Maintenance of Carriages and Wagons Main Head 400
Electrical Multiple Units
Coaches Main Head 500 TL, Fans & AC on Coaches.

Demand No. 7 -- Repairs and Maintenance of Plant and Equipment Main Head 400
Plant and Equipment Electrical

Demand No. 8 -- Operating Expenses Rolling Stock and Equipment Main Head 300
Electrical Locomotive Main Head 400- Electrical Multiple Units

Demand No. 10 -- Operating Expenses Fuel Main Head 300 Electric Traction.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME (12)

 GENERAL DESCRIPTION OF FIXED INSTALLATIONS
I. POWER SUPPLY ARRANGEMENTS AT SUB-STATIONS

Para No. Subject

10200 Power Supply
10201 Duplicate Supply
10202 Voltage Regulation
10203 25 kV Supply at Traction Sub-stations
10204 Feeding and Sectioning Arrangements
10205 Feeding Post (FP)
10206 Sectioning and Paralleling Post (SP)
10207 Sub-Sectioning and Paralleling Post (SSP)
10208 Sub-Sectioning Post (SS)
10209 Certain Equipment at Switching Stations
II. POWER SUPPLY FOR SIGNALLING
10210 Supply Arrangements
10211 Voltage Regulators

III. REMOTE CONTROL AND COMMUNICATION ARRANGEMENTS

10212 Remote Control

10213 Communication Facilities

IV. OVERHEAD EQUIPMENT

10214 Catenary and Contact Wires

10215 Height of Contact Wire
10216 Span of Supporting Mast/Structures
10217 Stagger
10218 Overlaps
10219 Regulated and Unregulated OHE
10220 Section Insulator Assembly
10221 Mechanical Independence of OHE Track - Structures
10222 Flexible Head-Span and Rigid Portals
10223 Maximum Speed

V. SPECIAL WARNING SIGNALS

10224 Signal Marking the end of Catenary

10225 Warning Signals for Neutral Sections
10226 Temporary Signals
10227 Special features of Traction Installations in Waltair - Kirandul section of
S. E. Railway

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1

 CHAPTER II
GENERAL DESCRIPTION OF FIXED INSTALLATIONS
1. POWER SUPPLY ARRANGEMENTS AT SUB-STATIONS

10200 Power Supply

25 kV, ac, 50 Hz single phase power supply for electric traction is derived from the grid system of
State Electricity Boards through traction sub-stations located along the route of the electrified
sections at distances of 35 to 50 km apart. The distance between adjacent sub-stations may
however be even less depending on intensity of traffic and load of trains.

At present there are broadly four different arrangements in existence as under :-

1. The Supply Authorities supply power at 220/132/110/66 kV Extra High Voltage (EHV) at each
traction sub-station which is owned, installed, operated and maintained by the Railway';

2. The Railway receives 3-phase power supply from the Supply Authority at a single point near the
grid sub- station, from where the Railway runs its own transmission lines providing its own traction
sub-stations;

3. All EHV and 25 kV equipment is owned, installed, operated, and maintained by the Supply
Authority, except 25 kV feeder circuit breakers which are owned, installed, operated and maintained
by the Railway;

4. All EHV and 25 kV equipment is owned, installed, operated and maintained by the Supply
Authority but 25 kV feeder circuit breakers alone are operated on remote control by the Traction
Power Controller (TPC).

10201 Duplicate Supply

1. Fig. 2.01 shows schematically the arrangement at a typical traction sub-station.

2. To ensure continuity of supply under all conditions, the high voltage feed to the traction
substations is invariably arranged either from two sources of power or by a double circuit
transmission line, so that even if one source fails, the other remains in service. Suitable protective
equipment is installed at the sub-stations to ensure rapid isolation of any fault in transmission lines
and sub-station equipment, so that the power supply for electric traction is maintained under all
conditions.

3. At each traction sub-station, normally two single-phase transformers are installed, one of which is
in service and the other is 100% stand by. The present standard capacity is 21.6 MVA (ONAN)/30.2
MVA (ONAF). However transformers of capacity 13.5 MVA (ONAN)/I0.8 MVA (ONAN) have also
been used at many of the sub-stations. These transformers step down the grid voltage to 25 kV for
feeding the traction overhead equipment (OHE). 25 kV feeders carry the power from the sub-
stations to feeding posts located near the tracks. Each feeder is controlled by a single-pole circuit
breaker equipped with protective devices.

10202 Voltage Regulation

The permissible variation of the bus bar voltage on the busbars at the grid sub-station is+
10% and 5% i.e., between 27,500 V. and 23,750 V. The tappings on the transformers are
on the secondary winding and are set to ensure that the voltage is maintained as high as
possible but not exceeding 27.5 kV at the feeding post at any time.

10203 25 kV Supply at Traction Sub-stations

1. On the secondary side, one transformer circuit breaker and one feeder circuit breaker are
installed with associated double pole isolator, the busbar connections being such that full flexibility
of operation is assured.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME (14)

2. The traction sub-station is designed for remote operation.

3. The facilities exist to change over from one feeder to the other by means of isolator/bus coupler.

4. One end of the secondary winding of the transformer is solidly earthed at the sub-station and is
connected to track/return feeder through buried rail.

10204Feeding and Sectioning Arrangements

1. The generation and transmission systems of Supply Authorities are 3-phase systems. The single-
phase traction load causes unbalance in the supply system. This unbalance has undesirable effects
on the generators of the Supply Authorities and equipment of other consumers, if its value becomes
excessive.

2. The permissible voltage unbalance at the point of common coupling on the grid supply system
should not exceed the following limits:-

Voltage Unbalance (%)

Instantaneous 5
2 hours 3
Continuous 2

3. To keep the unbalance on the 3-phase grid system within the above limits, power for ac single
phase traction is tapped off the grid system across the different phases at adjacent sub-stations in
cyclic order.

4. Thus it becomes necessary to separate electrically the overhead equipment systems fed by
adjacent sub- stations. This is done by providing a 'Neutral Section' between two sub-stations on the
overhead equipment to ensure that the two phases are not bridged by the pantographs of passing
electric locomotives/EMUs.

5. To ensure rapid isolation of faults on the OHE and to facilitate maintenance work, the OHE is
sectioned at intervals of 10 to 15 km along the route. At each such point a 'switching station
interruptors' usually rated at 600A are provided. The shortest section of the OHE, which can be
isolated by opening interruptors alone is called a 'sub-sector'. Each sub-sector is further sub-divided
into smaller 'elementary sections' by provision of off-load type manually operated isolator switches.

6. At some stations with large yards, alternative feeding arrangements are provided so that the
power for feeding and yards may be drawn from alternative routes. Normally the switch is locked in
one position, being changed to the other when required after taking necessary precautions.

7. To meet requirements at electric loco running sheds isolators with earthing device in the off
positions is provided. At watering stations manually operated interrupters and isolator with earthing
heels are provided to enable switching off of the power supply locally and earthing the OHE to
enable working on roofs of rolling-stock. There are several types of switching stations as detailed in
the following paras.

10205 Feeding Post (FP)

Each feeder supplies the OHE on one side of the feeding post through interruptors controlling
supply to the individual lines. Thus, for a two track line, there will be four interruptors at each
feeding post.

10206 Sectioning and Paralleling Post (SP)

These posts are situated approximately midway between feeding posts marking the demarcating
point of two zones fed from different phases from adjacent sub-stations. At these posts, a neutral
section is provided to make

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME (16)

 it impossible for the pantograph of an electric locomotive or EMU train to bridge- the different
Phases of 25 kV supply, while passing from the zone fed from one sub-station to the next one.
Since the neutral section remains 'dead', warning boards are provided in advance to warn and
remind the Driver of an approaching electric locomotive/EMU to open locomotive circuit breaker
(DJ) before approaching the 'neutral section', to coast through it and then switch 'on' on the other
side. Special care is taken infixing the location of neutral sections, on level tangent tracks far away
from signals, level crossing gates etc. to ensure that the train coasts through the, neutral section at
a sufficiently high speed, to obviate the possibility of its stopping and getting stuck within the neutral
section.

A paralleling interruptor is provided at each 'SP' to parallel the OHE of the up and down tracks of a
double track section. 'bridging interruptors' are also provided to permit one feeding post to feed
beyond the sectioning post upto the next FP if its 25 kV supply is interrupted for some reasons.
These bridging interruptors are normally kept open and should only be closed after taking special
precautions as detailed in these rules.

10207 Sub-Sectioning and Paralleling Post (SSP)

One or more SSPs are provided between each FP and adjacent SP depending upon the distance
between them. In a double track section, normally three interruptors are provided at each SSP i.e.
two connecting the adjacent sub-sectors of up and down tracks and one for paralleling the up and
down tracks.

10208 Sub-Sectioning Post (SS)

These are provided only occasionally. They are similar to SSPs with provision for sectioning of the
OHE but not paralleling.

10209 Certain Equipment at Switching Stations

Certain equipments are installed at various points to protect the lines, to monitor the availability of
power supply and provide other facilities. These are generally as under :-

1. Lightning arresters are provided to protect every sub-sector against voltage surges.

2. Auxiliary transformers are provided at all the posts and also at certain intermediate points to
supply ac at 240 V, 50 Hz required for signalling and operationally essential lighting installations. To
ensure a fairly steady voltage, automatic voltage regulators are also provided where required.

3. Potential transformers are provided at the various switching stations for monitoring supply to each
sub-sector.

4. A small masonry cubicle is provided to accommodate remote control equipment, control panel,
telephone and batteries and battery chargers required for the control of interruptors and other
similar equipments.

II. POWER SUPPLY FOR SIGNALLING

10210 Supply Arrangements

1. To ensure reliability of ac 240V, supply through 25 kV/240V auxiliary transformer by tapping 25

kV OHE is made available at following places:

(a) At each way side station for CLS.

(b) Level crossings located more than 2 km.away from Railway Station.
(C) At IBH.
(d) At all the power supply installations.
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME 1 (17)
2. In the event of power block being given on both the OHE sub-sectors from which the signal
supply is derived, electric traffic would necessarily have to be suspended on the line. During such
periods, colour light signalling will not also be in operation. Such cases are likely to arise very rarely
at any station and the duration of the block is not likely to exceed-one hour at a time. Therefore, no
additional power supply arrangement need be made by the Electrical Department at wayside
stations. However, to cater for this condition, portable-generating sets should be kept by the S&T
Department to be operated until 25 kV supply is restored. At large stations with considerable
shunting movements, a stand-by diesel generator set may be installed by the S&T Department to
meet emergencies, if considered essential.

10211 Voltage Regulators

The fluctuating nature of traction load causes perceptible fluctuation on the ac 240 V supply
affecting operation of signalling equipment. To overcome this, static type voltage regulators are
provided by the S&T Department to limit voltage fluctuations to + 5%. These voltage regulators are
installed either in separate kiosks inside the remote control cubicles, inside the ASM's room, or
inside the cabins depending upon the position of various load centres.

III. REMOTE CONTROL AND COMMUNICATION ARRANGEMENTS

10212 Remote Control

The interruptors at the various switching stations as well as the feeder circuit breakers (and other
switch gear owned and operated by the Railway) at the traction sub-stations are controlled from a
Remote Control Centre (RCC) manned throughout the 24 hours of the day. During each shift there
is one or more number of Traction Power Controllers (TPC), depending upon the work load. All
switching operations on the system are thus under the control of one single person, namely TPC,
who is responsible for maintaining continuity of power supply on all sections of the OHE. He also
maintains continuous and close liaison with the Section Controllers in regard to train operations on
electrified sections.

Further details regarding Remote Control are given in Vol. II of this manual.

10213 Communication Facilities

All aerial telecommunication lines running by the side of the tracks are replaced with under-ground
cables/ microwave to overcome the interference caused by 25 kV single phase ac traction. The
cables contain adequate number of pairs of conductors for the various types of Railway
telecommunication circuits on ac traction. For technical details reference may be made to Indian
Railways Telecommunication Manual.

In an electrified section it is essential, in the interest of efficiency, to provide several independent

telephone circuits to facilitate quick communication and to achieve necessary co-ordination between
different branches of the Railway. In an emergency several alternative telephone channels will be
available for communication should any one fail. The various telephone circuits provided in
electrified sections are described below briefly :-

1. Train Control/Section Control :

This circuit is operated by the Section Controller and is used mainly for controlling train movements
within his jurisdiction. It has connections with Signal Cabins, ASMs Offices, Loco Sheds and Yard
Masters' Offices.

2.Dy. Control Telephone

This circuit is operated by the Deputy Controller and is used for directing traffic operations in
general. It has connections with the important Station Masters' offices, Yard Masters' Offices, Loco
Sheds and Signal Cabins.
INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1 (18)
3. Stock Control Telephone:
This circuit is operated by the Stock Controller and is mainly used for keeping a continuous watch
and to maintain control over the movements of wagons. It has connections with Yard Masters and
important Station Masters' offices.

4.Traction Loco Control :

This is a circuit provided for ac traction and is operated by the Traction Loco Controller who is
responsible for movements of electric locomotives and Electric Multiple Unit (EMU) stock. It has
connections with Electric Loco Sheds, EMU Sheds, important Station Masters, Yard Masters,
Divisional Officers such as Sr. DEE/DEE, AEE (RS), Sr DEE/DEE/AEE- (OP), Traffic Control
Offices, Traction Foreman and important crew booking points.

5.Traction Power Control:

This is a special circuit on ac traction and is used by TPC for all communications in connection with
power supply, switching operations and permit-to-work'. It has connections with Station Masters'
offices, cabins, Traction sub- stations, feeding posts, sectioning and sub-sectioning posts, traction
maintenance depots, important Signal Cabins, Divisional Officers such as Sr. DEE (TrD), Sr.
DEE/OP and Traffic Control Offices.

6. Emergency Control Circuit

This circuit is provided to facilitate the traction maintenance gangs and electric train crew to get in
touch with TPC with the least possible delay in emergencies. It is also used by train crew in times of
accidents for communication with the Control Office. This circuit is operated by TPC and is located
in the RCC.

Emergency telephone socket boxes are provided along the track at an interval of 0.75 to 1 km and
also near the signal cabins, sub-sectioning and sectioning posts, insulated overlaps and feeding
posts etc. Portable emergency telephones are given to maintenance gangs, train crew and Station
Masters. By plugging the portable telephone into an emergency socket it is possible to communicate
with the TPC.

7. Hot Line Communication:

Hot line communication circuit should be provided between the HQ, divisional HQ traction loco
controller and electric loco sheds. These would be provided in the HQ with CEE, CEE/Loco, Dy.
CEE/RS, Sr. DEE/RS in the sheds and Sr. DEE/OP in the divisions.

8. Walkie Talkie sets

Every maintenance depot of OHE should have adequate numbers of walkie-talkie sets to be
available with them during their normal maintenance work as well as break-downs so that not only
effective communication is available at site but also to increase the efficiency and productivity of the
work during power blocks. These walkie-talkie sets are to be used primarily for the following
purposes:

a) To communicate to the maintenance/breakdown gangs/parties that power block has been

sanctioned;

b) To direct and supervise work during the period power block is in force;

c) Confirmation regarding cancellation of power block by each individual party and cancellation of
power block.

9. Other Communication Facilities:

An independent inter-communication 'circuit is also provided between the various Section
Controllers and the Chief Controller for local communication between themselves. Facilities are also
provided for the Chief Controller

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I (19)

to talk to any station on train control, deputy control, stock control and traction loco control circuits.
Similarly, facilities are provided to TPC to talk to any station on the train control and traction loco
control in an emergency. However, it will not be possible for the Chief Controller or TPC to ring
independently any station on any control circuit as this ringing facility is only provided to the
respective Controllers.

IV OVERHEAD EQUIPMENT

10214 Catenary and Contact wire

1. The overhead equipment above the tracks comprises of the following:-

a) A standard cadmium copper wire of about 65 mm2 section or standard aluminium alloy wire of
about 116 mm 2 section for catenary.

b) A grooved hard drawn copper contact wire of 107 mm 2 cross-section (when new) supported
from the catenary by means of droppers of 5 mm diameter spaced not more than 9 m apart.

2. The catenary and contact wire together have an equivalent copper section of 157 mm 2. The
current normally permissible on a single track is 600 A approximately, because of equivalent
cross-sectional area of OHE. This current limit is based on the temperature limit of 850 C in
contact wire. Certain sections in Waltair-Kirandul section have the catenary and contact wires
together having an equivalent copper section of 200 mm 2.

3. For loop lines, sidings, yards and spur lines excluding the main running lines and first loop or
lines taking off from main running line, tramway type OHE having only grooved hard drawn
copper contact wire of 107 mm2 section is provided.

10215 Height of Contact wire

The normal height of contact wire for regulated OHE is 5.60 m (with 10 cm presag for 72 m span)
above rail level. For unregulated OHE in areas with a temperature range of 40 C to 65 0 C, this
figure is 5.75 m and in areas with a temperature range of 15 0 C to 650 C, it is 5.65 m. In certain
cases, such as under over-line structures, the height may be as low as 4.65 m on BG and 4.02 m on
MG. For passing oversize consignments on such lines, special precautions have to be taken.

10216 Span of Supporting Mast/Structures

The span normally used for supporting the OHE from masts/structures using the cantilever type
bracket assembly varies from maximum 72 m on straight track to 27 m on curved track, the spans
depending upon the degree of curvature. The catenary system is normally supported on straight
tracks at maximum intervals of 72 m ( 63 m on MG) by cantilever type arms fixed to galvanized
broad flange or I section steel masts or fabricated steel structures. On curves the catenary is
supported at closer intervals, the spans adopted depending upon the degree of curvature.

10217 Stagger
The contact wire is staggered so that as the pantograph glides along, the contact wire sweeps
across the current collecting strips of the pantograph upto a distance of 200 mm on either side of
the centre line on straight runs and 300 mm on one side on curves. This ensures a uniform wear of
the current collecting strips of the pantographs.
10218 Overlaps
The OHE conductors are terminated at intervals of about 1.5 Km with an overlap generally as
shown in Fig. 2.02, the conductor height being so adjusted that the pantograph glides from one
conductor to the other smoothly.
There are two types of overlap spans as under :-
a) Uninsulated overlap spans where the distance of separation between two contact wires is 200
mm and
INDIAN RAILWAYS AC TRACTION MANUAL-VOLUME I [20]
the two conductors are permanently connected together electrically by suitable jumpers.
b) Insulated overlaps, where the two OHE systems are kept apart at a distance of 500 mm.
Normally the electrical discontinuity at insulated overlaps is bridged by interrupters or isolator
except at neutral sections.
10219 Regulated and Unregulated OHE
OHE with automatic tensioning called 'regulated OHE' is generally provided for all main lines, but for
large isolated yard and unimportant lines, automatic tensioning is dispensed with in the interest of
economy and only unregulated OHE is used.
10220 Section Insulator Assembly
Section insulators are provided to insulate the OHE of one elementary section from the OHE of the
adjacent elementary section such as at cross-overs.
When the pantograph of a locomotive passes from one track to another along a cross-
over/turnout, current collection changes from one OHE to other and therefore the runners of the
section insulators overlap with contact wire so that there is no arcing.
On double line sections with runners trailing, the section insulator assembly using porcelain insulators
are fit for speeds upto 120 km/h provided it is installed between the first one-tenth and one - third of
the span. In case the runners of the section insulator assembly are in the facing direction cr it is not
installed within the first one third of the span, the speed should be restricted to 80 km/h.
10221 Mechanical Independence of OHE Track - Structures
By providing independent structures for supporting the OHE of each track, complete mechanical
independence of each OHE is secured. Any irregularity or damage or maladjustment of the OHE of
one track will not, therefore, affect the performance of the other.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1 [21]

10222 Flexible Head-Span and Rigid Portals.

In large yards, where difficulty is experienced in locating individual supporting structures between
the tracks, a cross catenary wire system called flexible head-span is provided to maintain two or
more catenaries and their contact wires at the appropriate heights and locations. Where the OHE
has to be regulated, rigid portal structures are used.

10223 Maximum Speed

The OHE with maximum span of 72 m and with presag of that span of 10 mm and with tension of
1000 kgf in contact and catenary wire is designed for a speed potential of up to 160 km/h. The
existing system is generally fit for 140 km/h with AM-12 pantographs now in use on ac locomotives.

V. SPECIAL WARNING SIGNALS

10224 Signal Marking the end of Catenary

Certain loops and sidings at a station may not be wired. An electric locomotive should not be taken
into an unwired track as its pantographs and the OHE may get damaged and it will require a diesel
or steam engine to pull the electric locomotive out of the unwired track. Caution boards as per Fig.
2.03 are provided for warning the Drivers of the unwired tracks taking off from wired tracks. In
addition special indication boards are provided where the OHE ends on a track. Point levers
controlling the movement of trains from the wired track to the unwired track are fitted with warning
tablets (Boards) as per Fig. 2.04 painted yellow, to warn the cabinman not to admit electric
locomotives on the unwired track.

10225 Warning Signals for Neutral Sections

To indicate to the Driver that he is approaching a neutral section and should be in readiness to open
DJ, two warning boards as per Figs. 2.07 & 2.08 are fixed 500 m and 250 m ahead of the neutral
section. The point where DJ is to be opened is indicated by a signal shown in Fig. 2. 05. Indication
that the neutral section has been passed and DJ may be switched on again is given by another
signal shown in Fig.2.06.

10226 Temporary Signals

Occasionally it becomes necessary to lower the pantograph on certain sections when OHE is not
properly adjusted so as to avoid damage to the pantographs. In such cases temporary warning
boards as shown in Fig. 2.09 are placed ahead of the section, facing the direction from which
locomotives normally approach for this purpose. On reaching such a warning board, the Driver shall
open DJ and lower pantograph/s of his electric locomotive/s. He may raise the pantographs after
passing the section and reaching the signal provided for the purpose as per Fig. 2. 10.

After a break-down on OHE normally only temporary repairs permitting electric locomotives to pass
with their pantographs lowered are carried out in attending to break-downs, so that the traffic may
not be dislocated unduly. Permanent repairs are done as soon as possible thereafter by taking a
prearranged block in consultation with the Operating Department.

10227 Special features of Traction Installations in Waltair - Kirandul section of S. E. Railway

Waltair -Kirandul section of South Eastern Railway is about 471 km long , having large number of
tunnels and gradients as high as 1 in 60 and sharp curves of 8 degree . The configuration of traction
distribution system in the section is as under: -

i) OHE- About 329 km of the section has got 19/2.10 mm HDBC catenary and 150 mm2 contact
wire. The tension in catenary is 800 kgf while contact wire has got 1200 kgf tension.
INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1 (22)
CHAPTER III
GENERAL DESCRIPTION OF ELECTRIC ROLLING STOCK

10300 Classification of Electric Rolling Stock

Locomotives and Multiple Unit stocks are classified by means of a three/four letter code followed by
a number to indicate the individual class and a series of the same.

The code letters used for ac locos and EMUs are given below :

The first letter denotes the Gauge: 'W' for BG and 'Y' for MG.

The second (middle) letters 'A' denotes the system of power supply for which it is suitable - A for ac
& C for dc, CA for dc & ac.

The third letter for locos indicates the class of service -

'M' for Mixed traffic locos suitable for both passenger and freight services,

'G' for Freight (Goods) service locos,

'P' for Passenger services locos, and

'S' for Shunting locos.

Multiple Unit Stock is denoted by the letter 'U'

The various classes of ac locos and EMUs at present in service on Indian Railway are as under:-

a) ac Locos- WAG1, WAG2, WAG3, WAG4, WAG5, WAG6, WAG7, WAP1, WAP2, WAP3,
WAM1, WAM2, WAM3,WAM4, YAM1.

b) ac/dc Locos- WCAM1.

c) ac EMUs- WAU1, WAU2, WAU3, WAU4, YAU.

In addition two types of BG dc EMUs converted for ac working are in use on the Eastern Railway.

Salient particulars of each type of ac and ac/dc electric locomotive are given in Table No. 3.01 &
3.02.

A set of plates containing coloured photographs of each type of ac/dc Electric Locomotives along
with salient features are annexed with this chapter as a pull-out.

Salient particulars of each type of ac EMU are given in Table No. 3.03.

A set of plates containing coloured photographs of each type of ac EMUs alongwith salient features
are attached with this chapter as a pull-out.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME (25)

10301 Important Equipment of Electric Loco/ EMU

1 Pantograph

1.1 For collecting power from 25 kV ac contact wire pantographs are mounted on the roof of the
traction vehicles. AM12 pantograph of Faively design has been adopted by Indian Railways for 25
kV ac electric locomotives and EMUs. These pantographs are provided with steel strips for current
collection. The raising and lowering of the pantograph is by means of a pneumatically operated
servo motor. This pantograph is a single pan design having two o-springs mounted on it. For
keeping the pantograph in the lowered condition, main springs have been used. The suspension of
pan is on plungers.

This pantograph is suitable for operation upto 140 km/h. For increasing the speed potential,
improved pantograph with lower dynamic mass and independent pan heads have been used.
Further, in order to improve the life of the contact wire, use of carbon strips has also been tried. Use
of carbon strips for current collection has already been adopted in European countries.

1.2 Use of carbon strips necessitates change in the design of the pantograph .The pan head which
is more or less rigid in case of steel strip pantograph needs to be made more flexible in the vertical,
horizontal and transverse movement for carbon strip pantographs. This is achieved by improved
suspension of the pan head. The speed potential of such a pantograph is of the order of 250 km/h.

The pantograph of this design have been imported from M/s Stemman, West Germany for WAG6A,
from M/s SMC, Australia and M/s ETK, Austria for WAP1 and WAP3 locomotives.

2. Circuit Breaker

2.1 Since Inception of 25 kV ac traction system, Air Blast Circuit Breakers manufactured by M/s
Brown Boveri-Corporation were used on electric locomotives as well as on EMUs, and are still in
use for about 30 years. These breakers are designed for isolation of power to the traction vehicle in
the event of faults. The Air Blast Circuit Breaker needs great amount of maintenance due to inherent
features like large number of parts (735 nos.), complex control block and extinguishing of arc during
breaking of current in air. The life of the main contact on this account is also limited. This breaker
also requires substantial amount of dry air for each switching operation.

2.2 Vacuum Circuit Breakers were introduced on electric locomotives on Indian Rlys. in the year
1985. The VCB is a simplified design with fewer number of parts (260 Nos.), have a simplified
control block and self - contained interrupting medium, that is vacuum. Due to these features, the
life of the main contact achievable is as high as 1 lakh electrical operations as against 20,000
operations for air blast circuit breakers. As a result, the periodicity of replacement of main contact is
second POH for VCB and IOH for Air Blast Circuit Breakers. Besides, these factors, VCB also offers
the advantages of reduced size, reduced weight and reduced maintenance cost as compared to
these for air blast circuit breakers. The total trip-time for VCB is less than 60 milli-seconds while the
same is of the order of 100 milli-seconds for air blast circuit breakers. The air blast circuit breaker is
only capable of breaking the fault current with breaking capacity of 250 MVA. The VCB, besides
having breaking capacity is also designed for making capacity of the same rating, i.e. 250 MVA and
can handle the same level of fault current during closing also. .

These circuit breakers (VCBs) were initially imported from M/s. GEC, U.K. and are presently being
manufactured indigenously by GEC, Allahabad. The use of these breakers has been extended to
EMUs also.

3. Transformer

3.1 Power to the traction vehicles is available at 25 kV ac single phase from the contact wire. In
order to step down the voltage as well as to control the same for feeding to the traction motors, the
traction power transformers are provided on the traction vehicles.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME I (26)

1.2 These transformers generally have a primary winding , a regulating winding, traction secondary
windings and auxiliary windings. The regulating winding is designed for choosing appropriate
voltage for the traction motors. The auxiliary winding is required for feeding the auxiliary motors
on the locomotive.

3.3 In order to increase the h.p. Of the locomotives, the traction transformers have been uprated
from time to time keeping the overall dimensions unchanged on account of space constraint. The
upratings have been achieved by using increased copper section of the conductor used, improved
insulation scheme and in certain cases adoption of aluminium foil wound construction for minimising
the losses.

3.4 The original imported transformer used in WAGI locomotives had a capacity of 3000 kVA which
was increased to 3460 kVA for WAG4, 3900 kVA for WAG-5/WAP1 and has been now further
increased to 5400kVA for WAG-7 locomotives.

3.5 With the introduction of thyristorised convertors, the design of the traction transformer has
undergone simplification with the deletion of regulating winding. The transformer for thyristorised
convertor becomes a two limb construction and traction secondary winding split into 4 windings for
two step sequence control.

3.6 The traction transformer necessarily has to have forced oil circulation and forced air cooling. For
this purose oil pump, oil cooler and blower form an integral part of the traction transformer.

4. Tap Changer

4.1 On load tap changer Type No. 32 of M/s. Brown - Boveri Corporation has been used on most of
the 25 kV ac electric locomotives. This type of Tap changer is provided on 25 kV (HT) regulating
winding of locomotive transformer for controlling the voltage input to main transformer. The Tap
Changer operates with the help of elaborate mechanism using an air driven Servo Motor (SMGR)
and a bevel gear arrangement. Through precision adjustment and provision of transition resistance
(RGR) it is ensured that there is no break of load current in-side the selector (GR) which is oil filled
and the load current is broken by load switches known as CGR1, CGR2 and CGR3.

4.2 The on load tap changer presently used on electric locomotives for speed control requires great
deal of maintenance on account of its inherent design and construction. Problems of flash over
inside the selector and breakage of various components in SMGR and other sub-assemblies are
some factors affecting to reliability of the locomotives. The development of thyristor convertors for
controlling the voltage input to traction motors was therefore undertaken for replacing the existing
tap changer and silicon diode rectifier unit.

4.3 The thyristor convertors for electric locomotives offer the advantage of maintenance reduction,
smooth control of speed thereby improving the adhesion and permitting the realisation of higher
tractive effort. Thyristorisation of locomotives type WAG1, WAM1, WAM2 and WAM3 is being
indigenously done for realising the above benefits.
5. Traction Motor

5.1 In case of traction motor great emphasis is being given on improving power to weight ratio,
keeping in view the limited space available on locomotive for mounting the same. There is
continuous effort to improve the performance of traction motor by making them lighter/compact, at
the same time more reliable. Indian Railways have been adopting the latest technology available for
design and manufacture of traction motor. Over a period of years the traction motors have become
now 2.5 times lighter specially for EMU application.

5.2 Improvements in the basic design of traction motor has become possible due to availability of
new insulating materials with high thermal margins. Over the years not only new and superior
materials have been developed but even the basic concepts have undergone radical changes. The
method of classi-
INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME I (27)
fication of insulating material has also been changed and classification of material, as. generic type
or chemical identity is not considered justified. With a view to classify the new insulating material
correctly additional classifications are added.

5.3 Instead of dealing with individual insulating material, the specification now covers the
combination and system as a whole. The new feature is added because of thermal endurance of the
system which may not be directly related with thermal capability of individual materials.

5.4 The procedure for functional evaluation of insulation system also has been laid-down as per IEC
505 to evaluate the typical service life under functional test and the influence of thermal, electrical,
mechanical and environmental stresses.

6. Arno Convertor

6.1 Arno Convertor is a special duty machine for conversion of single phase in-coming supply into 3
phase out- put supply. 3 phase supply is essentially required on most of the electrical locomotives
for driving certain auxiliary equipment like blowers and compressors. The function of Arno Convertor
is to supply 3 phase power required for these auxiliaries.

6.2 Arno Convertor of ACEC make initially imported for WAM-1/WAG-1/ WAG4 were of horizontal
construction. Indigenously developed Arno Convertor however is of vertical construction. The
machine has mechanical construction suitable to withstand the severe vibrations encountered on
locomotives. There was a provision on its top for mounting battery charger generator which has
been eliminated in present Arno Convertors.

6.3 The performance of indigenously manufactured Arno was not up to the level of the performance
of ACEC make Arno convertor, however, certain improvements like class 'F' insulation scheme,
integral epoxy moulded terminal box and revised bearing scheme has led to significant
improvements in reliability and performance of these Arno Convertors.

6.4 As the Arno Convertor offers an inherent voltage unbalanced Indian Railways are making an
effort to develop suitable static convertor for taking its place. Static convertors are already available
in imported WAG6A locomotive.

7. Motor Compressor Set

7.1 There are few locomotives equipped with imported compressor motor set from M/s. Oerlikon.
Initially CLW had used motor compressor set developed and manufactured by M/s. Kirloskar
Pnuematic Co. however, M/s. Elgi Equipment Ltd. have developed these motor compressors for
electric locomotives and the same are being used for the last so many years by CLW. Efforts are
being made by CLW vigorously for development of more sources for supply of compressors. The
driving motor for the compressors have been developed indigenously by reputed motor
manufacturer namely M/s. Siemens, M/s. NGEF ,M/s. ABB & M/s. Crompton Greaves Ltd.

7.2. Indigenously manufactured Air Compressor is a vertical cylinder air cooled machine. The
compressor is directly driven through an extended crank shaft by an integral direct current motor or
alternatively through a flexible coupling by 3 phase induction motor. The compressor is designed to
supply compressed air to the associated equipment on 50% duty cycle in normal circumstances. It
can be allowed to run continuously without causing any damage or undue wear.

7.3 The driving motor is high torque 3 phase induction motor designed for direct on line starting.
The earlier motor manufacture and supply were provided with class 'B' insulation scheme. The
flexible complete assembly also incorporate the cooling fan for the compressor. With a view to
improve the reliability of 3 phase induction motor certain basic design changes like 'F' insulation,
use of double glass cover conductor winding wire Vacuum pressure impregnation, use of
solventless varnish were adopted. The reliability of the auxiliary motors have improved considerably
due to these steps.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME I (28)

TABLE NO. 3.01

Salient Data of Mixed/Passenger Electric Locomotives

SN. Type of Type of Guage Axle Weight Brake Max. Max. Horse Holding
Loco Traction Load Total system T.E. Speed Power as on
Max.
1.4.94

MM (t) (t) (t) (KM/H) (HP)

1. WAM-1 25 KV ac 1676 18.64 76 Air 25.00 100 2800

89

2. WAM-2 25 KV ac 1676 19.00 76 Air 25.24 100 2790

31

3. WAM-3 25KV ac 1676 19.00 76 Air 25.24 100 3640

2

4. WAM-4 25 KV ac 1676 18.80 112.8 Air Rheo 33.84 120 3640

484

5. WAP-1 25 KV ac 1676 18.05 108.3 Air 32.49 130

3800

6. WAP-2 25 KV ac 1676 19.00 76.0 Air 25.24 110 2790

54

7. WAP-3 25 KV ac 1676 18.05 108.3 Air 32.49 140 3800

8. WCAM- 1 25 KV a c 1676 18.80 112.8 Air ac 33.84 110 ac-

3640
dc 23.20 dc-
2930 52

9. YAM-2 25 KV ac 1000 13.00 82 Air 19.50 80

1630 20

732

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME1 [29]

TABLE NO. 3.02

Salient Data of Goods Electric Locomotives

SN. Type of Type of Guage Axle Weight Brake

Max. Max. Horse Holding
Loco Traction Load Total system T.E.
Speed Power as on
Max.
1.4.94

MM (t) (t) (t) (KM/H)

(HP)

1. WAG-1 25 KV ac 1676 21.30 85.2 Air 30 80

2900 103
Reg
2. WAG-2 25 KV ac 1676 21.30 85.2 Air
51.5 80 3180 39
Rheo
3. WAG-3 25KV ac 1676 21.83 87.32 Air 50 80
3150 10
Reg
4. WAG-4 25 KV ac 1676 21.90 87.6 Air 30 80
3150 163
Reg
5. WAG-5 25 KV ac 1676 19.80 118.8 Air
33.5 80 3850 972
Reg
6. WAG-6A 25 KV ac 1676 20.50 123.0 Air 46 100
6280 6
Rheo
7. WAG-6B 25 KV ac 1676 20.50 123.0 Air 45 100
6040 6 Rheo
8. WAG-6C 25 KV a c 1676 20.50 123.0 Air 45 100
6040 6
Rheo

9. WAG -7 25 KV ac 1676 20.50 123.0 Air 42 100

5000 18
Rheo (designed)

1323

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME I [30]

 CHAPTER IV

SAFETY PRECAUTIONS ON ELECTRIFIED SECTIONS

Para Subject

10400 Induction Effect of 25 kV ac 50 Hz Single Phase Traction

I. WORKING OF STEAM AND DIESEL LOCOMOTIVES IN ELECTRIFIED SECTIONS

10401 Prevention of Smoke Pollution

10402 Standing on Boiler Shell or Tender
10403 Working the Fire Spraying. Advancing of Fuel and Handling of Tools.
10404 Loading of Fuel
10405 Watering of Steam Locomotives
10406 Crane Working
10407 Decorative Fittings
10408 Engines Owned by Outside Parties

II. WATERING OF CARRIAGES IN ELECTRIFIED SECTIONS

10409 Watering Arrangements - Basic Precautions

10410 Watering Section
10411 Controlling Switches
10412 Sequence of Interlocking and Operation
10413 Persons Authorised to Open Interruptors and Isolator Switches
10414 Custody of Keys
10415 Watering of Carriages
10416 Restoration of Supply
10417 Key Register
10418 Loss of Key

HI. LOADING AND UNLOADING OF PETROLEUM PRODUCTS

10419 Precautions to be Observed

IV. RULES APPLICABLE TO PERMANENT WAY STAFF

10420 General
10421 Need for Precautions
10422 General Precautions
10423 Continuity of Track
10424 Permanent Way Tools
10425 Track-Circuited Rails
10426 Care in Handling Pipes etc.
10427 Steel Measuring Tapes not to be Used
10428 Traction Structure Foundations

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1 (32)

 V. RULES FOR S&T INSTALLATIONS

10429 Effect of 25 kV ac, 50 Hz, Single Phase Traction on S&T Equipment

10430 Precaution in the Event of Breakage of Wires
10431 Works on Signal Posts and Fittings
10432 Precautions Against build up of Potential due to Return Current in Rails
10433 Precaution Against Induction Potential in Metallic Bodies
10434
VI. OVER-DIMENSIONED CONSIGNMENTS

10434 Definition of Over-Dimensioned Consignment (ODC)

10435 Classification of ODCs
10436 Precautions for Movement of ODCs In 25 W ac Electrified Sections
10437 Power Blocks for Movement of ODC.
10438
VII. OTHER PRECAUTIONS

10438 Movement of Rubber Tyred Vehicles on Railway Wagons

10439 Hoarding Boards

VIII. COMPETENCY CERTIFICATE

10440 Competency Certificate and Course for Assistant Station Masters/Guards of EMUs

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUME (33)

 CHAPTER IV
SAFETY PRECAUTIONS ON ELECTRIFIED SECTIONS
10400 Induction Effects of 25 kV ac 50 Hz Single Phase Traction

1. The attention of all railway staff is drawn to the fact that under 25 kV ac 50 Hz single phase
traction, there is heavy induction on all metallic structures and conductors in the vicinity of the track.
The induction is two-fold:
a) Electro-static, which results from the high potential of 25 kV on the OHE system.
b) Electro-magnetic, which is proportional to the currents passing from the sub-station to the OHE
to the locomotives / EMUs and back partly through the track and partly through the earth.

2. Those who have been used to work on dc traction are liable to overlook taking adequate
precautions required to guard themselves against the dangerous inductive effects of 25 kV ac
system. Attention is therefore specially drawn to the need for taking adequate precautions.

3. The voltage induced is quite appreciable on overhead conductors running parallel to the tracks
depending ,on the length of parallelism. This explains why most of the overhead telecommunication
lines are replaced by underground cables. Special protective measures are required to reduce the
adverse effects of induction.

4. In a railway yard, voltage of the order of 200 volts may be induced on yard lighting mains situated
8 m away from the centre of a double-line track, if it runs parallel to the 25 kV lines for a distance of
about 270 m., it could be several thousand volts when parallelism is much longer. In such a case, a
dangerous voltage due to induction will exist even after power supply to the line has been switched
off. No one shall therefore attempt to work on any overhead line running alongside the electrified
tracks without taking special precautions of earthing on both sides of the work. Before a section is
electrified, the necessary modifications to distribution lines in all stations and yards should be
carried out, so as to limit the induced voltage within permissible values, but this by no means
obviates the need of earthing the lines on both the sides of the working party. Earthing should be
done individually by each working party as close to the work-spot as possible. The distance
between the two earths shall not exceed 1 km.

5. Such inductive effects occur on large metallic structures such as fencings, structural steelwork of
platforms running parallel to the track. They will therefore have to be earthed suitably to afford
safety.

6. Inductive effects also show themselves on any metallic conductor, such as metallic clothes-lines,
powerlines and lines belonging to private parties running parallel and close to the electrified tracks.
Wide publicity should be given to the effects of induction so that special precautions are taken by
the private parties.

I. WORKING OF STEAM AND DIESEL LOCOMOTIVES IN ELECTRIFIED SECTIONS

10401 Prevention of Smoke Pollution

Pollution of OHE insulators due to smoke on account of operation of steam locomotives causes
appreciable operating and maintenance difficulties. To reduce pollution to the minimum, the
following precautions shall be taken :
1. No steam locomotive should be left standing with the chimney under an OHE insulator. Stabling
of steam locomotives with chimneys under traction structure is prohibited.

2. Continuous blowing of safety valves, sudden opening of blower and priming through exhaust
steam should be avoided as they cause flashover of insulators resulting in severe consequences.
Sudden starting of a steam engine shall also be avoided as it may cause slipping of wheels which
would result in priming through exhaust steam, which in turn may cause flashover.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME (34)

10402 Standing on Boiler Shell or Tender

Staff are warned of the danger of standing on the boiler shell or tender when stabled under live OHE
as it may result in electrocution.

10403 Working the Fire-Spraying, Advancing of Fuel and Handling of Tools

1. Special care must be taken while firing coal or raking fire to ensure that the TOOLS DO NOT
GET WITHIN THE DANGER ZONE of the OHE.. Spraying of coal with water under electric
overhead lines is forbidden.

2. The firing tools must be handled with great care, and special care should be taken to see that
THESE TOOLS ARE NEVER LIFTED OR RAISED TOWARDS THE OHE. Tools must always be
placed in their respective positions after use.

3. A jet from a hose should never be directed towards the OHE. The jet of water should only be
directed horizontally far away from the live OHE and not vertically.

10404 Loading of Fuel

1. The loading of coal or fuelling of the locos shall only be carried out in yards outside the Electrified
zones.

2. The height of the coal in the tender must not be more than 4.28 m above the rail level on BG and
3.65 m above rail level on MG.

10405 Watering of Steam Locomotives

Whatever may be the height of the contact wire, NO ONE SHOULD CLIMB ON THE TENDER to
open the cover of the water tank or to insert the funnel of the water column. Water columns have
been suitably modified for operation from ground level. Only the operating rods provided should be
used for this purpose.

10406 Crane Working

No crane shall be worked on or near traction overhead equipment unless an authorised

representative of the OHE section is present. When so working, care shall be taken to avoid hitting
or damaging OHE structures.

10407 Decorative Fittings

No decorative or extension pieces be attached to the chimney of a steam locomotive that would
raise its effective height.

10408 Engines Owned by Outside Parties

The safety precautions mentioned above are equally applicable to locomotives owned by Steel
Works or other factories in the neighborhood of electrical sections that are likely to work in electrified
sidings for shunting or other purposes. The special safety rules to be observed in electrified sections
should be advised by Sr. DEE (TrD) to parties owning such locos and their written assurance
obtained that their operating staff have been made familiar with these rules.
II. WATERING OF CARRIAGES IN ELECTRIFIED SECTIONS
10409 Watering Arrangements - Basic Precautions

With electrification, 'side filling' arrangements for coaches have been introduced Asia long term
measure, in lieu of overhead filling arrangements which necessitate shut down of power for watering
and other precautions. Since all carriages have not yet been provided with side filling arrangement,
special arrangements have been made for
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME (35)
Overhead watering of carriages in some electrified stations. The following precautions must be
observed in such interim arrangements:

1. If the carriages are standing on lines having overhead traction wires, nobody shall get on to the
roofs of the carriages unless the overhead traction wires above are made dead and earthed.

2. Staff getting on to the roofs of the carriages for watering, after the overhead traction wires above
such carriages are made dead, should be warned against carrying long poles or any other articles
which may come within the danger zone, that is within 2 m of the live traction wires on the adjoining
lines. They should also be warned about the risk of extending the water hoses or any part of their
body or directing water jets within the danger zone i.e. Within 2 m of live overhead traction wires.

10410 Watering Section

1. For the purpose of isolation and earthing the OHE, wires above the watering arrangements for
each platform will form a separate elementary section i.e. different platforms will have different
watering sections. This is to ensure that isolation of each platform can be done independently. The
limits of each watering section shall be marked by danger limit board (Fig. 4. 0 1) hanging from the
catenary at either end. These constitute the limits within which, alone watering of the carriages may
be done. In Fig. 4.02 CD is the watering section.

Separate interruptors or isolators shall be provided for controlling supply to each watering section.
Keys for such interruptors/isolators shall be provided with metal tags on which the numbers of the
interruptors/isolators are punched.

2. A neutral section about 12 m long bounded by section insulators is provided at -, either end of
each watering section. The purpose of the neutral section is to afford additional protection to the
watering section against approach of any electric locomotive or any other type of "feeding in" from
the live sections on either end. In Fig. 4.02, BC and DE are the neutral sections.

10411 Controlling Switches

1 . 'L' is the locally operated interruptor/isolator at the end of the platform in a separate enclosure.
The Key for the enclosure is with the ASM on duty.

2. S 1 and S 2 are manually operated isolators - one at each end of the watering section, the
purpose being to switch off power from the respective small neutral sections and to earth the two
ends of the watering section. For this purpose the two isolators are provided with earthing heels.

3. Elernentary sections AB and EF are normally live.

4. A feeder line for maintaining continuity (shown dotted in Fig 4.02) is carried on the OHE structure
having supermasts.

10412 Sequence of Interlocking and Operation

The following are the interlocking arrangements and the sequence of operations:-

1. The enclosure to interruptor/isolator 'L' is locked and its key is with the ASM on duty. When
required, the ASM issues it to the lineman, only against a receipt on the register kept for the
purpose.

2. If an interruptor is provided, on its frame is mounted the opening key which is accessible only
after the enclosure to the interruptor is opened. This ensures that no one can open the interruptor,
without taking the key of the lock of the enclosure from the ASM. The tripping key is normally back
locked in the lock on the interruptor frame. It can be extracted from the lock only after the interruptor
is opened to switch off supply to the watering section. Similarly, when an isolator is provided it can
be opened only by the linesman on receipt
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME 1 (36)
BRASS BADGES FOR AUTHORISED PERSONS FIG. 4.03

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME (37)

of its key from the ASM on duty. For opening the (main) isolator 'L' the additional precautions detailed in the
Chapter VI of Vol. 11 of this Manual shall be observed.

3. Each of the isolators 'S1' and 'S2' is provided with a double lock. The opening key extracted as above from
interruptor'L'when inserted in S1 and turned, releases the operating handle of S1. If the isolator S1 is now
opened or closed, a key K 1 (normally back-locked in the double lock on S 1) is released, simultaneously
locking the operating handle as well as the opening key. This ensures that once the key KI is in the hands of
the operator, the interruptor 'L'as well as isolator S1 cannot be operated. The key Kl as obtained now is known
as the isolator Interlocked key.

4. Key K1 is taken to the other end of the platform and inserted into the double lock of S2. This releases the
operating handle of S2 and if isolator S2 is now opened another key K2 normally back-locked in lock of S2 is
released. This key is handed over to the TXR in charge by the authorised person as an assurance that the
supply to the watering section is cut-off and made dead and earthed. Key K2 is known as the "permit-to-work"
key.

5. The details given above and in subsequent paras are mainly for watering sections controlled by
interruptors. The same principles however apply for watering sections controlled by manually operated
isolating switches, though the details vary somewhat between installations at different stations.

10413 Persons Authorised to Open Interruptors and Isolator Switches

No staff of rank lower than a linesman working under the Traction Foreman (OHE) is authorised to open or
close the interruptors or isolators controlling power supply to the overhead traction wires in the watering
section.,

A list of names of the authorized linesmen duly signed by the Traction Foreman (OHE) shall be exhibited
prominently in the office of the ASM and the TXR of the station concerned. Each such linesman should also
carry an identity card with photograph or specimen signature.

It will be the duty of the linesman concerned to report to the ASM on duty at least half an hour before the
scheduled arrival of a train. No linesman on duty shall leave his place of duty until he has been properly
relieved by his reliever and that too after his reliever has been introduced by him to the ASM on duty at the
time.

10414 Custody of Keys

1. The keys of the interruptor enclosures and isolators shall be inscribed with the distinguishing marks and
locked in glass-fronted Key box and kept in the personal custody of the ASM on duty. The keys should never
be kept in a bunch, but hung on individual pegs provided for each. The description of each key shall be
painted above each peg to avoid confusion.

2. When the watering section of a particular platform is required to be made dead and earthed for watering of
carriages, the ASM on duty shall give the key of the lock of the enclosure of the controlling lnterruptor/ isolator
of the platform to the linesman on duty and getting his acknowledgment in a "Key Register" to be provided for
the purpose at the station. This key shall be handed over immediately on arrival of the passenger train
concerned, if hauled by an electric loco. If, however, the train, the carriages of which are to be watered, is not
hauled by an electric locomotive, the key may be handed over to the linesman even prior to the arrival of the
train, in question so as to save time, provided the earlier isolation of the watering section does not interfere
with the movement of the other train. (It is to be understood that the handing over of the key of the interruptor
enclosure to the linesman amounts to the requisition for a power block).

3. The ASM shall ensure that no electric locomotive with raised pantograph is allowed to enter a watering
section till the watering linesman returns the key back to the ASM and signs in the Key Register.

10415 Watering of Carriages

On receipt of the "permit-to-work" key of the concerned watering section, the TXR-in-charge of watering shall
personally check that the key received by him bears the correct number and relates to the concerned.
INDIAN RAILWAYS AC TRACTION MANUAL \/OLUME 1 (38)
watering section on which the carriages to be watered are standing. The TXR-in-charge shall also
ensure that the train is standing within the limit of the watering section bounded by the danger limit
boards on the overhead traction wires. He will then arrange to fix yellow flags (or yellow lights by
night) on either end of the train high enough to be visible from the carriage roof. He will at the same
time hand over to each of his men who are to go up on the roof of the carriages, a number badge of
the legend and description shown in Fig. 4.03 as the authority to go on the carriage roof for the
watering.

Only the staff holding the badges mentioned above are authorised to go to the roof of the carriages
and water the same. The badges when not in use, shall be kept in the personal custody of the TXR-
in-charge of watering under lock and key. Any loss of the badge shall be notified immediately and
the badge cancelled.

The TXR shall ensure that his staff deputed for watering are conversant with the following
precautions:

1. Watering operation shall be confined to the limits specifically marked by "Danger Limit Boards"
hanging from the catenary wire of the OHE above the concerned watering section.

2. The hydrants shall not be opened till the other end of the hose pipe has been inserted in the
overhead tank of the carriage.

3. The hose pipes shall not be withdrawn from such overhead tank, till the hydrant has been closed.

Precautions 2 and 3 above are necessary to avoid accidental contact of a water jet with the live
overhead traction wires of the adjacent tracks.

Each platform adjoining the watering section shall have a small area marked with the legend
"Watering Gang". Each of the staff deputed for watering shall be instructed to assemble in this area
as soon as watering is completed or they are signalled to stop watering and get down from the roof
of the carriages.

On completion of the watering, the TXR-in-charge of watering shall collect the authority badges
given to his men and ensure that all the badges have been returned and there are no men on the
top of the carriages in the watering section. The TXR shall also ensure that no material has been left
on the carriage roof and that all the watering hoses have been brought down and the watering
hydrants closed.

10416 Restoration of Supply

On receipt of the permit-to-work key the linemen on duty shall proceed to restore supply as under:-

He shall insert the "permit-to-work key" in the double lock of the isolator switch S2 and turn the
same. This will release the isolator switch handle which shall then be operated to close the isolator.
After this operation the isolator interlock key shall be extracted from the double lock and taken to
isolator Sl and inserted in its double lock and turned. This will release the operating handle of
isolator S1 which shall then be closed, thus back-locking the Isolator interlock key. The interruptor
opening key may then be taken out and inserted in the key hole of the interruptor lock and turned
after which operation the interruptor should be closed. The interruptor enclosure shall then be
closed and locked and the key returned to the ASM on duty. The returning of the key to the ASM on
duty signifies that the power block has been cancelled. The linesman on duty returning the key shall
sign the Key Register entering the time at which the key is returned. The ASM on duty shall also
sign the register in acknowledgment of having got the key back.

On receipt of the key the ASM shall arrange to start the train.
INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME (39)
10417 Key Register

Each watering station shall have a key register for recording the interchange of keys between the
ASM on duty and the linesman. This key register will have the following columns:

1. Date

2. Description of the key

3. Watering Section No.

4. Train No.

5. Time made over

6. Signature of the linesman

7. Time returnd

8. Signature of the linesman

9. Brief reasons for delay if any.

10. Signature of ASM on duty.

Safety depends essentially on the proper exchange of the keys and correct record of the same. All
exchange of keys shall take place directly between the persons concerned and not through
messengers. The custody of any key shall be the responsibility of the person possessing the same
at the time.

10418 Loss of Key

In case of loss or damage to any key controlling the switching arrangements to the watering section,
the same should be reported at once to the TPC over phone and by XXR message addressed to the
Sr. DEE(TrD), Sr. DOM and Chief Controller of the Division. The Sr. DEE(TRD) shall make
immediate arrangements for the provision of a new locking system requiring a different set of keys.

During such period the TXR-in-charge of the watering shall personally be responsible for making
dead and earthing the overhead traction wires of the watering section concerned. He shall arrange
to lock the operating handles of the interruptor'L' and isolator switches S 1 and S2 by his own
padlocks, the keys of which shall be in his personal custody-till the watering is completed and the
brass badges authorizing his staff to go on the top of the carriages for watering are returned to him.

III. LOADING AND UNLOADING OF PETROLEUM PRODUCTS

II. 10419 Precautions to be Observed

In order to avoid any sparking during loading or unloading of petroleum products at the petroleum
siding, electrical continuity must be maintained between the earth systems of petroleum
installations, the track and electric overhead traction installation. The loading zone should be
insulated from the rest of the railway net work during loading and unloading operations. The
following precautions / arrangements would be necessary.

Arrangements
1. Provision of an equipotential link between the earth system of petroleum siding installations and
the track via a switch.
INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME I (40)
 2. Setting up of neutral zones (insulating joints) in the track to avoid any risk of propagating stray
current.

3. Setting up neutral zones/ sections in the contact and catenary wires similar to loco inspection
pits.

4. Provision of longitudinal bonds on both the rails as well as transverse bond ( 30 m intervals) on
the track. All masts and metallic structures in the vicinity of the track/siding should be provided
with structure bond.

5. Provision of 10 Ohm earths connected to the petroleum siding on each side at the insulated
joint.

Precautions
1. No oil tanker is permitted to stable under live OHE for inspection purpose.

2. Fueling to be done by side filling arrangements only.

3. Pipelines in the vicinity of the track should be properly earthed.

4. Minimum 2 m electrical clearance from live OHE of the adjacent track or any other equipment
nearby must be maintained.

5. During service operations, the continuity of track and the contact wire should be set up at the
same time the link between the track and petroleum facility should be opened.

6. The isolators at the neutral section of OHE should be kept open, OHE made dead and earthed.

IV RULES APPLICABLE TO PERMANENT WAY STAFF

10420 General

These instructions have already been included in the supplement to Part J of Chapter II of the
Indian Railways Permanent Way Manual.

These instructions lay down precautionary measures to be observed by railway personnel working
in the vicinity of the tracks equipped with 25 Kv ac OHE. These have already been included in the
supplement to Para J of Chapter II of the Indian Railway Permanent Way Manual which are
reproduced below:-

10421 Need for Precautions

Precautions are required to be taken on account of the following :
a) Proximity of a live conductor: The risk of direct contact with live OHE is ever present while
working in electrified sections such as for painting of steel work of through spans of bridges and
platform covered sheds.

b) Build up of potential due to return current in rails : The return current in the rails may cause a
potential difference.

g) between rail and the surrounding mass of earth;

ii) between the two ends of a fractured rail ;

iii) between the two rails at an insulated joint;

iv) between earth and any other metallic mass.
INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME1 [41]
 c) Building up of potential due to induction in metallic bodies situated close the OHE. It is important
to note that dangerous voltages may be inducted in metallic masses such as fencing posts in
the vicinity of traction conductors. To avoid possibility of shock due to such voltages the metallic
structures are bonded together and earthed.

10422 General Precautions.

The precautions laid down below must be followed under all circumstances in sections equipped for
25 Kv ac single phase, 50 Hz. Traction in addition to those referred to in Indian Railway Permanent
Way Manual.

1. No work shall be done above or within a distance of 2 m from the live OHE without a permit to
work
2. No part of tree shall be nearer than 4 m from the nearest live conductor. Any tree or branches
likely to fall on live conductor should be cut or trimmed periodically to maintain this clearance.
Cutting or trimming should be done by engineering staff in the presence of authorized staff of
the OHE section.
3. No fallen wire or wires shall be touched unless power is switched off and the wire or wires
suitably earthed. In case the wires drop at a level crossing, the Gate-keeper shall immediately
make arrangements to stop all road traffic and keep the public away.
4. As far as possible closed wagons shall be used for material trains. In case open or hopper
wagons are used, loading and unloading of such wagons in electrified tracks shall be done
under the supervision of an Engineering Official not below the rank of a Permanent Way Mistry
who shall personally ensure that no tool of any part of the body of the worker comes within the
danger zone i.e. within 2 m of the OHE.
5. Permanent way staff should keep clear of the tracks and avoid contact with the rails either when
approaching or reaching the work-spot when an electrically hauled train is within 250 m.
6. When unloading rails along side the tracks, it should be ensured that rails do not touch each
other to form a continuous metallic mass of length greater than 300 m.

10423 Continuity of Track

During maintenance or renewal of track, continuity of the rails serving electrified tracks shall
invariably be maintained. For bridging gaps which may be caused during removal of fish plates or
rails, temporarily metallic jumpers of approved design shall be provided as under :-

a. In case of a rail fracture, the two ends of the fractured rail shall be first temporarily connected by
a temporary metallic jumper of approved design (Fig. 4.04). In all cases of discontinuity of rails,
the two parts of the rail shall not be touched with bare hands. Gloves of approved quality shall
be used.
b. In the case of track renewals, temporary connections shall be made as shown in Fig. 4.05.
c. In the case of a defective or broken rail bond, a temporary connection shall be made as
mentioned in (a) above.
d. Before fish plates are loosened or removed, temporary connections shall be made as in (a)
above.

10424 Permanent Way Tools

Permanent Way tools alongwith the gloves shall be used in the manner as approved by the Chief
Engineer of the Railway.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I (42)

FIG 4.05

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME-I [43]

 10425 Track-Circuited Rails.

In track-circuited areas where the rail/s has/have insulated joints, such joints shall not be bridged
with bare hands or any metallic article. Similarly simultaneous contact with an insulated section of
rail/s and non-insulated section of rail/s of the same or other tracks shall be avoided.

10426 Care in Handling Pipes etc.

Use of rails as a foot path, a seat or for such other purposes is strictly prohibited. Particular care
shall be taken when carrying or handling long pipes, poles, overhanging on the shoulder or
otherwise to avoid all possibility of such objects and work pieces coming inadvertently in contact
with or within 2 m of live equipment.

10427 Steel Measuring Tapes not to be used.

In electrified tracks, steel tape or metallic tape or tape with woven metal reinforcement should
not be used.

10428 Traction Structure Foundation

1) The top of foundation block of track structures shall be kept clear of all materials and kept tidy.
2) While excavation the foundations not be exposed and there should be no risk of sinking of the
foundations.
V. RULES FOR S&T INSTALLATIONS

10429 Effect of 25 KV ac, 50 Hz, Single Phase Traction on S&T Equipment

1. Any circuit in the vicinity of 25kv ac OHE is influenced by electrostatic and electromagnetic
induction. The electrostatic induction is practically eliminated by transferring S&T circuits into
underground cables protected with metal sheath. The electromagnetic induction causes various
currents and voltages to develop in conductors parallel to the track. These include the rails,
traction return conductor where provided, cable sheath, any other conductors in the vicinity and
S&T circuits. The voltages that occur in the conductors appear a potential gradients. The value
of induced voltage depends on various factors such as:

a) Length of parallelism between the cable conductor and electrified track.

b) Soil conductivity.

c) Screening efficiency of cable sheath where existing.

d) Return current through the rails and return conductor where provided.

e) Mutual inductance between catenary and cable conductors.

f) Current in the OHE.

Appropriate precautions to overcome the effects of the induced voltages therefore have to be taken
by S&T department.

Other aspects in which S&T equipment is affected are:

i) OHE structures and fittings affect visibility of signals to some extent and may come in the
way of a signal;

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME1 [44]

ii) Restrictions come in the path of traction return currents on section provided with track
circuits.

2. Essential precautions to be taken while working on signalling and telecommunication

installations as described. Reference may also be made to Chapter XVII of the Indian Railways
Telecommunication Manual.

10430 Precautions in the Event of Breakage of Wires.

Should a catenary or contact wire snaps and falls on the running track, it is possible that the fault
current may damage signalling equipment. The following precautions shall, therefore, be taken.

1. The Section Controller on receipt of an advice of a break in traction overhead lines shall
immediately advise, by the quickest possible means, the signal maintenance and operating staff
of the section where the catenary/contact wires have broken.

2. If abnormal working of any equipment is noticed, its working shall be immediately suspended
and necessary action under the rules shall be taken.

3. On receipt of the intimation from the Section controller the staff responsible for the maintenance
of signaling of the section shall immediately proceed to the site and test all signaling circuits and
allied equipment paying particular attention to the outdoor signaling gear to check if any damage
has taken place. An authorized representative of the Signal Department shall submit a
certificate that everything is working all right and send it to his superiors along with a detailed
test report as soon as possible.

10431 Works on Signal Posts and Fittings.

1. No staff shall work on any portion of a signal post or its fittings falling within a distance of 2 m
from a 25 Kv live OHE or a metal part electrically connected to this OHE unless such portion is
protected with a metallic screen in accordance with approved instructions.

2. If for any reasons the protective metallic screen is not provided, the staff shall not undertaken
any work on those portions of the signal or its fittings falling within 2 m of 25 Kv live OHE,
unless power to the 25 Kv live OHE has been switched off and a permit to work has been
obtained. To draw the attention of the staff in such cases a red band 10 cm wide shall be
painted all around the signal post at a height of 3 m above the rail level.

3. The inspectors of the Signal Department and the Station Masters shall explain these instructions
to the staff working under them and ensure that they are correctly understood.

10432 Precautions against build up of Potential due to Return Current in Rails.

1. The flow of return current in the rails may cause a potential difference to build up between:

a) two rails at an insulated joint of the track circuit at an ordinary joint in case the fish plates are
broken.
b) two ends of a fractured rail;
c) an insulated rail and the rail used for the traction return current ; and
d) the rail and the surrounding mass of earth.

2. Whenever staff have to work on installations which are in direct contact with the rails, they shall :

a) use tools of the type approved for the purpose by the Chief Signal and Telecommunication
Engineer of the Railways ; and
b) observe the provisions of Chapter II of the Indian Railways Permanent Way Manual .
INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME1 [45]
10433 Precautions against Induction Potential in Metallic Bodies.

Voltage will be induced in signalling and telecommunication circuits when the length of the
parallelism to the track is appreciable, due to normal load currents or short circuit current in the
event of a fault on the traction system. Dangerous potentials may also develop in circuits with earth
connection if the earth connection gets broken for any reason. Consequently every time staff have
to work on signalling and telecommunication circuits along with 25 Kv ac electrified lines, they shall
take precautions to protect themselves and the equipment as prescribed by the S&T Department.

Some of the important precautions are however given below:

a) Rubber gloves and tools with insulated handles should be used.

b) When the work to be done is of such a nature that rubber gloves cannot be used, splitting of the
circuits into sections to reduce the length of parallelism and earthing them to drain out the
voltage should be adopted. Both the steps should be taken simultaneously. If these protective
measures cannot be applied, staff must get insulated from ground by using rubber mats or other
approved form of protection.

c) The line wires of the electric block instruments are likely to get heavy induced voltages and
every time the staff handles the line wire terminals of the block instruments, they must observe
the provisions of paras (a) and (b) above. Line wire terminals should be painted red to remind
the maintenance staff of the danger. The maintenance inspectors shall explain the meaning of
this painting to the maintenance staff and ensure that it is correctly understood by them.

d) Before cutting the armour or the lead sheath of a cable or the wires in the cable, an electrical
connection of low ohmic resistance should be established between the two parts of the armour
or the sheathing and the wires that are to be separated by cutting.
VI OVER-DIMENSIONED CONSIGNMENTS

10434 Definition of Over-Dimensioned Consignments (ODC)

When a consignment whose length, width and height are such that one or more of these infringe
Standard Moving Dimensions at any point during the run from start to destination, then the
consignment is called an Over-dimensioned consignment (ODC). It is also known as out-of -gauge
load.

If any consignment exceeds the following dimensions, it is to be treated as ODC or over

dimensioned consignment.

BG MG

a) Length 13716 mm 12192 mm

b) Height
i) at centres 2743 mm 2540 mm
ii) at corners 2134 mm 2134 mm

c) Width 2997 mm 2540 mm

d) Top width 610 mm 610 mm

INDIAN RAILWAYS-ACTRACTION MANUAL-VOLUME1 (46)

10435 Classification of ODCs

ODCs are classified as under:

A class ODC having clearance (i.e. clearance measured under stationary conditions) as 228.6 mm
and above from the fixed structures but infringes the standard moving dimensions.

B class ODC having gross clearance of 152.4 mm

C class ODC having clearance of less than 152.4 mm but more than 76.2 mm.

10436 Precautions for Movement of ODCs in25 Kv ac Electrified Sections.

The following precautions must be observed for transport of ODCs in the electrified sections:

1. Movement of ODC shall undertaken only after sanction of competent authority has been
obtained.

2. In all cases where ODC is to be moved, staff accompanying the ODC shall remember that the
OHE is live except when a power block has been obtained from the traction officials. Even
when a power block has been obtained, all lines other than those for which the power block has
been granted are to be treated as live at 25 Kv.

3. The following are the prescribed clearances from contact wire for the passage of ODCs through
electrified sections and the special restrictions required:

a) Special speed restriction is not required when the gross clearance is more than 390 mm.

b) Speed must be restricted to 15 km/h when the clearance is between 390 mm and 340 mm.

c) Speed must be restricted to 15 km/h and power to OHE must be switched off when the
clearance from the contact wire is less than 340 mm.

4. No consignment with less than 100-mm clearance from the overhead contact wire will be
permitted in a 25 KV electrified section.

5. A representative of the OHE section should accompany all ODCs having clearance as specified
in items 3(b) and 3(c) of item (3) above, to supervise safe movement of the ODC at locations
where clearance from the contact wire is critical.
6. A representative of the OHE section should also accompany ODCs having width more than
1981 mm for BG (and 1910 mm for MG) from centre line of track.
7. Section Controller and Traction Power Controller must coordinate while an ODC moves in
electrified section in order to ensure that OHE masts are not damaged at locations where the
clearance is critical.
8. A list of structures where the clearance are restricted in the electrified section and also the
clearance, available under the over-bridges should be with the Section Controller and TPCs.

9. To facilitate checking of clearance from the Contact wire for over-dimensioned consignments,
the Operating and Engineering branches at the Divisional and Headquarter level should have
with them up-to-date charts showing location of the minimum height of contact wire and
clearances of OHE structures in the electrified section. The Operating Department may permit
movement of ODCs on the basis of clearance checked with the help of the above mentioned
charts subject to the speed restrictions. However, when sanction of CRS is required to be
obtained for movement of any particular

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME1 [47]

 ODC, a specific reference should be made to CEE and a certificate obtained from him in the
following form.

Certified that the minimum height of contact wire on the section over which the consignment is to
move is not less than except at the following locations where restrictions are indicated below
should be observed:-

Section Location Height of Power ON Speed Restriction

Contact wire or OFF in km/h

1 2 3 4 5

10437 Power Blocks for Movement of ODC

When an ODC is permitted to be moved in an electrified section with the OHE power off, it will be
the responsibility of the Section Controller to arrange with the TPC for power to be cut off before
admitting the ODC into the section. An authorised representative of the Traction Distribution
Branch will obtain confirmation from TPC by message supported by private number that power has
been switched off and then issue a memo to the Guard of other traffic official in charge of the train to
the effect that power has been switched off over the specified section. Only on receipt of such
memo may the train carrying the ODC be allowed to enter the section.

Note: Since such a memo is not a permit to work, earthing of the OHE is not necessary.

VII. OTHER PRECAUTIONS

10438 Movement of Rubber Tyred Vehicles on Railway Wagons.

All metallic parts of rubber tyred vehicles which are transported on railway wagons through 25 KV
electrified areas, shall be earthed to avoid the effect of induction.

10439 Hoarding Boards.

Hoarding boards provided in the vicinity of electrified tracks should be located at a safe distance
from the track so that the event of their supporting structures being damaged during agitation or
storms it should not fall on the OHE or infringe the track. For this purpose, CCS and CPRO will
ensure that while granting approval for erection of hoardings boards, it must be ensured that not
only these are located at the safe distance from the track but also their structural arrangements are
properly secured.

VIII COMPETENCY CERTIFICATE

10440 Competency Certificate and Courses for Assistant Station Masters/Guards of EMUs.

All staff who are required to work in electrified territory must have undergone a course in Electric
traction so that they are made familiar with the working rules in the electrified sections. ASMs are
also sometimes required to operate isolators at the station premises for which necessary training is
to be imparted. Similarly, the guards of the EMUs are also required to undergo an operational
course for the working of EMUs and are to undergo a refresher course at regular intervals of 6
months at Electrical Training Schools. Operating department will ensure that only that staffs who
have undergone the course in Electric traction are posted in electrified areas.

INDIAN RAILWAYS-AC TRACTIO MANUAL-VOLUME 1 [48]

 CHAPTER V

ELECTRICAL ACCIDENTS

Para No. Subject

10500 Electrical Accident

10501 Electrical Accidents Action to be taken
10502 Observance of Rules
10503 Electrical Inspector to Railway
10504 Reporting of Accidents
10505 Accident Inquiries
10506 Accident Registers and Annual Returns
10507 First Aid

RESUSCITATION FROM ELECTRICAL SHOCK

10508 Instructions to be Displayed

10509 Removal from Contact
10510 Artificial Respiration
10511 Typical Electrical Accidents.

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME 1 [49]

 CHAPTER V

ELECTRICAL ACCIDENTS

10500 Electrical Accident

An electrical accident is caused directly or indirectly due to electrical causes, that is, it includes any
electric shock or electric burn, whether minor, major or fatal and whether suffered by railway
servants or others.

A person may suffer electric shock by coming in contact with :-

1. Live mains. LT or HT.

2. Overhead lines, which although made dead by isolation at both ends still develop high potentials
on account of electro-static or electro-meganetic induction due to parallelism with other high
voltage live lines, or due to lightning discharges during thunderstorms:

3. Parts which have become live due to leakage either because of low insulation resistance of the
electrical windings, high earth resistance of discontinuity of the earthing lead to the body:

4. Areas which develop a high potential gradient such as near an earth electrode through which a
fault current is flowing, and is insufficient to blow the fuse or cause the circuit breaker to trip.

In any well-maintained installation, no electrical accidents should occur. Every accident can, in the
final
Analysis, be traced to one or more of the following causes, if properly probed into:-

1. Disregard or non-observance of the prescribed rules laid down:

2. Ignorance of rules and insufficient training of staff:

3. Carelessness, casual and indifferent methods of working, including improper earthing indicating
inadequate supervision:

4. Faulty protective equipment and poor maintenance:

5. Over-confidence or sheer laziness:

6. Old habits of working on non-electrified lines:

7. Misunderstanding of instructions:

8. Inadvertence.

Every rule prescribed is the result of experience gathered over the years by several persons, and
owes its origin to some electrical accident or damage to equipment observed in the past. Rules and
procedures prescribed should therefore, be taken seriously, and never allowed to fall into discuss.
To enable a better appreciation of the need for meticulous observance of the safety rules
prescribed, brief particulars of several case histories have been presented in para 10511.
10501 Electrical Accidents Action to be taken

1. In the event of an electrical accident or the possibility of an accident, the senior most official
present at the site of the accident shall take the following preliminary precautions immediately:-
INDIAN RAILWAYS-AC TRACTION MANUAL VOLUME I [50]
a) If there is a breakdown of the overhead lines, he should arrange to cordon off the area, so that no one
else may get injured. He shall also warn Drivers of trains.

b) Arrange to cut off supply to the installation concerned by telephoning to the Traction Power Controller or
the nearest Electrical Department official, and simultaneously arrange for an Authorised person to the spot.
No one may attempt to rescue an electrocuted person untill power supply has been cut off.

b) Send for medical assistance. In the meanwhile, after the injured person, if any, has been separated from
the electrified lines, he shall arrange to render first aid; artificial respiration should be started immediately
if the patient is not breathing.

2. Immediately on arrival at site, the Authorised Electrical Department Official (Foreman/Chargeman), shall
first check and made sure that the steps mentioned have been correctly taken. After attending to the
injured and clearing the lines, he shall make a detailed note of all factors relating to the accident, preserve
evidence and record the statements of those who were near the accident spot. He shall also carry out a
preliminary investigation as to the possible cause of accident and get full particulars of the injury or
damage suffered and advise the Sr. Divisional Electrical Engineer of the details in writing.

The treatment laid down for resuscitation after electric shock shall be carried out immediately if applicable.
The treatment should be continued for at least two hours or more as there have been cases where patients,
although apparently dead, have regained consciousness.

3. All electrical accidents occurring within Railway premises shall be reported to the Electrical
Foreman/Chargeman in charge of the area and by him to the Sr. Divisional Electrical Engineer without
delay, however slight the injury may be and even though the injured man is capable of performing his
duties.

10502 Observance of Rules

All accidents arising out of the use of electricity within the railway premises are required not only to be dealt
with under the provisions of the Rules for Reporting Accidents of the Zonal Railway but also according to the
procedures under the Indian Electricity Act,. 1910, section 33 and Rule 44 A of I.E. Rules, 1967.

Section 33 of I.E. Act 1910 reads as under:

1. If any accident occurs in connection with the generation, transmission, supply or use of energy in or in
connection with any part of the electric supply lines or other works of any person and the accident results
or is likely to have resulted in loss of human or animal life or in any injury to a human being or an animal,
such person shall give notice of the occurrence and of any such loss or injury actually caused by the
accident, in such form and within such time as may be prescribed, to the Electrical Inspector and to such
other authorities as the appropriate Government may be general or special order, direct.

2. The appropriate Government may, if it things fit, require, any Electrical Inspector, or any other competent
person appointed by it on his behalf, to inquire and report:

a) as to the cause of any accident affecting the safety of the Public, which may have been occasioned by or
in connection with, the generation, transmission, supply or use of energy, or

b) as to the manner in, and extent to, which the provisions of this Act or any license or rules thereunder, so
far as those provisions affect the safety or any person, have been complied with.

3. Every Electrical Inspector or other person holding any inquiry under sub-section (2) shall have all the
powers of a Civil Court under the Code of Civil Procedure 1908, for the purpose of enforcing the
attendance of witnesses and compelling the production of documents and material objects; and every
person required by an Electrical Inspector or such other person as aforesaid to furnish any information
shall be deemed to be legally bound to do so within the meaning of Section 176 of the Indian Penal Code.

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME1 [51]

10503 Electrical Inspector to Railway

The Chief Electrical Engineer of each Railway is appointed to function as Electrical Inspector to the
Central Government for the Railway vide Railway Boards Notification No. 60/Elec/112/6 dt. 10th
June 1961. All matters in regard to the functions of Electrical Inspector shall be referred to him.
10504 Reporting of Accidents

The Electrical Foreman/Chargeman shall send in respect of every electrical accident a notice of the
accident in writing to the Electrical Inspector viz., Chief Electrical Engineer, through the
Sr.DEE/DEE.

In case where the accident results in or is likely to have resulted in loss of human being or animal,
intimation shall be given within 24 hours of the knowledge of the occurrence of the accident by
express telegram to be confirmed by a post copy.

The written report of the accident shall be sent in the form set out at Annexure XIII of I.E Rules.

All fatal and grievous hurt accidents shall also be immediately reported to the nearest Police Station.
District Magistrate or Sub-Divisional Officer in charge of the Civil Jurisdiction and the body (in case
of fatal accidents) shall not be moved until the Police Inquiry is completed.

In the case of electrical accident occurring within workshop premises, the Factory Rules and Act will
apply. In this instance the Manager of the workshop will send the detailed report on the forms
prescribed in the Factory Rules to the Factory Inspector, in addition to CEE, CWE,DRM etc.

10505 Accident Inquiries

Every electrical accident shall be inquired into by an officer and a report submitted to the Chief
Electrical Engineer (functioning as the Electrical Inspector for the Railways) giving complete
information within one week of the accident. The report should in particular cover the following
points:-

1. A clear description of the locality and a sketch showing all the relevant details;
2. An analysis of the evidence recorded;
3. Findings as to the exact cause of the accident;
4. Fixing up of responsibility of staff negligence, if any, indicating whether the Rules for Safe
Working on Electrical Equipment have been followed or not:
5. Recommendations for preventing such accidents in future : and
6. Any special features peculiar to the case.
Until the official inquiry is conducted all material evidence should be preserved by the official in-
charge of facilitate the inquiry. Where restoration of supply is likely to obliterate marks on the
premises or in any other way destroy evidence which may be of use in an inquiry, the Senior
Electrical Official who first arrives at the site should carefully make notes and sketches and preserve
the evidence as far as possible, for production at the inquiry.

10506 Accident Registers and Annual Returns.

Every Electrical Official in-charge shall maintain a register showing the particulars in regard to all
electrical accidents taking place under his jurisdiction in the proforma below:-
----------------------------------------------------------------------------------------------------------------
Date Time Brief description Date & Time of Date accident
of the accident issue of accident report submitted
Telegram

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME I [52]

 He will also submit by 15th April of each year a statement of accidents during the previous financial
year to Sr. DEE, who in turn will submit the statement for the entire division to the CEE for
incorporation in the Electrical Inspectors Annual Report to CEA.

10507 First Aid

A box containing first aid equipment shall be kept in each generating station or each sub-station and
electrical work depot (except where adequate medical facilities exist for all the 24 hours of the day)
close at hand for use when required. A periodical check shall be made of the contents and any
deficiencies shall be reported to the Medical Department for replenishment.

RESUSCITATION FROM ELECTRICAL SHOCK

10508 Instructions to be Displayed

Instructions in English and the Regional language regarding the treatment of persons suffering from
electric shock shall be exhibited in all inspection sheds, stabling depots, repair shops, stations, sub-
stations etc. and it is the duty of every authorised official to make himself thoroughly familiar with
such instructions, and to be able to render artificial respiration when necessary. Instructions
regarding the methods of rendering artificial respiration have been given in paras 10509 and 10510.

Electrical shocks are easily received but are as easily avoided if proper precautions are taken in
maintaining and handling electrical equipment.

10509 Removal from Contact

If the person is still in contact with the apparatus that has given him the shock, the rescuer should, if
possible, stand on a dry wooden chair while removing the victim. Otherwise pull him free by using a
dry coat, dry rope, coconut matting or stick, preferably standing on a rubber mat or any other dry
mat handy. Never touch the mans body with bare hands.

Extinguish any sparks if the patients clothes are smouldering; ascertain if he is breathing and send
for a Doctor. If apparently not breathing, proceed as described in para below.

10510 Artificial Respiration

If there are any burns, avoid, if possible, so placing the patient as to bring pressure on the burns. It
is preferable to operate as in the Diagrams A & B, Fig. 5.01, with the face downward. If badly burnt
in front, turn to the second method shown later.

First Method
First Motion : Observe Diagram A Expiration. Kneel over the patient, rest the hands flat in the
small of his back, let your thumbs nearly touch, spread your fingers on each side over his lower ribs
as in the first diagram.

Now lean firmly but gently forward over the patient, exerting a steady pressure
downwards, still following the first diagram.

Second Motion : Observe Diagram B Inspiration. Rock yourself gently backwards but do not
remove your hands.
Merely keep then in position for the next expiration pressure.

Continue these two movements.

The double movement should be gone through about fifteen times per minute. The object is to keep
expanding
INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME I [53]
and contracting the patients lungs so as to imitate slow breathing. If the operator himself breathes
slowly, letting the air out as he presses forward, and drawing it in as he rocks backward, he will
naturally arrive at the proper rate, and will understand the reason for the movements.

Do not cease operations until natural breathing is re-established. It may take half an hour or even
longer, to produce a desired effect.

Second Method

Should it be expedient to place the patient on his back , first loosen the clothes around the chest
and stomach. Then placed a rolled-up coat, or other improvised pillow, beneath the shoulders so
that the head falls backwards. The tongue should then be drawn forward.

First Motion : The operatoe must kneel in the position shown by Diagram C. Grasp the patient just
below the elbows and draw his arms over his head until horizontal, retaining them there for about
two seconds.

Second Motion : Next bring the patients arms down on each side of its chest and pressing inwards
upon his arms so as to compress his chest as in Diagram D.
Remain thus for two seconds, and then keep repeating the two motions at the
same rate.

INDIAN RAILWAYS- AC TRACTION MANUAL-VOLUME I [54]

 The lung-inflating effect in Diagram C is much assisted if the arms be swung outwards as they are lifted.

If more than one person is present, the patients tongue should also be drawn out during each outward or
lung-inflating stroke (Diagram C) and released during each inward or lung deflating stroke (Diagram D).

In both case, be careful to avoid violent operations, as injury of the internal organs may result from excessive
and sudden pressures. After recovery, burns if serious, should be treated with a proper oil dressing. Avoid
exposing patient to cold. Administer no restoratives until the Doctor comes. Cold water may be given and
smelling salts applied in moderation.

Two methods of treatment for electric shock have been described above. It is the duty of every railway
servant to be familiar with these methods of rendering artificial respiration.

10511 Typical Electrical Accidents

Brief particulars of a few electrical accidents which have actually occurred are given below. A study of these
particulars will help officers and staff in appreciating the importance of the various safety rules prescribed.

1. A khalasi of the Engineering Department, engaged in construction work, sustained severe burns when
handling a long boiler tube under live OHE. The boiler tube accidentally touched the contact wire. This
accident could have been prevented if proper supervision had been exercised and the Supervisor in-
charge of the work had warned all his staff of the danger of electrocution if the OHE is accidentally
contacted by poles, ladders, pipes or tools. Whenever there is even a remote possibility of any person
coming within the danger zone of live 25 kV installations at sub-station, Switching stations or if any work
has to be done within 2 m of live OHE, the supervisory official in-charge should invariably obtain permit to
work after the lines are made dead and earthed before allowing staff to start work.

2. An electric fitter working on a locomotive stabled in a loco shed climbed on to the roof to examine the
pantograph which was in the lowered position. The height of the contact wire on the stabling line was 5.5
m and the height from rail level of the pantograph in the lowered position was 3.66 m. The fitter was
apparently under the impression that he could conveniently examine the lowered pantograph taking
advantage of the clearance of nearly 2m. Unfortunately, while he was examining the lowered pantograph,
the other pantograph of the locomotive was inadvertently raised by another employee thus energising the
lowered pantograph also. There was also danger of the employee getting a shock if he had inadvertently
stood up on the roof in the course of his work. This emphasizes that no one should ever get up on the
locomotive roof when the locomotive is under a live OHE. A shut down should invariably be effected
before climbing on to the roof of stabled locomotives.

3. Two work parties were required to work at an insulated overlap connected together by an interruptor.
Shutdown was effected on both the elementary sections and the interruptor was also opened. One party
earthed the OHE on one side of the insulated overlap and the supervisor of this party permitted his men
to commence work on the insulated overlap without earthing the other portion of the OHE presuming that
the other portion had been earthed by the other work party. This resulted in some of the workmen getting
electric shock due to contact with the unearthed wires. This accident emphasizes the importance of the
rules that (a) each party should protect itself by independent earths and (b) when work is to be done at an
insulated overlap either both portions of OHE should be independently earthed or the electrical continuity
between the two portions should be ensured by keeping isolators/interruptors closed.

4. A supervisor took power block for two elementary sections supported on a portal and overlooked the fact
that the same portal supported the wires of a siding. Consequently a worker sent to work on the portal
structure came into contact with the live OHE of the siding and sustained shock which resulted in his
death. This serious accident could have been prevented if the supervisor had made himself thoroughly
familiar with the details of OHE supported on the portal and had ensured that all the wires on the portal
structure were made dead and earthed before permitting his men to commence work on the portal .

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUMEI [55]

5. An Electrical Chargeman (OHE Maintenance) received a fatal shock when he came into contact
with OHE, which had been isolated but not earthed. On completion of work , he removed the
earth and went down into the OHE Inspection Car to check up the time. Subsequently, he went
up the OHE Inspection Car again and came into contact with OHE, which was not earthed
though isolated. A slight drizzle earlier contributed to the severity of the shock as the
Chargemans feet and the tower wagon platform were wet. Due to parallelism with the live OHE
of an adjacent line, there was an appreciable induced voltage in the line, though it was isolated.
This emphasizes the need for ensuring that the OHE is earthed in accordance with the rules
prescribed before commencing work and during the whole time the work is in progress.

6. An Assistant Driver of a diesel locomotive of a Steel Works doing shunting work in an electrified
yard close to the Steel Works received a severe shock when he went up on the roof of the
locomotive. The warning notice regarding live OHE was not painted on the locomotive nor was
the Assistant Driver properly instructed on the hazards of working in close proximity to live OHE.
This emphasizes the need for painting the warning notice not only on the locomotives belonging
to the Railway but also of private parties likely to work in electrified railway yards. Operating
staff of private parties also should be educated in the safety rules prescribed.

7. A Linesman received a severe shock when working on an isolator. Before commencing the
work one
earth has been placed on each side of the isolator. However, during the course of the work, the
isolator was opened when the Linesman received a shock. The possible cause is that one of the
discharge rods was not making proper contact with the result that effect of induced voltage on that
portion of the OHE caused the shock. This emphasizes the need for ensuring that when working
on an isolator, either the isolator is kept jumpered or not opened at all during the course of the
work , in addition to the precaution that an earth should be placed on each side of the isolator.

8) Supply from an auxiliary transformer has failed . An unskilled khalasi was sent by the fitter to
check up and renew the high voltage fuses. The khalasi attempted to do this without getting a
permit to work, accidentally came into contact with live 25kv wires and was electrocuted . This
accident was a direct result of an unauthorized person not holding a certificate of competence
being deputed to work on live equipment.

9) An electrical fitter was electrocuted while carring out repairs to a jumper connection to a
transformer. He had isolated the transformer and climbed up the pole to repair the jumper . He had
posted a helper near the circuit breaker with instructions that on receiving a signal from him, the
helper should close the circuit breaker . The helper saw a person at a distance waving his hands
and presuming that the signal is from the fitter, closed the circuit breaker . The accident was the
result of adopting short circuit methods rather than the prescribed procedure for effecting shut down
and issue of permit to work . Such short circuit methods are not permissible even if the intention is
to speed up the work.

The above cases would illustrate that a heavy responsibility rests with officers and senior
supervisory officials to prevent possibilities of electrical accidents not only by insisting on strict
compliance with rules and procedures laid down for safe working on electrical equipment, but also
by giving wide publicity to the need for utmost precautions on the part of everyone when working in
electrified sections.

INDIAN RAILWAYS AC TRACTION VOLUME -I (56)

 CHAPTER VI

FIRE PRECAUTIONS.

Para No. Subject

10600 Duties of Electrical Department Staff

10601 Classification of Fires

10602 Precautions to be Observed

10603 Fire Extinguishers

10604 Training of Staff

10605 Technical Investigations of Fires

10606 Fire Accidents

10607 Organisation for Fire Fighting

10608 Maintenance and Inspection of Fire Extinguishers

10609 Code of Practice for Prevention of Fires of EMU Stock

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME I [57]

 CHAPTER VI
FIRE PRECAUTIONS
10600 Duties of Electrical Department Staff

1 It is the duty of every railway officer and supervisor to ensure by periodical inspections that
installations, offices, shops and rolling-stock under his control are: -

a) well protected against risk of fire;

b) well equipped with fire-fighting equipment, and

c) that staff are well trained and fire-fighting appliances are properly maintained to fight the fires,
should they
develop.

2. The majority of fires are preventable if only those in charge are security minded and make it a
point to check the installations under their control from the point of view of fire risk and take
necessary precautions. Accumulation of debris and rubbish near offices, workshops and
installations should never be permitted even from the point of view of cleanliness -- much more so
because it is such accumulations that are responsible for most fires.

3. Points which should be checked during periodical inspections are :-

a) Whether the fire fighting appliances are maintained in working condition, and if each installation
has the full
complement of fire buckets, extinguishers etc.

b) How well staff are trained to fight a fire.

b) Whether close liaison is maintained by the local official with the Fire Fighting Organization and
telephone
numbers of Fire Station are properly displayed.

c) When the last fire drill was conducted, a fire drill register should be maintained at each
installation by
subordinate incharge.

10601 Classification of Fires

For all practical purposes the basic types of fires can be grouped into following four classes;

Class A Fires:

Fires involving combustible materials of organic nature, such as wood, paper, rubber and many
plastics, etc., where the cooling effect of water is essential for extinction of fires.

Class B Fires :

Fires involving flammable liquids, petroleum products, or the like, where a blanketing effect is
essential.

Class C Fires:
Fires involving flammable gases under pressure including liquefied gases, where it is necessary to
inhibit the burning
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 1 [58]
gas at fast rate with an inert gas, powder or vaporizing liquid for extinguishment.

Class D Fires:
Fires involving combustible metals, such as magnesium, aluminium, zinc, sodium, potassium, when
the burning metals are reactive to water containing agents, and in certain cases carbon dioxide,
haloginated hydrocarbons and ordinary dry powders. These fires require special media and
techniques to extinguish.
10602 Precautions to be Observed
1. Class A Fires:

Fires of this type can be readily extinguished by water or a solution containing large amount of water
due to the cooling and quenching effect of water.

The following precautions should be taken to prevent Class A Fires: -

a) Glowing cigarette butts and matches shall not be thrown into waste baskets, oil rag bins, or other
places of fire hazard.

b) Smoking and use of open flames shall be prohibited in oil storage rooms, battery rooms and
places where combustible material is kept.

c) High standard of cleanliness shall be maintained. Waste material, oily waste or rags etc. shall be
removed from the premises daily and suitably disposed of.

d) Trees and rank vegetation shall not be permitted to grow in the neighbourhood of sub-stations,
switching stations or other buildings. Roofs of buildings and the whole area of the sub-stations and
offices shall be kept clear of dry leaves, packing cases or other dry combustible material.

e) Before starting welding and cutting operations, it shall be ensured that sparks arising therefrom
do not lodge in wood-work or ignite other combustible material in the area.

f) While installing heating device, hot water pipes, etc. suitable clearances from the combustible
material shall be maintained.

2. Class B Fires:
For extinguishing these fires some blanketing agent is required such as foam which deprives the fire
of its oxygen requirement. If water is used, there is greater danger of the fire spreading.

The following precautions are required against Class B fires :-

a) Cable trenches inside stations containing cables shall be filled with sand or pebbles or covered
with non- inflammable slabs.

b) Oil-filled containers and equipment in receiving stations, sub-stations, buildings, store rooms, etc.
be so located that fire and smoke from oil is not likely to do any damage.

c) Concrete dykes or floor drains and loose rock-filled pits shall be provided near oil storage rooms
and oil filled equipment to prevent spread of spilled oil [(I.E. Rule 64 (2) (e) ].

d) Empty oil drums, boxes or other combustible material shall never be piled near storage oil tanks
and oil-filled equipment.

e) Petroleum containers shall be labelled and kept securely stoppered.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME 1 (59)
f) When a vehicle is re-fuelled or petrol transferred from one container to another, no smoking or
open flames shall be permitted in the vicinity.

g) Places where paints, varnishes, lacquers, thinners, etc. are stored or used shall be kept
scrupulously clean.

3. Fires in Electrical Equipment:

Fires that occur in electrical equipment or in equipment close to electric circuits preclude the use of
water spray or foam type extinguishers. Such fires are extinguished by employing some insulating
agent like sand, carbon tetra- chloride or carbon dioxide or halon type fire extinguishers.

The following precautions are required against such fires: -

a) Electrical equipment shall be installed, operated and maintained properly and in such a manner
as to eliminate arcs due to poor contacts in switches and fittings, damaged insulation, crossed
wires, opening of switches carrying large currents, etc.

b) Leakage on and/or overloading of circuits with consequent heating up of wiring must he guarded
against.

c) Motors shall be equipped with over-current and under-voltage protection to prevent excessive
heating.

d) Insulation strength of the equipment and cable shall be checked periodically.

e) Temperature and loading conditions of the equipment shall be recorded and studied.

f) Electric lamps shall not be surrounded by or laid on combustible material.

g) The vicinity of cables should be kept clear of oily dirt or other combustible material.
h) Battery rooms shall have no loose connections and there shall be no sparking devices e.g., bells,
buzzers, relays, fuses or switches in the room. Smoking shall be prohibited and rubbish and other
combustibles shall not be permitted to accumulate in the battery room.
i) Metal parts of oil tanks, electrical equipment and buildings shall be adequately bonded and
earthed to prevent fires by lightning and static electricity. The earth resistance shall be checked
periodically.

j) Flammable gases and materials shall not be stored near electrical equipment.

In designing, electrical installations in buildings, Indian Standard 1646 (Code of Practice for Fire
Safety of Buildings (General): Electrical Installations and IS 3034: Code of Practice for Fire Safety of
Industrial Buildings: Electrical Generating and Distributing Stations )should be followed.

10603 Fire Extinguishers

1. The types of extinguishers mentioned below against each class of fire are generally most suited.
Details of suitability as a guide of each type of extinguisher is, shown in Table 1. It may, however,
be noted that this is only for guidance and does not cover special cases.

a) Class A Fires - Water expelling type extinguishers.

b) Class B Fires - Foam, dry powder, vaporizing liquid, carbon dioxide extinguishers.
c) Class C Fires - Dry powder and carbon dioxide extinguishers.
d) Class D Fire - Extinguishers designed for expelling special dry chemical powder.
INDIAN RAILWAYS -AC TRACTION MANUAL VOLUME I [60]
 Table 1

Suitability of Different Types of Fire Extinguishers for Different Class of Fires

-------------------------------------------------------------------------------------------------------------------------------------
S.No. Types of Extinguishers Types of Fires
-------------------------------------------
A B C D
-------------------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------------------

1. Fire extinguisher, soda acid (see IS..934) S NS NS NS

2. Fire extinguisher water type,

gas cartridge (see IS:940) S NS NS NS

3. Water type bucket pump (see IS:6234) S NS NS NS

4. Water type stored pressure (see IS:6234) S NS NS NS

5. Fire extinguisher chemical foam (see IS:933) S S NS NS

6. Fire extinguisher dry powder (see IS: 2171) NS S S NS@

7. Fires extinguisher carbon

dioxide type (see IS:2878) NS S S NS

8. Fire extinguisher using Halon gas

(see IS: 11108) S S S S
-------------------------------------------------------------------------------------------------------------------------------------
S - suitable. NS - not suitable, @ - suitable if special dry powder for burning metal is used.
2. Where the energized electrical equipment is involved in a fire, the non-conductivity of the
extinguishing media is of utmost importance and only extingushier expelling dry powder or carbon
dioxide (without metal horn) or halon should be used. Once the electrical equipment is de-
energized and extingusher suitable for Class A, B and C Fires may also be used safely.
Where cleanliness is of importance and contamination of sensitive electrical equipment
should not be caused, only carbon dioxide or Halon type fire- extinguishers should be used in case
of fire in such equipment.
3. At times it may become necessary to use water from a fire hydrant to control a major fire
involving electrical equipment or in the vicinity of electrical equipment. In such cases, it must
be ensured that the electrical equipment is made dead before using the fire hydrant.
10604 Training of Staff
1. Sr. DEEs concerned should ensure that categories of staff listed below are adequately
trained in fire precautions:-
i) Drivers, Motormen, Asst. Drivers, Engine Turners:- They should be fully familiar with
the physical location of fire fighting equipment in locos/EMUs and the correct method
of operation of the equipment including the precautions to be followed. Guards of
trains hauled by electric locos and of EMU trains should be similiarly trained by the
Operating Department.

INDIAN RAILWAYS AC TRAC.TION MANUAL - VOLUME 1 (61)

ii) All supervisors and skilled artisans of Loco and EMU sheds, OHE depots, PSI & RC sections:-
They should be familiar with the physical location of all fire fighting equipment including fire hydrants
in their place of work, the correct method of operating the equipment and precautions to be
observed, as well as location of and means of summoning of Railway and Municipal Fire Brigades.
Immediately after coming on duty the supervisor must daily check the fire fighting equipments.

2. The Security Department of the Division will train the staff in operation of fire fighting equipment
on requisition from the Electrical Department. A register should be maintained in each Loco/EMU
shed, OHE depot, TF(R)'s office etc. indicating the name of staff who have been so trained.
Divisional Fire Inspector be contacted for advice and training in fire fighting.

10605 Technical Investigations of Fires

1. Constant study and investigation of causes of fires are very essential. Every case of fire minor or
major, irrespective of the location, whether in power, auxiliary or control circuits, should he
investigated very carefully, even though an enquiry in accordance with the Accident Rules may not
be called for. The causes as established by the investigation should be analysed by the SR.DEE
periodically to identify areas requiring further investigation and to tighten up preventive measures.
The Divisional Fire Inspector should always be associated in any fire enquiry.

2. A report on each case of fire should also be furnished to CEE as well as the Divisional Fire
Inspector concerned.
10606 Fire Accidents
1. Fires in trains, whether carrying passengers or not, resulting in loss of human life or injury to any
person or loss of or damage to railway property to the extent of Rs.500 or over are required to be
treated as "accidents" and have to be inquired into in accordance with the "Rules for Reporting and
Inquiring into Accidents". Fires in other railway premises resulting in damage to railway property of
Rs.500 or over are also to be treated as "accidents". Fire accidents involving loss of human life or
injury to persons or damage to railway property estimated to cost Rs. 300,000 or over have also to
be reported as soon as possible on telephone to the Railway Board by the Operating (safety)
Branch.

2. When electrical installations or electric rolling-stock are involved or when there is possibility that
the fire was caused by electrical short circuit or due to defect or malfunctioning of electrical
equipment, a representative of the Electrical Department should invariably be a member of the
inquiry committee. Rules also require that a representative of the Security Department should be
associated with all inquiries into fire accidents.

3. The composition of the inquiry committee and the method of disposal of the report of the inquiry
committee will be as laid down in the "Rules for Reporting and Inquiring into Accidents" issued by
the Zonal Railway, with which the officers and supervisor should be fully conversant.

10607 Organisation for Fire Fighting

1. On each railway a fire-fighting organisation exists primarily to look after major fires and to render
help to the Department in imbibing good fire fighting practices and achievement of high fire fighting
efficiency.
2. The administration and control of the Fire Service organisation in the Zonal Railways is under the
control of the Chief Security Commissioner of the Railway with an Assistant Security Commissioner
(Fire) in direct overall charge of the work in the Headquarters office. ASC (F) is a specialist officer
responsible not only for exercising technical supervision over the fire service organisation on the
entire railway but also for advising other Departments in regard to fire precautions.
3. The day-to-day control over all Fire Fighting units in the divisions is exercised by the Divisional
Security Commissioner of the Division/Security Officer of the Division.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I (62)

4. The responsibility for providing adequate fire fighting equipment, initially as well as on
replacement account, rests with the Departments concerned. The type and scale of fire fighting
equipment to be provided in each installation as also on rolling-stock should be decided on the
advice of ASC (F).

5. All fire fighting equipment in traction installations, loco sheds etc. excluding the mobile fire
engines and trailer pumps, if any, should be borne on the books of the Electrical Department. The
mobile fire engines and trailer pumps will be on the books of the Security Department.

6. Repairs and maintenance of the fire fighting equipment will be undertaken by Fire Service
Section of Security Department .Detailed local instructions should be issued jointly by the Sr.
Divisional Electrical Engineer concerned and the Divisional Security Commissioner fixing the
periodicity of inspection of the fire fighting equipment by the Security Department, the procedure for
requisitioning the services of the Fire Service personnel for repairs and maintenance of the
equipment and similar connected matters.

7. Officers and supervisors in charge of traction installations and rolling-stock will render all
necessary assistance to the Security Department in inspection, maintenance and operation of the
fire fighting equipment. Although ultimate responsibility for efficient working of fire service
organisation is that of the Security Department, the officials of Electrical Department may also
organise surprise fire drills in loco and EMU sheds, OHE depots etc. and record the same in Fire
drill register.

10608 Maintenance and Inspection of Fire Extinguishers

1. Inspection and testing:

Routine maintenance of all fire extinguishers in respect of mechanical parts, extinguishing media
and expelling means should be carried out by properly trained personnel at frequent intervals but at
least once in a month to make sure that these are in their proper condition and have not been
accidentally discharged or lost pressure or suffered damage. Following procedure should be
followed for monthly maintenance, inspection and testing. Divisional Fire Inspector should be
approached for this purpose.

a) Clean the exterior of the extinguisher :polish the painted portion with wax polish, the brass parts
with metal polish, chromium plated parts with silver polish.
b) Check the nozzle outlet vent holes and the threaded portion of the cap for clogging and check
that plunger is in fully extended position and is clean.
c) Check the cap washer, grease the threads of cap plunger rod and wipe clean.
d) Make sure that the extinguisher is in proper condition and is not accidentally discharged. In case
of stored pressure extinguisher, pressure gauge is to be checked for correct pressure.
e) Check all mechanical parts thoroughly.
f) All fire buckets should be refilled, some with clean water and others with dry sand and checked
daily by the supervisor incharge of the maintenance.
2. Annual Inspection
At least once in a year, inspection and maintenance of extinguisher, including chemical charge
inside and expellent should be carried out by trained personnel. Any extinguisher showing corrosion
or damage to the body internally or externally should be replaced. Faulty, damaged and corroded
parts shall be replaced by correct component. Illegible labels should be replaced.
10609 Code of Practice for Prevention of Fires of EMU Stock
Guide lines for prevention of fires on EMU stock have been laid down in Code of Practice for
Preventon of Fires of EMU stock (first revision) issued by RDSO in October 1991.

The Code lays down detailed instructions regarding prevention of fires on the EMU stock which is
newly built and also instructions regarding prevention of fires on EMU stock already in service.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME I (63)

 CHAPTER VII

ENERGY CONSERVATION

Para No. Subject

10700 Monitoring of Energy Conservation
10701 Energy Conservation Measures
10702 Energy Conservation Measures for Traction Installations
10703 Energy Conservation Measures for Rolling Stock
10704 Energy Conservation Measures for Maintenance Installations
10705 New Developments

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1 (64)

 CHAPTER VII
II. ENERGY CONSERVATION

10700 Monitoring of Energy Conservation

1. The Staff connected with electric traction shall make every effort to avoid wastage in use of
electricity through constant vigil.

2. One Senior Administrative Grade Officer of Electrical Department shall be nominated by Chief
Electrical Engineer to be incharge of matters pertaining to Energy Conservation. The officer shall :

- Monitor pattern of consumption of electrical energy on electrified divisions based on the

reports from Divisions;

- Plan for Energy Conservation measures and monitor their implementation;

- Provide guidance to Divisional Officers;

- Arrange for training of officers and supervisors;

- Discharge other related functions.

3. Sr. DEE (TrD) and Sr. DEE (OP) shall hold monthly meetings to analyze energy consumption and
maximum demand for the preceding month vis-a-vis earlier months. The figures should have a
relation to the traffic moved. In the event of maximum demand and energy consumption being found
disproportionately high, a detailed investigation should be made and corrective action, if any, should
he advised to concerned departments.

10701 Energy Conservation Measures

While development of better designs and use of energy efficient equipment will bring about
reduction in energy consumption, yet on the existing systems the following measures listed below
will contribute to conservation of electrical energy in traction. While working to these recommended
measures no compromise shall be made with the safe and reliable operation of equipment and train
services.

10702 Energy Conservation Measures for Traction Installations

1. Shunt capacitor banks shall be provided at traction sub-stations, where not done, to reduce
maximum demand and line losses. Priority should be given to the sub-stations feeding large
marshalling yards.

2. Standby traction transformers should be kept de-energized to save on no load losses.

3. Demand monitoring equipment, wherever provided, shall be maintained in the working order.

4. Traction Power Controller should co-ordinate with the Section Controller to avoid simultaneous
starts of trains, as far as practicable. Bunching of the train in the event of breakdown has to be
avoided to the extent feasible.

5. Wherever standby emergency power supply is also derived from OHE, the associated auxiliary
trans-

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME 1 (65)

 former should be kept isolated from 25 kV side to avoid no load loss. This, however, shall not be
applicable for power supply to signals where changeover has to be immediate.

6. Ensuring of good electrical contact to attain low resistance at conductor joints (splices) and
parallel groove (PG) clamps through periodical inspection and maintenance.

7. Connections to buried rail opposite sub-stations for return current are prone to corrosion leading
to increased resistance and loss of energy. These connections should be inspected periodically and
maintained to obtain good electrical connection.

10703 Energy Conservation Measures for Rolling Stock

1. Drivers/Motormen are expected to be well - conversant with the road to make the best use of
down gradients to effect maximum possible saving in energy consumption.

2. In level sections and particularly in suburban sections, coasting should be resorted to as much
as possible and brake applied only when essential to control the speed or stop the train. To help
Drivers and Motormen "Coasting Boards" are fixed at appropriate points on suburban sections. In
some Railways, time totalizers have been provided in EMUs.

3. In the undulating terrain, speed may be allowed to drop down when going up a short up-gradient.
After passing over the crest, the train will automatically pickup the speed with power off when going
down- hill, so that it attains maximum permissible speed on the section when it arrives at the foot of
the next up-gradient. This feature should receive special emphasis during learning the road period.

4. Re-scheduling of booked speed of EMU to help conservation of energy.

10704 Energy Conservation Measures for Maintenance Installations

1. Switch off lights, fans and air conditioners when not required.

2. Keep standby transformers deenergized from HV side .

3. Check idle running of machines.

4. Check leakage and misuse of compressed air.

5. Check leakage and wastage of water.

6. Maximise use of natural day light in service building to reduce need for electric light.

10705 New Developments

1. The traction staff should keep themselves fully abreast of technological developments like 3
phase drive Electric locos being made elsewhere, within the country and abroad, in respect of
efficient utilization of electric power in traction applications and try to derive benefits from such
developments.

2. Electric locomotives simulator : Training of Drivers on simulator can help drivers in running of
trains with optimum consumption of energy.

3. On Board Power factor correction Equipment on Electric Locomotive.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME 1 (66)

 CHAPTER VIII

TRACTION STORES AND THEIR ACCOUNTAL

Para No. Subject

10800 Introduction
10801 Standardization of Stores
10802 Stock Items and Special Requisitions
10803 Emergency Stores
10804 Imprest Stores
10805 Proprietary Articles
10806 Estimates for Stock items
10807 Items with Protracted Delivery
10808 Local Purchase by DRM
10809 Specifications
10810 Preparation of Indents
10811 Imported Stores
10812 Follow up
10813 Check on Bills
10814 Break-Down Stores
10815 Stores for Works
10816 Liaison with Stores Department
10817 Custody and Accountal of Charged-Off Stores
10818 Inspection of Stores
10819 Inventories of Dead-Stock
10820 Safe Custody of Stores
10821 Accountal and Disposal of Scrap, Emptys etc.
10822 Condemnation Certificates
10823 New for Old
10824 Verification of Stock
10825 Computerised Stores Accounting

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1 (67)

 CHAPTER VIII

TRACTION STORES AND THEIR ACCOUNTAL

10800 Introduction

The Indian Railway Code for the Stores Department (herein after referred to as the Code) contains
instructions for the purchase, receipt, custody, issue, accountal and disposal of stores of all kinds.
Officers and staff of the Electrical Department should make themselves familiar with the relevant
portions of the Code, which have a direct bearing on their day-to-day work. Instructions in this
Chapter are supplementary to the provision of the Code.

10801 Standardization of Stores

1. All items for which the demand is recurring and in sizable quantities should be standardized and
arranged to be stocked in the concerned Stores Depots.

2. The work of standardization and issue of stocking advice to the Stores Branch should be dealt
with by a separate section in CEE's Office. When a new item is required to be standardized, the
SR.DEE concerned should send a preliminary proposal to CEE giving the description of the item,
available details of specifications and drawings, where item is proposed to be used, estimated
annual consumption, basis of the estimated consumption, likely sources of supply and other
relevant details. The proposal will be carefully scrutinized in CEE's office and if standardization is
considered justified, a complete proposal, as prescribed by the Stores Department will be forwarded
to COS, who will arrange to include the item in the 'Standard Nomenclature List of Stores under
advice to the Stocking Depots and the Sr.DEEs concerned.

3. Standard drawings and specifications for some items to be used by more than one Zonal Railway
are also issued by RDSO . Items required exclusively by a Railway will be covered by drawings and
specifications issued by CEE. Sr.DEEs may issue local specifications and drawings for items
required to be purchased once or only occasionally.

10802 Stock Items and Special Requisitions

1. Items having a recurring consumption should as a rule be only obtained through the Store
Depots. Procurement of stores against requisition for direct delivery by the trade to the consuming
units should be avoided except in the following cases;-

a) Items which have a very low annual consumption and hence cannot be included as stock items
and at the same time do not fall within the definition of 'Emergency' stores e.g., bearings of
particular sizes only a small number of which may be required per annum.

b) Stores required for special works, modifications or programmed replacement of parts,

c) Items, although stocked by the depot, which have a non-recurring demand for a specified
purpose and cannot be met from the stocks held for normal consumption e.g. , cables required for
special rewiring of locos and EMUs.

d) 'Break-down Stores' such as OHE conductors and other stores to be held by OHE depots to meet
unforeseen contingencies such as thefts and accident.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I [68]

e) Non-standard items and other items required regularly but not stocked by stores Depots,
pending standardization.
2. Quantities to be obtained against requisitions for (b) and (c) above should be on the basis of
approved estimates for each item for the specified purpose. Quantities against (a), (d) and (e)
should be generally equal to the anticipated consumption for one year or for such longer period as
convenient for procurement, fixed in consultation with the Stores Department, taking into account
the normal delivery period for the anticipated consumption during the period required for receipt of
fresh stocks according to normal delivery anticipated for each item plus a buffer stock to cover 6
months requirements. On the basis of experience it should be possible to fix this minimum level
quantitatively for each item.

3. Requisitions for non-stock stores and special requisitions for stock items as above are required
to be scrutinized personally in regard to specification and quantity and signed by Technical Officers
of appropriate rank. Officers/Supervisors initiating such requisitions should enclose a brief note for
the information of the officer empowered to sign the requisition, bringing out the need for the
procurement and explaining how the quantity has been arrived at.

10803 Emergency Stores

1. 'Emergency Stores' comprise items of stores which do not ordinarily wear out or require renewal,
which have, however, to be kept in stock to meet, emergencies, such as that due to breakage or
unanticipated deterioration, and which are not readily obtainable. The stock cards relating to such
stores should be marked with the letter 'E'.

2. When an item is to be stocked as 'Emergency Stores', the Sr. DEE concerned should, in
consultation with DCOS/ACOS in-charge of the depot, obtain CEEs personal sanction giving
adequate justification.

3. The list of 'Emergency' items should be reviewed annually by the Sr. DEE and the Depot
Officers concerned. It may be possible to transfer some of the items to ordinary stock and to
dispose off items no longer required on account of obsolescence.

10804 Imprest Stores

Stores with a regular recurring consumption required by OHE depots, PSI depots, etc. and for
outstation maintenance of rolling-stock should be arranged against 'charged off' imprests. The
procedure as detailed in the Stores Code should be followed in regard to sanction, recoupment and
accountal of such stores.

10805 Proprietary Articles

1. Proprietary articles are required to be purchased from the specified firm on single tender basis.
Only when acceptable alternatives cannot be used a 'Proprietary Article Certificate' be issued. The
officer signing a Proprietary article certificate should satisfy himself on this point.

2. A proprietary Article Certificate in the prescribed form should be issued only by technical officers
of appropriate rank. The name and designation of the officer signing the certificate should be clearly
indicated in the certificate.

3. While the greatest care should be exercised before issuing a Proprietary Article Certificate,
when the Department officer is personally satisfied that the item of the required quality can only be
obtained from the original manufacturer, there should be no hesitancy in issuing the Proprietary
Article Certificate.

10806 Estimates for Stock Items

1. The procedure to be followed by stores depots in compiling annual estimates for stock items is
given in Chapter VI of the Stores Code. In regard to traction items, the quantity should be vetted and
countersigned by Sr.DEEs concerned before submission of the estimate sheets by the Depots to
COS.
INDIAN RAILWAYS -AC TRACTION MANUAL- VOLUME I [69]
since the Stores Department has to follow a rigid time table for preparation and submission of the
estimate sheets, Sr.DEEs should have suitable machinery for expeditious scrutiny and return of the
estimate sheets when received.

2. In scrutinizing the estimate sheets Sr.DEEs may, if necessary, suggest modification of the
quantities arrived at by the depot giving specific reasons. These suggestions should be considered
by the Stores Department before finalizing the Estimate Sheets.

3. Another important check to be made by Sr.DEEs when scrutinizing the Estimate Sheets is to
see whether all the items included will actually be used. If there are many items which have become
obsolete, they should be discontinued.

10807 Items with Protracted Delivery

1 The minimum limit should be a quantity of stock representing an average weekly issue multiplied
by the number of weeks, which from past experience, it is known will lapse from the date of placing
an order before fresh stocks can arrive at the depot.

2. In fixing the minimum stock for traction items,the protracted delivery periods for imported items
and items for which the approved sources are limited, should be invariably taken into account and
an adequate buffer stock also fixed to ensure that the items do not go out of stock due to delayed
supply or other reasons.

10808 Local Purchase by DRM

1. The power of local purchase delegated to DRM should be made use of by Sr. DEEs to the
minimum extent necessary to meet urgent requirements of stores only. Detailed local instructions
should also be laid down to regulate the scrutiny of demands for local purchases as well as
accountal of stores purchased in this manner.

2. Stores Code lays down the powers of DRM for local purchase of stores. DRMs are also
empowered to re-delegate these powers to lower authorities.

10809 Specifications
Procurement of stores should be arranged against standard specifications wherever possible. Local
specifications when framed should be clear and precise in regard to requirements, tests etc. It must
be remembered that a vague specification may result in incorrect supply. It may also attract offers
which do not meet the Railway's requirements, but at the same time are difficult to be ignored,
necessitating cancellation of tenders and re-tendering, which result in infructuous expenditure, apart
from delay in procurement.

1 0810 Preparation of Indents

When indents are prepared, the essential points to be borne in mind are listed below

a) The description should he complete and written out clearly. Figures in the description (e.g., kW
rating) should be spelt out also in words. If the space in the standard form is not sufficient to write
out the description in full, it should be given in a separate attached sheet, preferably typed.
b) When mention is made of a local drawing or specification, requisite number of copies should be
attached, taking care that these are with the latest amendments.
c) The quantity should be invariably given in words and figures in the respective columns.

d) The designation and full postal address of the consignee and the controlling officer should be
given to facilitate correct dispatch of Railway Receipt and other documents.

e) When a non-standard item is asked for, particulars of the last supply, if any, should be given to
enable the Store Department to locate likely suppliers.
INDIAN RAILWAYS -AC TRACTION MANUAL-VOLUME I [70]
f) When the requisition is for a proprietary article, the ordering reference as given by the Manufacturer should
be quoted and carefully tallied and a Proprietary Article Certificate in the prescribed form should be attached,
duly signed and countersigned by the Competent Authority.
g) The rate should be either on the basis of last purchase rate suitably adjusted for price variations or on the
basis of actual market quotations or a reasonable estimate. It will be helpful if the basis on which the rate is
quoted is mentioned on the indent itself or in the covering letter.

h) The chargeable head of account should be correctly indicated.

i) Any corrections should be initialed by the officer signing the requisition.

10811 Imported Stores.

1. .All demand for stores involving imports should be meticulously scrutinized by the indenting officer to
ensure that the requirement is for minimum quantity possible.

The procedure involved in import is summarized below : -

i) On receipt of tenders, if import is found necessary, the stores Department will prepare a 'Foreign Exchange
Proposal' in the prescribed form. The possibility of obtaining an alternative available from indigenous sources,
if any, will be carefully considered by a Committee of officers before import is considered. A higher price, upto
certain limits is also admissible for indigenous stores.

The foreign exchange proposal will be personally countersigned by the Head of the user Department, after
satisfying himself that import is inescapable and also that the quantity asked for cannot be reduced. The
proposal accompanied by its justification is then vetted by the Accounts Department and then forwarded to the
Railway Board.

ii) In every case the requisite foreign exchange requires sanction by the Railway Board, either against
allotment made periodically by the Ministry of Finance or after getting special clearance from that Ministry,
where large amounts of foreign exchange is released, clearance is also required from the Directorate General
of Technical Development.

iii) On receipt of sanction for the foreign exchange, the Stores Department will issue a Purchase Order to the
firm concerned, the delivery period stipulated counting from the date of issue of import license.

(An import license where the quantity imported is meant solely for use of the organisation sponsoring the
issue of license is called an 'Actual User's license'. Sometimes, firms offer stores imported against block
licenses in their own possession in which case the Railway does not have to assist them in obtaining an
Actual User License).

iv) On receipt of the Purchase order, the firm will submit an application for import license in the prescribed
form quoting reference to the Purchase Order, which will be scrutinized and forwarded by the Stores
Department to the Chief Controller of imports, New Delhi, through the Railway Liaison Office, New Delhi.
When an import license is issued, the purchasing authority is also advised.

Import License is valid for a stipulated period. If the item is not imported within that period, the license requires
re-validation by the issuing authority.

2. Because of the involved procedures as above, all requirements for imported stores should be foreseen well
in advance and indents placed in time. A time lag of two years or more is not unusual between the placing of
indent and actual receipt of the stores.

3. A register should be maintained in the CEE's office listing out every approved case for imported equipment.
This register should be scrutinized every month by a nominated officer, to keep track of the progress and to
take prompt steps if there is any hold-up.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 1 (71)
4. Defective Imported Equipment: Sometimes imported equipment are found on receipt to be defective,
having suffered damage during transit before the equipment are cleared from the port. Such defects/damages
should be noted and a certificate obtained from the port authorities. Such defects/damages are usually
covered by Insurance and replacements will have to be obtained.

Occasionally some imported equipment are found to have inherent manufacturing or other defects, after they
are put into service. If they are covered by guarantee, the railways are entitled to obtain free replacements.
The Contractor of firm concerned will then have to obtain another import license duly supported by a
certificate issued by the Railway to import the replacement. Where the defective part has to be returned, an
export/import license will have to be obtained by the firm.

5. With changes in Govt. policy regarding import, certain changes in procedure are being progressively
introduced. Indenting officials should make themselves familiar with such changes.

10812 Follow UP
1. When issuing reminders to the Stores Department regarding supplies due against requisitions placed, care
should be taken to give complete references such as description and quantity of item, indent number and
date, forwarding letter number and date etc. Each reminder should be self-contained in regard to these
details.

2. In the case of stores to be received directly against purchase orders, consignees should arrange to notify
the Controlling Officer, COS/DCOS/DGS & D who has placed the purchase order and the firm on whom the
order has been placed, if supply or dispatch advice is not received by the due date. Prompt advice of failure of
supply to materialize by the stipulated date will enable the Purchasing officer to take up the matter with the
supplier and arrange alternative procurement, if required.

10813 Check on Bills

Detailed instructions issued by the Stores Department are available in regard to the procedure to be followed
for checking and passing of supplier's bill. The 'original' bill is sent to the consignee and the 'duplicate' to the
controlling officer. The original bill checked and signed by the consignee is sent to the controlling officer for
countersignature and onward transmission to the supplier under advice to the bill passing Accounts Office. A
few illustrative points in regard to technical and other checks to he exercised by consignees and controlling
officers are explained below for guidance. These are supplementary to the procedural instructions of the
Stores Department referred to above: -

1. Sometimes Purchase Order are placed FOR destination station. Freight then is required to be borne by the
suppliers and the accepted rate is inclusive of this. In some other cases Purchase Orders specify dispatch of
the stores FOR dispatching station, when freight is to be borne by the consignee. Only in the latter case
should the consignee ordinarily give a credit note to cover the freight charges. In the case of the first type of
Purchase Order i.e., FOR destination, if erroneously the stores are booked by the supplier 'freight to-pay', the
freight, for which a credit note is given by the consignee, is recoverable from the bill and the controlling officer
should be advised accordingly.

To avoid errors of this type, it is advisable for consignees to maintain separate registers, preferably in different
colors, to register purchase orders of the two types. It should also be remembered that loss suffered by the
railway due to such errors is recoverable from the supervisor responsible.

2. Inspection of the equipments supplied should be carried out carefully in accordance with the specifications
and drawing mentioned in the Purchase Order. Metallurgical tests should invariably be arranged through the
Chemist and Metallurgist of the Railway when required, particularly for OH E fittings, alloy steel components
for rolling-stock etc., where strict adherence to the specified material is very important. Test certificates
produced by the suppliers are of doubtful reliability, unless they are from recognized laboratories.

2. Quantity check should be carried out carefully, number, weights and lengths stated by the suppliers
on packages should he checked at random and based on these checks, if required, 100 per cent checks
should be carried out. Where Railway samples have been made available to the manufacturer these should
be taken back and accounted for.
INDIAN RAILWAYS-AC TRACTION MANUAL- VOLUME I [72]
4. The quantities accepted are required to be entered forthwith in ledgers and the details of entries shown on
the bills before they are certified. Controlling Officers should test-check these entries frequently.

5. Where the supply has been received after, the due date stipulated in the order, sanction of the Competent
Authority should be obtained before the supply is accepted.

3. In the event of rejection, a letter should be addressed to the firm forthwith detailing the reasons and
duly countersigned by the controlling officers. Rejected supplies when dispatched by rail to the supplier,
should be invariably sent freight to pay. Rejected supplies not removed by local suppliers from the
consignees premises within the stipulated time are liable to levy of storage charges as laid down by local
instructions.

7. Occasionally suppliers allow a small rebate if their bills are passed within a specified period. This condition
is incorporated in the order itself at the time of analyzing the order or it may be indicated by the Supplier when
submitting his bill. Such bills specially watched and passed in time, both by the consignee and the controlling
officer, to take advantage of the rebate admissible. It should, however, be noted that tests required to prove
the quality of the supply should not be waived merely to pass the bill by the stipulated date.

8. Occasionally, orders are placed on time preference' basis i.e., a lower quotation is passed over and higher
quotation accepted to take advantage of the earlier delivery offered by the latter. In such cases delivery of
supplies after the stipulated date will automatically involve certain penalties on the supplier. Acceptance of
delayed supplies against time preference orders should be in accordance with instructions on the subject
issued by the Stores Department.

10814 Break-Down Stores

1. The breakdown stores should be kept earmarked for use in breakdowns and should not ordinarily be
diverted for normal maintenance work or against sanctioned works. Such diversion may be resorted to only in
exceptional circumstances and with the prior written approval of competent authority.

2. As soon as the authorized minimum limit for any particular item has been reached, stock should be
recouped by placing requisitions and by effectively chasing supplies.

3. The maximum and minimum limits should be reviewed periodically by Sr.DEE and revised as required
based on experience.

108 15 Stores for Works

Officers and Supervisor in-charge of maintenance have to often execute sanctioned minor works such as
electrification of additional sidings new cross-overs etc. The basic rules to be followed in regard to
procurement and accountal of stores for such works are as under -

1. For each work a detailed estimate is required to be sanctioned by the competent authority before any
procurement of stores for the execution of the work is initiated. The stores indented for the works should only
be in accordance with the sanctioned detailed estimates. Even though detailed estimates for certain new
minor works are not required a rough estimate should be prepared and got approved by Sr. DEE,
incorporating therein a list of stores required for the purpose. When placing indents, availability of funds
against the sanctioned budget should be invariably certified by the works accountant for receipt and issue of
stores.
2. A tally book should be maintained separately for each sanctioned work to account for receipt and issue of
stores.
3.Maintenance stores should not ordinarily be drawn for use against works.
Transfer of stores to and from a sanctioned work should invariably be authorized by competent authority and
covered by adjustment memo.

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME I (73)

5. On physical completion of a work surplus stores received against the work and stores released, if any, on
execution of the work, should be disposed off in the manner authorized by SR.DEE.

10816 Liaison with Stores Department

1. Officers and nominated supervisors at the Divisional and Shed/Workshop level should be in touch with the
stores depots in regard to the supply position of stores required by them. By scrutiny of the depots in cards it
should be possible to anticipate if any critical situation is likely to develop due to non-availability of any
particular item and to initiate timely measures for Purchasing up supplies.

2. A meeting should be held periodically at agreed intervals between stores officers and traction officers at the
Divisional/Workshop level. Apart from general review of the stores position, a detailed review of vital items
should be carried out so as to foresee in time difficulties likely due to short-supply of any item and to decide
on measures to be taken to forestall such difficulties. Matters requiring decision of Executive officers such as
review of annual requirements of particular items, clarifications regarding specification etc. are best discussed
and settled, at such meetings rather than by correspondence.

Minutes of such meetings should clearly bring out items on which action is required to be taken by the
Divisional/ Workshop electrical officers, Stores Depot Officers and headquarters officers. Meetings should also
be held at agreed intervals at headquarters level between officers of the stores and Electrical Departments, to
review the position and to settle matters requiring decisions at headquarters level. The minutes of meeting
held at Divisional/ Workshop level should generally be the basis of discussions at the meetings in the
Headquarters office.

3. During their visits to Stores Depots, electrical officers should particularly check the manner in which
electrical stores are stored/stacked and guide the Depot officials for safe storage. Particular attention should
be paid to shelf stacked items such as varnishes, resins and other explosive/inflammable materials.

10817 Custody and Accountal of Charged-Off Stores

1. In loco and EMU sheds the receipt, custody and issue of charged-off stores mentioned should be under the
supervision of the DCOS/ACOS attached to the shed. An experienced supervisor of the Electrical Department
may be posted to work under the day-to-day control of the DCOS/ACOS to look after this work and to assist
him in technical matters as required.

2. In OHE depots, PSI depots and outstation rolling-stock maintenance depots, such custody and accountal
will be the responsibility of the supervisors incharge of the depots. Delivery of such stores from the trade to
the depots should be routed through the nearest stores depot, except in special circumstances.

1 0818 Inspection of Stores

1. The responsibility for inspection of stores and the procedure for inspection have been defined in paras 757
and 761 of the stores code reproduced below;-

'757. Inspection: All stores purchased direct by the Controller of Stores should ordinarily be inspected by an
Inspecting Officer of the Railway. When however, the Controller of Stores, places an order for stores with
instructions to dispatch the materials directly to an Indenter, the Indenter is responsible for the inspection and
for arranging for suitable tests to be carried out where he considers these necessary.

'761. Procedure of Inspection: Stores should be checked with the standard specification or drawing on which
the order is based. In the rare cases where orders have been made to a sample, a standard sealed sample
shall be held by the Inspecting Officer and Stores accepted only if they are up to the standard sample.

2. Sr. DEE should assist Stores Depots in regard to technical inspection of stores received by the depots.
Such inspections should not be merely left to subordinates. Sr.DEE/DEE should carry out surprise checks as
often as possible to make sure that accepted items do comply with the specifications and items rejected are
for sufficiently valid reasons. All inspection reports should be sent to the Stores Depots countersigned by an
officer.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I (74)

10819 Inventories of Dead Stock
Inventories of Dead Stock (i.e.,Tools and plant Registers) should be maintained in accordance with
the rules contained in the Stores Code.

10820 Safe Custody of Stores

During periodical inspection, officers and supervisors should critically review the adequacy of
security precautions against possibility of pilferage,loss; damage or misuse of stores held by
themselves or their subordinates and take preventive action as necessary.

For each establishment, clear standing instructions should be available defining the procedure to be
followed and fixing the responsibility for-

a) Locking and sealing of stores,

b) Custody of keys and

c) Opening the stores in the event of any emergency arising during non-working hours and on
holidays.

Officers should, during their inspections, make it a point to check that the prescribed procedure is in
fact being followed.

10821 Accountal and Disposal of Scrap, Emptys etc.

Care should be exercised in the accountal and disposal of scrap, unserviceable stores and empties.
This applies particularly to non-ferrous scrap such as copper conductors and non-ferrous fittings,
which being costly are liable to be pilferred. In view of this the Sr,DEE/DEE should as soon as
possible after renewals make regular checks to ascertain whether the quantities brought on the
books are commensurate with quantities expected to be released. Such scrap should be disposed
on in the manner laid down in the Stores Code. Similarly empties such as oil drums, cable drums,
packing cases etc. should be accounted for and disposed of in the manner laid down in the Code.

10822 Condemnation Certificates

The general rule governing the condemnation of assets is contained in para 716 of the General
Code, VolumeI which is reproduced below:

'Scrapping, condemning and abandoning assets: An asset may be scrapped, condemned or

abandoned without replacement, when the service rendered by it is no longer required. If the service
rendered by it is still necessary and if it is proposed to make other arrangements for such service, it
should be definitely established that it is more economical to scrap condemn or abandon the
existing asset and obtain the required service from the new arrangement than to continue to obtain
the required service from the existing asset. Here also the relative economy of the two proposals
should be assessed on the basis of the average annual cost of service or the cost per unit of service
as the case may be.

When important components used in traction installations or rolling-stock such as traction motors,
rectifier assemblies, auxiliary machines, circuit breakers, control panels, section insulators,
machinery, testing instruments etc., are to be condemned, the SR.DEE should personally inspect
the item and satisfy himself that it is beyond economic repairs. A Condemnation Certificate detailing
the reasons for condemnation should be issued to the subordinate supervisor authorizing him to
return the item to the Store Department as unserviceable. In the 'Advice of Return Stores' the
reference to the condemnation certificate issued should invariably be quoted.

2. In the case of electric locomotives and EMU coaches which have completed their normal life,
condemnation has to be sanctioned by CEE and CME following the procedure prescribed for the
purpose and obtaining FA &
INDIAN RAILWAYS -AC TRACTION MANUAL-VOLUME-I [75]
CAO's concurrence. Similarly CEE and CME can sanction with Finance concurrence the
condemnation of over- aged electric locomotives and EMU coaches which have not completed their
normal life. It requires sanction of the Railway Board based on the joint recommendation of CEE
and CME and concurrence of FA & CAO.

10823 New for Old

In accordance with para 1839- certain items can be obtained from the Stores Department only in
exchange for corresponding old items. A list of items which should be obtained only by exchange in
this manner is also given in the Stores Code. It is important that in regard to such items the
procedure laid down is strictly followed.

10824 Verification of Stock

Instructions for verification of stock by stock verifiers of the Accounts Department are contained in
the Code.

2. Each stockholder should verify his stocks once in six months. He may do so by verifying certain
items every month provided the whole stock is verified in the course of six months prior to April and
October every year. The date of verification should be entered in the relevant page of the tally
book/tally card along with the signature and designation of the official. Excesses and shortages
discovered during the verification should be dealt with as laid down in the Code.
3. Officers should carry out test verification of stock with Stock Holder under them to cover important
items the charged-off and surplus stocks and items in which deterioration is liable to occur, such as
insulating varnishes and lubricants with limited shelf-life. The test verification should not be confined
to new items only, but should also include second-hand stores and scrap returned to stock and
released from works.

During the test verification the officer should initial tally books and ensure that -

A) The materials and tools are borne against proper classifications;

b) Surplus stores for which no immediate use can be found are referred to SR.DEE for orders
regarding disposal;

c) Unserviceable items that have scrap value are returned to the Stores Department;

d) Unserviceable items that have no scrap value are written off with Sr.DEEs approval and a
certificate recorded to this effect;

e) Repairable or reconditionable items are sent to workshops with work orders;

f) Contents of tools and materials in Break-down Train, Wiring Train, Tower Wagon, OHE Depot etc.
are in ready-for-use condition and to the approved scales;
g) The issues shown are commensurate with requirements. Heavy issues soon after receipts should
be particularly scrutinized carefully.
4. DEE/AEEs should carry out such test verification of stores of all their subordinates atleast once in
6 months and Sr. DEEs once per annum.

5. Verification of balances are made periodically by stock verifiers of the Accounts Department to
whom every assistance should be afforded. The stock verification sheets should be signed jointly by
the Stock Holder and the Stock Verifier.
Discrepancies should be explained, but no adjustments should be made until orders have been
received from SR.DEE. The necessary receipts and issues should then be shown in the ledgers and
returns with remarks and references to the order of SR.DEE.

10825 Computerized Stores Accounting

With computerization of stores accountal, certain changes in procedures are being progressively
introduced with which indenting officials should make themselves familiar.
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I [76]
 CHAPTER IX

QUALITY ASSURANCE & RELIABILITY ENGINEERING

Para No. Subject

10900 General

10901 Definition of Quality

10902 Purchase of Spares

10903 Application of Reliability Engineering

10904 Employees Participation

Annexure 9.1 - Note on Quality Management

Annexure 9.2 - Note on Reliability Engineering.

INDIAN RAJLWAYS - AC TRAC'TION MANUAL VOLUME I [77]

 CHAPTERIX

QUALITY ASSURANCE & RELIABILITY ENGINEERING

10900 General

It shall be endeavour of every official to take steps towards quality in their set-up to improve
productivity. Quality Assurance involves effects towards quality improvement, quality development
and quality maintenance to meet service requirements at economical levels. This would require
enhancing quality of products, services and activities.

10901 Definition of Quality

Use of quality spares for maintaining traction assets plays a vital role in their reliable operation.
Quality of a product/ equipment is defined as compliance with the following :

a) The specifications as established by the purchaser and accepted by the supplier;

b) The design details as declared by the supplier and accepted by the purchaser; and

c) Sound engineering practice though not specifically defined either in the specifications or in the
designs.

A note on scope of quality assurance, quality aspects in manufacturing, system of acceptance

sampling, quality, indices for acceptance is given in the Annexure - 9.1 for reference.

10902 Purchase of Spares

The following guide-lines have been laid down for purchase of quality spares: (ref. Board's letters
nos. 73/RS(G)/ 30/RLL dt. 30.3. 87 & 17.2.89).

The various components, sub-assemblies and spare parts shall be purchased from
original/approved suppliers. Railways will however make out a compendium of RDSO approved
manufacturer's list. Any variation from the same shall only be permitted personally by the Chief
Electrical Engineer.

10903 Application of Reliability Engineering

To improve quality of service and improve availability of equipment for operations, application of
concept of reliability engineering is also being considered as one of the scientific approaches in use.
A note on Reliability Engineering is enclosed as Annexure-9.2 for reference.

10904 Employees Participation

Participation of employees in Quality Circles and quality improvement is essential for Quality
Management of services. It is to be remembered that Quality involves every one in the organisation,
management, workers towards improving performance at every level to build an organisational
culture where the quality improvement are embedded into the work and the activities.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 1 [78]

 Annexure 9.1

NOTE ON QUALITY MANAGEMENT

1. Scope of Quality Assurance

1) Quality Assurance consists of the measures taken to ensure that three conditions listed below are
fulfilled.

a) The specifications as established by the purchaser and accepted by the supplier ;

b) The design details as declared by the supplier and accepted by the purchaser; and

c) Sound engineering practice though not specifically defined either in the specifications or in the
designs.

2. The main aim or objective of Quality Assurance is to prevent any defect form appearing or
developing in the work done and not merely to detect and reject defective work.

3. While occasional rejection requiring rework or replacement is not ruled out, the objective is to
take every possible step to eliminate the basic or root causes of defects.

4. It is also the purpose of Quality Assurance to maintain records in such detail and manner as to
facilitate investigations into problems or failures that may arise during the life time of the work done.

2. Quality Aspects in Manufacturing

The specific quality aspect in manufacturing includes :

1. Choice of machines, processes and tools capable of maintaining the tolerances.

2. Choice of instrument of an accuracy adequate to control the processes.
3. Planning the flow of manufacturing information and criteria.
4. Planning of process quality controls.
5. Selection and training of production personnel.
6. Planning the quality aspects of purchasing and shipping.

3. Planning Through Trial Lots

The trial lot is used to " clear the track" for full scale production by: -

1. Proving that the tools and processes can indeed turn the product out successfully.

2. Proving, on test, that the product will process the essential functional features.

3. Proving, on use, that the product will achieve the desired field performance.

4. Remedying the deficiencies in manufacturing process of product before embarking on full scale
production.

These proofs and remedies cannot be provided from the record of samples made in the pilot plant.
In the pilot plant the basic purpose is to prove engineering feasibility, in the production shop the
purpose is to meet standard of quality, cost and delivery. The pilot plant machinery, tools,
personnel, supervisions, motivation, etc. are all different from the corresponding situation in the
production shop.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME I [79]

4. Acceptance Sampling

1. Introduction

1. 1 Acceptance Sampling is the process by which decisions are taken either to accept or to reject
an entire 'Lot' of products offered for inspection, on the basis of detailed 100 percent inspection of
one or more samples drawn at random from the lot.

1.2 The number of items to be drawn from each sample, the number of samples to be drawn from
the lot and the number of permissible detectives in each sample, constitute what is known as the
Sampling Plan.

1.3 Acceptance Sampling is based on the mathematics of Probability and Statistics. Sampling plans
are generally selected from published tables to suit the expected quality levels.

1.4 The following Indian Standards must be studied by all Engineers concerned with Inspection and
Quality Control.

a) IS 397 -Methods of Statistical Quality Control During Production

b) IS 1548 -Manual on Basic Principles of Lot Sampling

c) IS 2500 -Sampling Inspection tables

Part I - Inspection by Attributes and by Count of Defects.

Part II - Inspection by Variables for Percent Defective .

d) IS 5002 - Methods for Determination of Sample Size to Estimate the Average Quality of a
Lot or Process.

2. Quality Indices for Acceptance Sampling

2.1 Acceptable Quality Level (AQL):

This is usually defined as the worst quality level that is still considered satisfactory. The units of
quality level can be selected to meet the particular needs of a product. Thus, MIL-STD-105 D"
defines AQL as "the maximum percent defective (or the maximum number of defects per hundred
units) that, for purposes of sampling inspection, can be considered satisfactory as a process
average." If a unit of product can have a number of different defects of varying seriousness, then
demerits can be assigned to each type of defect and product quality measured in terms of demerits.

As an AQL is an acceptable level, the probability of acceptance for an AQL lot should be high (see
Figure 9.01)

2.2 Rejectable Quality Level (RQL):

This is a definition of unsatisfactory quality. Different titles are sometimes used to denote an RQL for
example, in the Dodge-Romig plans, the term "Lot tolerance percent defective (LTPD)" is used. As
an RQL is an unacceptable level, the probability of acceptance for an RQL lot should below (see
Figure 9.01). In some tables, this probability is known as the consumer's risk designated as Pc and
has been standardized at 0.1 .

The consumer's risk is not the probability that the consumer will actually receive product at the RQL.
The consumer will in fact not receive 1 lot in 10 at RQL fraction defective. What the consumer
actually gets depends on actual quality in the lots before inspection, and on the probability of
acceptance.
INDIAN RAILWAYS -AC TRACTION MANUAL VOLUME I [80]
2.3 Indifference Quality Level (SQL):
This is a quality level somewhere between the AQL and RQL. It is frequently defined
as the quality level having a probability of acceptance of 0.50 for a given sampling
plan (see Figure 9.01).

2.4 Average Outgoing Quality Limit

A relationship exists between the fraction of defectives in the material before
inspection (incoming quality p) and the fraction of defectives remaining after inspection
(outgoing quality AOQ) : AOQ= pPa. Obviously, when incoming quality is perfect,
outgoing quality must likewise be perfect. However when incoming quality is very bad,
outgoing quality will still be perfect because the sampling plan will cause all lots to be
rejected and detailed inspected. Thus at either extreme-incoming quality very good or
very bad- the outgoing quality will tend to be very good. Between these extremes is
the point at which the percent of defectives in the outgoing material will reach its
maximum. This point is known as the average outgoing quality limit (AOQL).
3. Sampling Plans
3.1Normally, Sampling Plans have to be specified clearly by the purchaser because it is
essential to have agreement on this issue between the Purchaser and the Supplier.
When so specified, the sampling plans should be followed scrupulously by the
Inspector.
3.2When the specification does not include Acceptance by Sampling and if the Inspector
considers that 100 percent inspection is neither practicable nor necessary, a
reference should be made to the purchaser.
3.3Different Sampling plans may be adopted for different properties or parameters of the
items to beinspected. More important properties may be checked on sample of larger
size.

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3.4 Where the items being inspected are being produced by fully automatic machines the sample
size specified may be smaller than in the case of manually produced items. It is desirable in such
cases and also in general when lots of identical items are inspected repeatedly, to carry out the
inspection in the same sequence as manufacture. Control charts should also be maintained to
enable timely detection of dimensions going beyond permissible limits. Whenever the machine is
reset or retooled, 100 percent inspection should be carried out by the manufactur's Inspection
organisation until consistently good results are obtained.

4. Random Sampling

The conclusions drawn, relating to the quality of a whole lot on the basis of a 100 percent check on
a sample, can be relied upon only if the sample is sufficiently large and the sample is selected in a
totally unbiased or random manner. Above all, the selection should not be influenced in any manner
by the Supplier's suggestions or actions. The quality of acceptability of an item should not determine
the choice of items for the sample. Even the inspector himself should try to avoid any inadvertent or
unintended bias in the selection of the sample. This can be ensured by using a table of random
numbers.

5. Sample Size

5. 1 One item drawn from a lot of any size cannot be relied upon to give any idea of the quality of
the lot except in the case of fluids or fluid-like fine powders which have been thoroughly mixed
together. In these exceptional cases a small quantity-apparently a single sample-will give a reliable
measure of the whole lot.

5.2 The Sample size, i.e. the number of items included in the sample, is very important. It increases
with increasing lot size-but not in the same proporation. For example, for an AQL of 0.65 :-

Lot Size Sample Size Sample Percentage

100 20 20
1000 125 12.5
3000 200 6.7

6. Limitations of Acceptance Sampling

6. 1 The limitations of Acceptance Sampling are as follows :

a) Acceptance Sampling involves some uncertainty or risk. For instance, it is not possible to say
with certainty whether any individual item taken from a lot which has been accepted by Sampling, is
good or bad. Therefore, Acceptance Sampling should not be adopted where defects are not
acceptable in even one item as, for example, in Safety Items.

b) It is possible to estimate the percentage of good or bad items in a lot accepted by sampling with
adequate accuracy and confidence, only if all the rules of sampling are followed strictly.

c) If an incorrect sampling plan is adopted or if sample selection is not properly randomized there is
danger of very bad lots gettng accepted.

6.2 Where large quantities or numbers of identical items have to be inspected, the advantage of
acceptance Sampling outweigh its limitations. Moreover, destructive tests have necessarily to be
based on 'Sampling' basis.

INDIAN RAILWAYS --AC TRACTION MANUAL VOLUME I [82]

 Annexure 9.2
NOTE ON RELIABILITY ENGINEERING
1. Introduction

Reliability Engineering is not totally new to engineers. They have always been practicing the
essentials of reliability engineering without giving it this name or using its terminology.

1.1. Reliability engineering is the discipline concerned with the prevention of defect, failures, fires,
accidents etc., in all types of hardware from the smallest items like hand tools to the largest units
like loco- motives, boilers, turbines etc. This discipline has been successfully applied in a number of
complicated and baffling cases to reduce the breakdown rate of equipments, improve the availability
of plants for operation and thus to help in reduction of costs and improvement of efficiency and
productivity.

1.2. Even though the overall or general design of the multitudes of types of hardware are widely
different, the detailed design of components as also the mechanisms of failures are generally
similar. The basic principles of reliability engineering can be applied to identify the root causes of
failures such as weak links in the systems, starting points of material failures, causes of
workmanship defects, degradation processes, and many other such factors which usually lie
hidden under the obvious causes of failures.

1.3. Reliability engineering is most appropriate for repetitive types of failures which continue to
occur again and again despite various measures being taken to avoid these failures. In such
intractable cases, the user has either to suffer the failures continuously or to take the burden of
replacing the entire equipment in question. Such intractable cases have been solved economically
by the application of the principles and methods of reliability engineering.

While the basic principles of design, manufacture and maintenance differ widely between the fields
of civil, electrical, mechanical or signal & telecommunication engineering, across all these specialist
branches cuts the new disciplines of reliability engineering. The modes and mechanisms of failures
of all types of hardware are the same and the statistical/ mathematical methods for understanding
and studying them all, are identical.

2. Basic Principles

2.1Definition of Reliability
Formally, reliability is the probability that an item will perform as required, under stated condition, for
a stated period of time. Thus if we have a large number items on test, we can write:-

Number surviving at present

Reliability at time t = R(t) ---------------------------------------
Number at start
2.2.Failures

When an item no longer works as intended we say it has failed. Therefore, "Failure is the
termination of the ability of an item to perform its required function.

2.3. Classification of failures.

Failures can be classified as follows :
a) As to Cause:
'Misuse failure' is a 'failure attributable' to the application of stress beyond the stated capability of
the item. Thus it has been ill treated. An 'inherent weakness failure' is a failure inherent in the item
itself,
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b) Constant failure period:

Once the early failures have been removed, the parts usually settle down to what may be a
relatively long period, when the failure rate is approximately constant.

During the constant failure period, it is usual for failures from a wide variety of causes occur at
random with no obvious pattern, except that the failure rate is roughly constant. Such failures are
also commonly called random or chance failure. Where failures do form a well defined pattern the
reliability engineer calls them 'systematic failures' and such patterns usually provide valuable
information about the cause of a failure.

c) Wear out failure period:

The incidence of failure in this period is high since most of the component will have exceeded their
service life and consequently would have deteriorated.

2.5. Failure Mechanism:

A few of the common failure mechanisms are

Adherence Deterioration Piezo electric defect

Arcing Diffusion Radiation damage
Backlash Drift and shift Secondary Current
Bleeding Dynamics out of limit Seizure
Carbonisation Electric Breakdown Silver migration
Composite behaviour Erosion Slip
Contact bounce Fatigue Smearing
Contamination Fretting or galling Sublimation
Corona Frequency effect Voltage Breakdown
Creep Leakage Voltage overload
Creep rupture Magnetic hystreresis Wear
Cross talk Mass unbalance -
Current Overload Noise
Decarbonisation Opens

2.6. Mean Time Between Failures (MTBF):

Where the failure rate is approximately constant, it is convenient to use the Mean Time between
Failures (MTBF). The mean time between failures is the reciprocal of the failure rate. It should be as
long as possible.

2.7.Mean Time To Failure (MTTF):

The term mean time to failure is analogous in every way with mean time between failure and is used
where a failure can not be repaired.

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2. 8. Mean Time To Repair (MTTR):

It is the mean time taken to put the equipment right after it has failed. It should be as short as
possible.
2.9. Availability:
It is the probability that an equipment will be available for use and is given by the following
relationship:
MTBF
Availability = -----------------
MTBF + MTTR

3. Failure mode effect and criticality analysis (F-MECA)

a) F-MECA method is used very widely at the design stage for estimating the reliability of any new
system.or product and, more importantly, for evolving more reliable designs through the
identification of vulnerable or failure prone components.

b) The method is described in United States MIL - STD-1629 (Procedures for Performing a Failure
Mode, Effects and Criticality Analysis). The basic principle of this method consists of listing all the
components of an equipment or system and to evaluate, the effects of each possible failure mode of
each component on the equipment or system as a whole. The results of failures are classified
according to the severity of the effects.

c) This method was originally developed mainly for electronic equipment but it can be applied
equally well to heavy electrical equipment or even mechanical equipment or systems.

d) Formal application of F - MECA methods is certainly useful for evaluating or designing complex
systems but there is another advantage of learning this system. It gives an insight to the engineer
which is useful for not only designing but also for investigating failures of small equipment or
components. Therefore, it is useful to study this system for even those who will not be called upon
to apply it for designing, evaluating or improving complex systems.

e) Although F-MECA methods as defined in MIL-STD-1629 were originally developed for the
purpose of evaluation of reliability of electronic equipment at the design stage, it is possible to
devise a variation which is suitable for a complex operational system such as the Railways, not so
much for designing the system as for evaluating the effects of various failure modes on
performance. Such an analysis will help to place in the proper perspective different types of failures
which occur everyday. The overall picture -so produced will help the top management firstly to
determine the most effective application of available resources and secondly to asses the
effectiveness of measures taken to prevent any type failure.

4. Failure Reporting and Corrective Action Systems (FRACAS)

a) FRACAS system was originally designed for reporting and investigating systematically all
failures which occur during the development of any new product. However, it can equally well be
applied to an organization such as the Indian Railways to systematize the action that needs to be
taken to improve the reliability of the hardware. It is as important for old designs of equipment which
have been in service for many years as for new equipments introduced into service recently. If the
very first failure of each type on any new equipment is treated as a problem to be investigated and
corrected much time and money can be saved.

b) The starting point for the establishment of a FRACAS is the constitution of a failure review group
(FRG) comprising:
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME [86]
Divisional officer in-charge of maintenance.

HQ officer in-charge of design/development

Any other officers who could contribute to the solution of the problem.

c) The FRG should work as a team to solve the problem and not as a forum for fixing
responsibility, preparing a report or commenting on failure reports. Its recommendations should aim
at practical and economical solutions. Where action is within their own powers or capacity the FRG
should implement their decisions, if not, they should consider it their responsibility to obtain the
required approvals from higher levels. They should always keep in mind that the effort must always
be to determine the technical solution in detail. Merely reporting the problems to manufacturers for
necessary action is not the function of an FRG.

d) The FRG should meet at least once a week to review the failure reports on the equipment under
consideration and to determine the corrective actions.

e) Whenever any new equipment is commissioned an FRG should be set up. Similarly an FRG may
be established for a few specific problems of old standing which may be causing concern. The FRG
should remain in force until the reliability of the equipment attains the desired level.

f) The starting points for an FRG are the source reports on defects, failures, observations on
operating irregularities etc. United States MIL-STD-781 provides a description of failure reporting
methods. The common elements of all such failure reports are:

- description of failure symptoms

- effect of failure
- immediate action taken
- elapsed time after commissioning, after various maintenance schedules.
- operating conditions
- date, time, place of failure
- make, type, serial number of equipment and of component(s)
- opinion of person writing the report regarding possible cause of failure
- design modifications, if any.

g) Failure report forms should be designed to cover all the above details as also any other relevant
data specific to the equipment in question.

h) Corrective action proposed by the FRG and approved for implementation should be clearly
defined and its implementation on the entire population of the equipments in question should be
watched. Then performance after the corrective action should be monitored. The FRG for any
particular equipment may be wound up only when the desired reliability level is attained.

5. Potential of Reliability Engineering

5. 1 Design Stage

i) If the specification is drawn up carefully, it takes care of what we may call the 'Gross' design
requirements. If the equipment complies with the specification and passes the tests stipulated
therein, it will meet all the performance requirements and is unlikely to have any major defects
which could render it unserviceable in a short time. However, this is not enough. The number of
ways in which things can go wrong is so large that careful scrutiny of design details in every
component is essential. Such scrutiny is inescapable in the case of equipments being manufactured
by new firms for the first time. Even in the case of products made by reputed firms, if it is a new
product, it is desirable to carry out such detailed scrutiny of designs. Very often, apparently minor
deviations or discrepancies.

INDIAN RAILWAYS AC TRACTIAON MANUAL VOLUME I [87]

can lead to avoidable failures in service. It is in the interest of not only the user but also the supplier that the
detailed working drawings are scrutinized by reliability engineers familiar with the performance of the
equipments under actual service conditions. The only time such designs scrutiny can be waived is when an
identical design has been in successful service for many years under identical conditions. Even in such cases
it is necessary to check that there has been no change in the detailed design of any component. Further, the
opportunity should be taken to review the reliability and failure statistics to see whether any improvements in
the design of the concerned components can be introduced.

5. 2 Manufacturing Stage

i) It is always not possible to visualize every thing at the drawing board stage. When the manufacture of the
high prototype is undertaken, various problems may be exposed, particularly in the case of complex systems.
The problems may relate to manufacture or to maintainability and reliability. Studies relating to
maintainability/reliability must continue concurrently during the manufacture of prototypes.

ii) As far as the actual method is concerned the best way in the long run to ensure reliability is to insist on a
fanatic or rigid adherence to drawings, process sheets and such other production documents.
Relaxations/deviations and even so called 'improvements' in process should be reviewed carefully by both
basic design engineers and reliability engineers before permitting them on the production line. If such scrutiny
reveals an unnecessary or superfluous feature in the drawing, the drawings or processes should be modified
but as regards the production staff are concerned, production documents mentioned above viz. working
drawings, process sheets, etc. should be treated as sacrosanct.

5.3 Inspection and Testing

i) While the function of inspection and testing organization is to carry out the actual inspection and testing, it is
the function of reliability engineering service to define what these inspections and tests should be, when they
should be carried out and what criteria should be followed and so on.

ii) Organization of stage inspection from raw material stage through components and sub-assemblies upto the
final inspection and testing of the finished product is of the utmost importance. There are many types of
defects in regard to tolerances, material specification and process parameters which will have little or no effect
on the performance of the equipment as may be judged during acceptance tests or even limited actual service
but such defects can cause even catastrophic failures in actual service. These failures may occur at any time.
Some may occur within days after commissioning whereas some others may develop after several years
service. It is the function of the reliability engineer to investigate all such failures to determine the real or
probable causes and to alert the stage inspection organization to watch for and eliminate these types of
defects.

iii) In this connection, special mention must be made of screening or burning-in procedures. Many
components, particularly those which require sophisticated technology in production or those in which
contamination and invisible dimensional inaccuracies can cause failures, exhibit a high rate of failure, initially.
This is termed as 'Infant mortality'. Examples of components which exhibit this pattern of failures are semi-
conductors, fuses, incandescent lamps, coils with very fine wire etc. Reliability of such components in service
can be improved by operating them at a stress level which is significantly higher than that in service. Weak
components which would otherwise have failed in service will fail or at least show some deterioration of
properties during the screening procedures. By eliminating such components the reliability of the remaining
components which survive the screening process will be much higher in actual service. It must be noted that
'screening or burning - in' does not improve the quality of the components. It merely accelerates the failures of
those which would have failed any way in service.
5.4 Operation and Maintenance

i) The most important contribution that can be made by operating staff and maintenance staff towards the
improvement of reliability is in regard to investigation of failures. It is necessary to determine and

INDIAN RAILWAYS AC TRACTION MANUALVOLUME 1 [88]

analyze as accurately as possible the actual conditions of service under which the failures occur
and to re-construct from the observed data and study of failed components the exact mechanism of
failures. On the success of these studies depends the evolution of the quickest and most cost-
effective solutions to the problems. Experience in failure investigations is invaluable for this purpose
but a systematic study and application of the principles of reliability engineering can greatly speed
up the investigation. A through insight into the design of the equipment with regard to the calculation
of various types of stresses is of-course desirable and often essential but it is also possible to
evolve elegant solutions without going into the full design details.

6. Reliability and Cost

a) It is not always necessary that improvement in reliability must cost more. Better designs, different
materials, better quality control during production etc. may achieve improved reliability at little or no
extra cost. If scrap is reduced at the same time, the overall cost may actually come down. Predicting
the cost of achieving any given reliability is nearly always difficult, so that in general we only know
the cost accurately afterwards.

b) Maintenance costs are also difficult to estimate. If we know precisely what repair work has to be
done each time an equipment fails, then we can predict its cost.

However we are unlikely to be able to foresee associated costs such as:-

i) The value of production/service lost through breakdowns.

ii) The cost of having the equipment of action.

7 Suggested Books for Further Reading

1. Practical Reliability Engineering by Patric O'Connor (Published by John Wiley)

1. A Practical Approach to Reliability by R. H. Caplen (Published by Business Books Ltd.

*3.MIL-HDBK-217C: Reliability Prediction for Electronic Systems

*4.MIL-STD-1629: Failure Mode, Effects and Criticality Analysis

*,5 MIL- HDBK-189: Reliability Growth Management.

*6.MIL-STD-781 Reliability Qualification and Production Approval Tests.

7- Selection and use of Engineering Materials by FAA Crane and J.A. Charles (Published by
Butterworths).

* United States Military Standards obtainable from National Technical Information Service,
Springfield Virginia, USA.

INDIAN RAILWAYS- AC TRACTION MANUAL VOLUME I [89]

 CHAPTER X
SURVEYS, ESTIMATES & PROGRAMMES
11000 General

Engineering Code covers various aspects of Project development process. The following relevant
Chapters of the Code should also be referred:

Chapter II Modes of Investigation of Railway Project

Chapter III Traffic Survey

Chapter IV Engineering Survey - Reconnaissance, Preliminary and Final Location Surveys

Chapter V Engineering Survey - Project Reports, Techno- Economic Survey Report and Feasibility
Report

Chapter VI Estimates

I. SURVEYS

11001 Railway Electrification Surveys

1. Only a brief introduction to Railway Electrification surveys is given in this Chapter.

2. Railway Electrification surveys may be classified broadly in two categories;-

a) Cost-cum-feasibility-survey as a pre-investment investigation to assist decision making: and

b) Foot by foot survey to assist in preparation of working designs and drawings for actual
construction work.

In case of urgency it may be necessary to include portions of (b) along with (a), but normally the two
surveys are taken up separately.

11002 Cost-cum-Feasibility Survey

It is quick survey of the route proposed for electrification to examine major engineering installations
which may have a bearing on the cost of electrification.

1) Civil Works:

This will include study of heavy overline structures like flyovers, road over bridges, through girder
bridges and long deck type girder bridges and tunnels to examine whether these will require major
or minor modification to permit erection of overhead equipment. An examination of the proposed
remodelling plans, rack renewals, reballasting including changes in the level of track, realignment of
curves, all having a bearing on track geometry and the dates when these are proposed to be
completed, will be necessary. In yards, a survey of track proposed to be wired will have to be
examined for track centres to prepare slewing plans and assess their cost, for location of OHE
structures.

- Feasibility of running 12 wide stock on suburban routes in vicinity of cities.

INDIAN RAILWAYS -AC TRACTION MANUAL -VOLUME 1 [91]

- Availability of suitable land for location of locomotive shed, remote control centre,
maintenance depots.

- Quick survey of soil to assess cost involved in foundation.

2. Signalling & Telecommunication works.

- Modification needed to existing installations General Power Supply.

3. Modification to track crossings

- Modification to HT and LT lines.

11003 Foot by Foot Survey

On acceptance of a project report, foot by foot detailed surveys are required for the preparation of
working drawings for the electrification.

The scope broadly is as under: -

- Checking of configuration of layout of the track, chainage of turnout, cross overs, diamond
crossing etc., Inter - track distances, curvature of tracks, versine, super elevation, cross section of
track formation at an interval of 200m, detail of embankment/cutting etc.

- Checking of setting distance of existing signals, signalling rocks, wires junction boxes, cranes
blocks etc.

- Checking of position of cabins, cable huts, station buildings, goods shed etc.

- Checking of position of overline structures.

- Determination of type of soil along the route at intervals not more than 5 Km.

- Collection of site details regarding bridges, tunnels etc. including study of clearances.

The data so collected is utilized to correct and update survey plans. These are then used for of
preparation of pegging plans showing tentative location of OHE structures following 'Principles for
OHE Layout Plans and Sectioning Diagrams for 25 kV ac Tractions', Appendix I, Vol. II of this
manual. Site confirmation of prepegging plans is then carried to ascertain feasibility of structural
locations.

II. ESTIMATES

11004 Estimates

All proposals for-

a) The construction or purchase of material for new works or assets,

b) The renewal and replacement of existing works or assets,
c) The scrapping, dismantlement or abandonment of existing works or assets,
d) The repairing or reconditioning;
e) Temporary and experimental works;
Should be scrutinized by the authority Competent to sanction them before any expenditure or
liability is incurred thereon.
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Broadly estimates are of two types: -

a) Abstract Estimates
b) Detailed Estimates

11005 Abstract Estimates

An abstract estimate is prepared in order to enable to the authority competent to give administrative
approval to the expenditure of the nature and magnitude contemplated to form a reasonably
accurate idea to enable that authority to gauge adequately the financial prospects of the proposal.
Abstract estimates avoid the expense and delay of preparing estimates for works in detail at a stage
when the necessity or the general desirability of the works proposed has not been decided upon by
competent authority. An abstract estimate should contain a brief report and justification for the work,
specifications, and should mention whether funds are required in the current year and to what
extent. It should also show the cost subdivided under main heads and subhead or specific items,
the purpose being to present a correct idea of the work and to indicate the nature of the expenditure
involved. The allocation of each item as between Capital, Development Fund, Open Line Works -
Revenue, Depreciation Reserve Fund and Revenue should be indicated.

11006 Detailed Estimates

On receipt of administrative approval to a project or scheme conveyed through the sanction to the
abstract estimate relating there to detailed estimate for various works should be prepared and
submitted for technical sanction of the competent authority. It should be prepared in sufficient detail
to enable the competent authority to make sure that the abstract estimate sanctioned by the higher
authority is not likely to be exceeded. No work included in an abstract estimate should be
commenced till a detailed estimate for the same is prepared and sanctioned and adequate funds
are allotted by the competent authority allots adequate funds. The detailed estimate will comprise (i)
statements showing details of estimated cost and (ii) an outer sheet giving the abstract of cost of
work, the report, the financial justification and the allocation.

11007 General Rules Applicable to All Estimates

1. Responsibility for Preparation of Estimates

For proposals initiated in the Division estimates shall be prepared in the Division. Estimates of
works, which the Senior Divisional Electrical Engineer or the Divisional Railway Manager is not
empowered sanction, shall be submitted to the Chief Electrical Engineer duly verified by the
Accounts Officer for Administrative approval and Technical sanction.

2. Design and Execution

The designs and execution of all new works and designs of equipment should conform to
IRS/RDSO Standards, Drawings, Codes, Rules, Principles, Guidelines wherever available. No work
which infringes "Schedules of Dimensions" shall be executed unless prior sanction of the CRS has
been obtained.

3. Altemative Proposals

When alternative proposals are made, separate estimate should be prepared for each, together with
a general abstract showing in tabular form the comparative cost of the various alternatives.

4. Grouping of Items

As far as possible items of estimates chargeable to the same head or sub-head of account should
be grouped together so that the number of items under expenditure posted in the Register of Work
may be reduced to a minimum.
INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME I [93]
5. Grouping of Works

a) When two or more works are so connected either by their situation, or by the purpose or
purposes which they are designed to serve, that the construction of one necessarily involves that of
the other or others, the works should be considered to comprise one scheme and the aggregate
estimated cost of the works so connected shall determine the authority competent to sanction
expenditure on the scheme.

When the works constituting a connected scheme are situated in more than one executive division
separate detailed estimates should be prepared of the cost of the work in each division so that the
Engineer entrusted with the actual construction may be in a position to watch expenditure against
sanctioned estimate of the cost of the work in his charge.

6.Establishment and Other Charges

a) It should be ensured that due provision for establishment charges is made in major schemes
under the heading 'Establishment'. If any such charges are not foreseen and additional
establishment is required, sanction of the competent authority should be obtained and the
expenditure shown against 'Establishment' and not against 'Contingencies', the excess being
subsequently provided for in a revised estimate, if necessary, or explained in the completion report.

b) The engagement of work-charged establishment is subject to the following conditions-

i) The cost of establishment should be shown in detail under separate sub-heads of the estimate.

ii) If an Engineer, Supervisor, or other staff is actually employed on the supervision of two or more
works his pay and allowance should be charged proportionately to those works. .

Provisions made in Indian Railway Financial Code should be kept in view in respect of various
charges to be included.

7. Currency of Sanction
The sanction to estimate shall ordinarily remain current for 5 years from the date it has been
accorded, unless it has been renewed for a further term by the acceptance of a revised estimate.
Acceptance by competent authority, however, of a budget estimate which includes specific provision
for expenditure on a work which is in progress, may be regarded as reviving for the year in which
provision is made, the sanction to the estimate regardless of the five years limit. But if no work has
been commenced within 2 years of the date of sanction, the sanction shall be considered as having
lapsed and fresh sanction shall be obtained from the competent authority by submitting an up-to-
date estimate.

8. Register of Estimates

All estimates should, before they are submitted for accounts verification for sanction of the
competent authorities, be registered in the office of origin. For this purpose register in the following
form should be kept-

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 CHAPTER XI
DOCUMENTS FOR REFERENCE
11100 Books of Reference

A list of books of reference to be held at various Electrical Department offices is appended. CEE
may authorize additions to this list as required.

The Chief Electrical Engineers and Sr. Divisional Electrical Engineers offices should be equipped
with adequate number of copies of each publications. The publication should he accounted in the
Dead Stock Register. Officials for whose personal use publications are supplied shall be responsible
for their custody and handing them over prior to retirement from service.

11101 Standing Instructions

Instructions of a standing nature issued by the Railway Board, RDSO, CEE, Sr.DEE / DEE etc.
should be filed subject-wise to be readily available for reference. An index sheet should be opened
on the file containing a complete and up-to-date list of the standing instructions received. This file
should be gone through from time to time to make certain that all of them are being complied with .
When taking over charge of a post, the officer/supervisor should study these standing instructions
carefully.

11102 Drawings and Specifications

1. In CEE's Drawing Office original tracings of drawings and copies of documents listed below
should be carefully stored and preserved for reference when required: -

a) Specification and relevant tender and contract documents pertaining to OHE, PSI, RC and
Rolling- Stock for the entire Railway.

b) Tracings or reproducible prints of design drawings and ' as erected' drawings for all Traction
Installations and Rolling-Stock.

c) Drawings and specifications for all modifications approved for Traction Installations and Rolling-
Stock on the Railway.

d) One set with up-to-date corrections of all Maker's Manuals and Maintenance Instructions issued
by RDSO etc. for Traction Installations, Rolling-Stock and important machines installed in Loco and
EMU sheds, OHE depots etc.

2. Officers and supervisors who have independent offices should similarly maintain drawings,
specifications, Maintenance Manuals and other documents pertaining to installations and equipment
under their charge. Each supervisor will be responsible for safe custody and keeping up-to-date the
documents in his charge. Sr. DEEs may nominate a supervisor attached to their offices for the
purpose.

INDIAN RAILWAYS - AC TRACTION MANUAL -VOLUME 1 [97]

APPENDIX I

DOCUMENTS FOR REFERENCE

List of Books for Reference
Offices which should be equipped with copy of the publication.
-------------------------------------------------------------------------------------------------------------------------------------------
Item Publication For the Sr. DEE AEE Traction Foreman/ TPC TLC Electrical
Chargeman
No. Personal DEE Asst. Traction
use of such Foreman
officers and ----- ------ ----- ----- ---- ------ ---- ----- ----- -----
suprvisors OHE PSI RC RS OHE PSI
RC RS
as may be
prescribed
-------------------------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
-------------------------------------------------------------------------------------------------------------------------------------------
1. Act, Indian Boilers 1 ..
and Manual of Boiler
Inspection as issue.
2. Act, Indian Electricity 1 1 1 1 1 1 1 1 1 1 1 1 1
Rules issued and State
Government publications.
3. Act, Indian Explosive 1 1
and State Government
publications.
4. Act, Indian Factories 1 1 1 1 1
and State Government
publications.
5. Act, Indian Railways -- 1 1 ..

6. Act, Land Acquisition 1 ..

and State Government
publications.
7. Act, Payment of Wages 1 1 1 1 1 1 . . . .
with Notification as issue.
8. Act, Workmens 1 1 1 1 1 1 1
Compensation
9. Act, Indian Lifts. 1
10. Act, Indian Minds 1 1
and State Government
publications.
11 For Later additions
12 Act, Indian Petroleum 1 1 1 1 1 1
13 For Later use
14 Alphabetical List of 1
Railway Stations

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME I [98]

-------------------------------------------------------------------------------------------------------------------------------------------
Item Publication For the Sr. DEE AEE Traction Foreman/ TPC TLC Electrical
Chargeman
No. Personal DEE Asst. Traction
use of such Foreman
officers and ----- ------ ----- ----- ---- ------ ---- ----- ----- -----
suprvisors OHE PSI RC RS OHE PSI
RC RS
as may be
prescribed
-------------------------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
-------------------------------------------------------------------------------------------------------------------------------------------
32. Manual, Indian 1 1 1 1
Railways Works
33. Manual, Indian 1 1 1 1
Railways Track

34. Manual, Indian 1 1 1

Railways Bridge

35. Manual, Indian 1 1 1 1

Railways Signalling

36. Manual, Accident and -- 1 1 1 1 1 1 1 1 1 1 1 1

Circular pertaining to
Accidents
37 Manual, acTraction 1 1 1 1 1 1 1 1 1 1 1 1
1
Maintenance and Operation

38. Manual, Opaeraion for 1 1 1 . 1 . 1

Various types of
Rolling-Stock.
39. Manual, Maintenance 1 1 1 . 1 1
for Various types of
Rolling-Stock
40. Loco Inspection Books 1 1 1 . . . 1
41. Inspection Charts 1 1 1 . 1
42. Trouble Shooting Charts 1 1 1 . 1
43. Technical Charts 1 1 1 . 1
44. Price List of Stores, 1 1 1 1 1 1 . 1 1 1 1
Store nonenclature
and circulars as applicable
45. List of Approved 1 1 1 1 1 1 .
Suppliers
46. Regulations, Hours of 1 1 1 1 1 1 1 1 1 1 1 1
Employment, with
Notifications as issued
47. Regulations Governing 1 1 1 1 1 1 1
the Crossing of Electric
Transmission Lines across
and underground cables
under Railway track.

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME I [100]

 CHAPTER XII
MISCELLANEOUS INSTRUCTIONS
Para No. Subject
11200 General
I. GENERAL INSTRUCTIONS
11201 Knowledge of Rules
11202 Co-operation With Other Staff
11203 Periodical Inspections
11204 Responsibility For Work Done By Staff Below
11205 Personal Contact With Staff Below
11206 Courtesy
11207 Review Of Security Measures
11208 Economy
11209 Records Registers eltc.
11210 Statistical Returns
11211 Daily Diary
11212 Office Work
11213 Major Emergencies, Breakdowns and Accidents
11214 Training of Staff
11215 Relinquishment of Charge
11216 Duties Defined Not Exhaustive

II. THEFTS AND LOSSES

11217 Responsibility for Losses

11218 Thefts
11219 Anti Theft Measures
11220 Watch on Criminal Elements
11221 Procedure to be Followed

III. CARE AND CUSTODY OF INSTRUMENTS

11222 General
11223 Distribution of Instruments
11224 Use of Instruments
11225 Periodic Calibration and Repair of Instruments

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I [102]

 CHAPTER XII
MISCELLANEOUS INSTRUCTIONS

11200 General

These instructions are for general guidance of officers and supervisory officials. Every railway
servant connected with ac traction shall be responsible for compliance with the instructions.

I. GENERAL INSTRUCTIONS

11201 Knowledge of Rules

He shall observe the rules and procedures laid down in the General and Subsidiary Rules, Manual
of ac Traction, the departmental codes, orders and circulars issued from time to time and shall
ensure by frequent inspections and questioning of staff, relevant rules and working methods and are
observing them in practice and performing their allotted duties efficiently.

11202 Co-operation with Other Staff

He shall co-operate fully with officers and staff of the Electrical and other departments in all matters
that warrant joint action.

11203 Periodical Inspections

He shall, by periodic and surprise inspections, ensure safety of installations and equipment under
his charge and in particular the safety of men under his control in carrying out works on high voltage
equipment and rolling-stock.

11204 Responsibility For Work Done-By Staff Below

He is answerable to his superiors not only for his own work but also for the work done by staff below
him and hence should consider it as part of his supervisory duty to guide the men below in the
proper discharge of their duties.

11205 Personal Contact with Staff Below

He shall maintain cordial relations with men below and pay particular attention to their problems and
difficulties met within their daily work. Where he is unable to find a satisfactory solution, he shall
seek the guidance of his superiors. A sympathetic and human approach should be brought to bear
especially when dealing with the personal problems of staff under him.

11206 Courtesy

All staff, particularly those whose duties bring them into frequent contact with the Public, should
always be courteous towards the public in all their dealings.

11207 Review of Security Measures

A constant review should be made of the adequacy of security measures for traction installations,
offices, stores depots, maintenance sheds and workshops including efficacy of fire-fighting
arrangements.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I [103]

11208 Economy
All possible economy should be exercised in the operation and maintenance of traction installations and
rolling- stock, so as to achieve maximum benefits from electric operations.

11209 Records, Registers etc.

Prescribed records, registers, plans, specifications, technical data etc. relating to his work shall be maintained
up- to-date and stored properly to be readily available when required. Superseded documents, drawings and
specifications shall be cancelled and taken out of circulation.

11 2 1 0 Statistical Returns

Prompt submission of periodic statistical returns is of the utmost importance. Compilation of primary records
should be accurate and returns should be carefully scrutinized before submission to higher authorities. Failure
reports shall be carefully and objectively analyzed to establish the root cause of failures and corrective steps
taken to prevent recurrence.

11211 Daily Diary

A daily diary shall be maintained in which all important work done, instructions given, movements, inspections,
meetings etc. are recorded.

11212 Office Work

All offices shall be maintained neat and tidy and correspondence dealt with promptly. Where replies are due,
reminders should be issued periodically. References should be given clearly on letters to facilitate quick
disposal.

11213 Major Emergencies, Break-Downs and Accidents

The organization should always be maintained in a state of readiness to meet any emergency. Emergency
equipment should be maintained in proper condition and emergency staff kept fully aware of their respective
duties. While possible action should be taken to initiate and progress restoration work, an important duty is to
keep superiors fully informed of what is being done, so that they in turn can give further guidance or render
additional assistance, if required.

11214 Training of Staff

It is a part of one's duty to be acquainted with latest developments and to instruct, educate and train men
below and make them proficient in their allotted work. The performance of each person should be reviewed
periodically. Deficiencies, if any, should be pointed out and opportunities given to improve. Where, however, a
person continues to be negligent, indifferent or inattentive to his duties, appropriate disciplinary action should
be taken. It is equally important on the other hand to notice the good work done and express appreciation.

Personal interest should be taken to see that staff posted for training receive the necessary assistance and
facilities to learn the work.

Periodic tests should be conducted in accordance with prescribed procedure and an objective and informative
assessment report submitted to superiors.

11215 Relinquishment of Charge

The officials handing over and taking over should carry out joint inspection of all important installations to the
extent possible. The'Transfer of Charge' statement should include a detailed list of maintenance works in
progress and in arrears, if any ; list of items requiring special attention, details of plant out of commission for
repairs or overhaul, progress of works, particulars of important works, proposed and staff position. This
statement should be submitted in duplicate to the higher authorities. One copy of this statement of transfer of
charge between officers shall be submitted to CEE.
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I [104]
After taking over charge, the official concerned shall pay particular attention to the prompt clearance of
pending items and submit a progress report at the end of three months to his superior.

11216 Duties Defined Not Exhaustive

The duties prescribed in the Manual are meant for general guidance and pertain mainly to technical aspects of
the work. In common with other railwaymen, duties and responsibilities prescribed in the Establishment,
Accident and other Manuals are equally applicable to staff connected with electric traction.
II THEFTS AND LOSSES

11217 Responsibility for Losses

Para 1801 of the General Code is reproduced below:

"Every public officer should exercise the same vigilance in respect of public expenditure and public funds
generally as a person of ordinary prudence would exercise in respect of the expenditure and the custody of
his own money. Means should be devised to ensure that every railway servant realizes fully and clearly that
he will be held personally responsible for any loss sustained by Government through fraud or negligence on
his part and also for any loss arising from fraud or negligence on the part of any other railway servant to the
extent it may be shown that he contributed to the loss by his own action or negligence".

11218 Thefts

Thefts of stores or equipment pertaining to electric traction can be of the following types:

1 Thefts of OHE conductors or fittings or equipment from sub-stations, switching stations or RCC.
2. Thefts from electric locos or EMU stock, when stabled or otherwise.
3. Thefts of stores and equipment in the custody of traction officials or from loco/EMU sheds, depots or PSI
depots and offices.

11219 Anti-Theft Measures

Officers and supervisors should constantly review the security arrangements which are in force in the various
offices, stores and depots under their control and endeavour to develop ways and means of combating thefts
of OHE conductors, fittings and other equipment. Surprise checks should be made to make sure that locking
and sealing of doors of offices, stores etc. are being done properly and they are handed over to the custody of
Security staff.

Staff below should also be encouraged to come forward with their ideas regarding anti-theft measures and
should be adequately rewarded for helpful suggestions resulting in development of such anti-theft measures.
Other Divisions and Railway should also be informed of details of any device or modification found successful
in combating thefts.

Particular care should be taken in regard to the accountal and disposal of valuable components such as
copper scrap.

11220 Watch on Criminal Elements

Officers and Supervisors of the Electrical Department should keep themselves informed of bad characters
amongst their staff and pass on the information in their possession confidentially to the Security Officer
concerned. Similarly, any other information which may assist the Security Branch in apprehending criminals
should also be given to the Security Officer. DRM and CEE should also be kept informed of all important
cases reported to the Security Department.
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I [105]
11221 Procedure to be Followed

If a theft has occurred or is suspected as having taken place, the procedure to be followed is as
under:-

1 The official holding charge of the installation should make a thorough check of the
stores/installation and carry out an investigation:

a)To check whether the procedure laid down for locking up and sealing of premises is being
complied with.

b) To assess the extent of loss suffered, if any.

c) To take possession of relevant registers, account books and other evidence which may be of
assistance to the RPF and Police authorities in their investigations.

d) To record all the facts of the case such as the time when the theft occurred, statements of the
concerned staff etc.

2. All cases should without delay be reported to the Railway Police Authorities, the Security
Department and SR.DEE concerned. Complete details such as description and quantity of materials
lost, estimated cost, place of occurrence, time of occurrence and any other relevant particulars
helpful to the investigations should be given. When the amount of loss is estimated to be over Rs
500, a copy of the report must invariably be sent to the Accounts Officer concerned also.

3. Every important case should be reported by the Sr. DEE promptly to GM(Elect) who in turn will
report the matter to the Railway Board and to the Chief Auditor through FA&CAO, if the loss
exceeds Rs. 5,000.

4. The SR.DEE should arrange for a departmental inquiry into every important case with the
association of the Accounts Officer concerned. The inquiry amongst other things should fix
responsibility for the theft to the extent possible and submit recommendations to set over the
lacunae which may come to light during the investigation.

Such departmental inquiries should not be delayed pending police investigation or decision of
criminal cases.

5. Cases reported to the Railway Police should be followed up vigorously with the Police authorities
by Sr. DEE/AEE, with the assistance of the Security Officer.

6. All irrecoverable losses are required to be written off with Accounts concurrence and sanction of
the competent authority, in accordance with local delegation of powers.

The following procedure should be followed for periodic reconciliation of losses:

a) All losses, on their detection, should be entered in a register by the officer incharge. A similar
register is also required to be maintained by the Accounts and Security Officers.
b) At the end of each quarter, the figures in their respective registers should be totaled up by the
official in-charge, the Security Officer and the Accounts Officer.
c) The reconciled figures, duly signed by the Sr. DEE, Accounts Officer, and Security Officer will be
forwarded to CSO and FA&CAO for compiling a consolidated figure for the railway as a whole for
submission to the Railway Board. (Board's letter No. 64/Sec.(CR)147/13/Pol dated 2nd August,
1968).
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME I [106]
III. CARE AND CUSTODY OF INSTRUMENTS
11222 General
The maintenance of electrical equipment necessitates the use of variety of specialized and often
costly instruments. Proper use of these instruments, their care and custody should receive special
attention.

11223 Distribution of Instruments

1. Instruments for day-to-day use e.g. megger, cell-testing voltmeter, ordinary types of volt-meter,
ammeter, ohm meter etc. may be issued to each section supervisor requiring such instruments, for
custody. It may even be necessary to issue a few instruments for every day use to selected
individual workmen.

2. Specialised instruments such as multi-metres, sub-standard metres, precision gauges, Ductor set
etc. should be kept in the custody of senior supervisors only to be issued as and when required to
individual sections.

3. Some types of special instruments such as high voltage insulation tester, sub-standard energy
metres, oscilloscopes, instruments for localization of cable faults etc. should generally be kept in a
central place in each Division to be used for special tests as authorised by Sr. DEE/DEE/AEE.

4. Certain types of special and expensive instruments such as HV pressure testing sets may be
maintained in a common pool for a Railway as a whole.

5. All instruments should be borne on the "Inventory of dead stock" and should bear the T&P
number, either painted or punched on a metallic label securely fixed to the instruments. Periodic
verification of stores should he carried out as explained in Chapter X. A separate register should be
maintained to record issues and receipts.

11224 Use of Instruments

1 Testing and measuring instruments are delicate equipment and should be handled with great care
otherwise they will get damaged and their accuracy badly impaired. These remarks apply
particularly when instruments are being transported from one place to another; they should be taken
properly packed in a wooden case with enough cushioning material.

Certain types of instruments e.g. CRO, Selective level meter, sub-standard and standard
instruments etc. are meant only for stationary use and should not be moved outside the testing
laboratory. Such instruments should be carefully stored in a cup-board and care should be taken
that they are not taken out for field use.

Oil testing sets should be permanently installed at suitable locations e.g. Central/PSI Depot, a
nominated room in the loco / EMU shed etc. Test samples should be taken to the depot/ shed for
testing, by a trained supervisor.

2. Operating instructions received with special types of instruments should be carefully preserved.
When only one copy is received, additional copies as required should be made out. One set of
instructions should be kept with the instrument for day to day use and at least one more set should
be kept in a central place e.g. Foreman's or Sr. DEE's Office. The T&P register for each item should
show the distribution of copies of its operating instructions.
At least two supervisors should make a detailed study of each instruction book and be fully familiar
with their use. Experience has shown that quite often a number of instruments are held which are
never used in practice either because it has been handled or used by someone who is ignorant or
not qualified to use it. Every supervisory official shall inspect the equipment under his control at
least once in 3 months and certify that it is in good working order.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME I [107]

Only persons who are fully familiar with all the details should be permitted to handle and use the
instruments, especially the expensive specialized instruments. Amateurish handling.of instruments,
even comparatively simple instruments such as Avo-meters, can result in serious damage to them.

4. Instruments meant for field use should invariably have suitable carrying cases. Even if such
carrying cases are not received with the instruments, they should be got manufactured to ensure
that the instruments do not get damaged due to careless transporting.

11225 Periodic Calibration and Repair of Instruments

1. Each Zonal Railway should have a qualified supervisor and a few specially skilled and trained
men, attached to the Central PSI Depot or other convenient place, for carrying out simple repairs of
common instruments such as ammeters, volt-meters, ohm-.meters, pressure gauges etc. The repair
section should be equipped with special tools like watchmaker's hand tools, watchmaker's lathe,
winding machine for small coils, testing instruments of sub-standard accuracy, test bench with
variable voltage and current supply etc.

2. Special instruments should as far as possible be got repaired by the makers or their authorized
representatives. When these are not available, care should be taken to entrust such repairs only to
reliable firms specializing in such jobs and having adequate facilities for repair and testing.

3. Standard and sub-standard meters, gauges etc. should be got tested once in two years by
recognized laboratories and test certificates obtained. A copy of the test certificate should be placed
in a plastic envelope and kept along with the instrument, while the original should be carefully filed.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME I [108]

 CHAPTER I
POWER SUPPLY FOR TRACTION

20100 Supply System

1. The single phase 50 Hz. Power for the electric traction is obtained from 220/132/110/66 KV
Extra High Voltage 3-phase grid system through step down single-phase transformers. For this
purpose duplicate feeders comprising of only 2 phases are run from the nearest grid substation of
the Supply Authority to the traction substation. The brief description of the system is given in
Chapter 2 of Volume I. The 25 KV single phase conventional system as adopted on Indian
Railways has been described in that chapter. A schematic diagram of the traction sub station and
feeding post indicating the general feeding arrangement is indicated at Fig. 1.01.

Salient technical features of the 2x25KV AutoTransformer (AT) feed system are indicated in Chapter XI.

20101 Liasion with Power Supply Authorities.

For ensuring continuity and reliability of power supply for traction it is important that effective liaison
is maintained between the officials of Railway and Supply Authorities. Broadly action on the
following lines be taken:

a) A system of periodic meetings at different levels at mutually agreed intervals needs to be

evolved.

b) Reliability of supply involves also the maintenance of traction voltage between 25 KV and 27.5
KV at the feeding posts and frequency between 48.5Hz. and 51.5 Hz. The serious repercussions
on Railway traffic if the above limits are not adhered to should be constantly impressed upon the
Supply Authorities.
c) The traction load should be treated as essential load and should not be disconnected or reduced
to meet supply system exigencies. This principle has been accepted by most Supply Authorities
and where this has not been done, constant efforts should be made at the high level periodic
meetings to get this principle accepted.
d) Since the cumulative effect of frequent power supply interruptions, even though of short duration
at a time, can be very serious to Railway working, a periodical review of all such interruptions should
be made at the Divisional level and the cause of each interruption ascertained as far as possible.
The results of the review should be furnished to CEE to keep him fully informed of the power supply
position. This subject should also form an important item for discussion at the periodic meetings
with the Supply Authorities.

e) Power supply for electric traction should be governed by a specific Agreement entered into by
the Railway with the concerned Supply Authority before the supply is actually taken. Where this has
not been done already, urgent action should be taken to have it finalized without delay.

f) When grid supply to any traction sub-station fails and consequently emergency working has to
be resorted to by extending the feed from adjacent sub-stations, the maximum demand at these
sub-stations may go up. Most Supply Authorities have agreed to ignore such temporary increase in
maximum demand for billing purposes. Where this has not yet been agreed to, efforts should be
continued to persuade the Supply Authorities to accept this principle.

g) The present methodology of measuring maximum demand at each individual sub-stations for
the purpose of billing has been reviewed by the Central Electricity Authority. It has been agreed that
Railways should be charged for traction power on the basis of simultaneous maximum demand
recorded in contiguous sub-stations of the SEB serviced by the same grid transformers. Modalities
to implement the decision would have to be mutually settled between SEBs and Railways, with cost
of the equipment borne by Railways.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME II PART I (3)

20102 Tariff for Traction

a) In Electric Traction the energy cost forms a substantial portion of the total operating and
maintenance cost. The tariffs charged by various state Electricity Boards vary from a simple flat
rate for the energy (charged by some states like MSEB & GEB) to a very complex tariff structure
covering a variety of parameters (as indicated in the tariff charged by MPEB). The implications of
the various parameters should be studied carefully to keep the energy cost to the minimum possible
level.

b) Contract demand for each sub-station should be stipulated in relation to the expected actual
Maximum Demand in such a manner that in fructuous payments by way of minimum guarantee on
the one hand and penal charges for exceeding the contract demand on the other, are avoided.
Notice period for altering Contract Demand should also be kept as low as possible in the
agreement, preferably 4 to 6 weeks.

c) In the tariff charged for electric traction, following are some of the parameters that should be
given careful consideration with a view to keeping down the energy bill to the minimum.

i) Maximum demand charge Rs/KVA/month : Normally one feeder is ON for feeding the traction
load. If two sets of trivector meters are provided, the higher of the two should be the MD to be
charged. Caution may be exercised to ensure that addition of both is not taken as MD in billing.

ii) Energy charge Paise/Kwh

iii) Fuel Adjustment Charge (FAC) accounting for the variations in cost of fuel and calorific value
compared to stipulated basis figures. This charge should be realistic and should be periodically
verified with the Supply Authorities.

iv) Penalty for low power factor : The penal charge is prescribed as an extra amount livable in
Rs/KVA of Maximum Demand if power factor falls below a specified value. SEBs usually insist on
consumer providing PF correcting equipment and do not permit power factor lower than a
prescribed value.

v) Billing Demand is usually a certain percentage of contract demand or the actual MD

whichever is higher.

vi) Excess over Contract Demand and corresponding units of energy are usually charged at
higher tariff (excluding FAC). Even if the excess MD is for a short period of just 15 min.
proportionate units for the entire month are charged at penal rate. One of the SEBs does
computation of excess energy as under:

Excess Energy = TU (1-CD/MD)

Where TU = Total Energy
MD = Maximum Demand
CD = Contract Demand
The Contract demand therefore, has to be carefully determined, and reviewed periodically and if
necessary modified to avoid penal charges.

vii) Minimum Guarantee

Usually, the agreement with SEB stipulate a percentage of 15 to 20% on the capital cost invested by
the SEB for giving the connection, as minimum guarantee. This is generally met by the pattern of
energy consumption in traction. However, minimum guarantee in some cases is specified in terms
of guaranteed average load factor (say 30%). This ties up the Contract Demand with the units
consumed. [5]
 If a few heavy trains operate in a section raising the Maximum Demand high, the average load
factor may not reach 30% unless adequate frequency of passenger trains also forms part of the
traffic pattern. Here, if contract demand is too high, 30% load factor is difficult to achieve while if
contract demand is too low, exceeding it and attracting penal changes becomes a possibility.
Careful balance between the two conflicting requirements has, therefore, to be struck.

viii) Harmonic Voltage Distortion

The consumer is required to carry out Harmonic Analysis under full load conditions. It is stipulated
that the individual harmonic voltage distortion (Vn) at the point of supply shall not exceed 1% and
3% respectively.

V - RMS value of fundamental voltage.

Vn RMS value of harmonic voltage of order n , expressed as percentage of RMS value of the
fundamental and shall be calculated using the following expression:
[(V2)2+(V3)2+(V4)2+---+(V13)2] 1/2 x 100
Vt = V

d) The tariff charged for traction should be reviewed periodically with the SEB, it should be ensured
that the rates do not exceed those charged in EHV tariff of the SEB applicable to other consumers.

20103 Monthly Meter Readings

a) In earlier Railway Electrification installations, only one set of meters owned by the Supply
Authorities has been installed to meter the traction load. In later installations, a second set of
meters is being provided on the sub-station switchboard at Railways cost. Where only one set of
meters belonging to the supply authority is installed yearly testing of the meter should be carried
out. If its accuracy is in doubt at any point of time, the Railway is entitled to ask for testing and
certification of the meter. Where a second set of meters has been provided at Railways cost, the
figures for billing purposes should ordinarily be based on the average readings of the two sets of
meters, unless specifically provided for otherwise in the Agreement. The exact procedure covering
these aspects should be embodied in the Agreement with the Supply Authorities.

b) The monthly meter readings should be taken on an agreed date each month jointly be
representatives of the Supply Authority and the Railway. The meter card as well as the
printomaxigraph chart reading showing the maximum demand for the month should be initialed by
representatives of both parties. Only readings jointly recorded as above should be accepted for
billing purposes.

c) When visiting the grid sub-stations for taking meter readings, the supervisory official concerned
will also obtain additional information such as daily maximum demand for traction, power factor,
load factor, variation of voltage, changes in the system of interconnection, which have a bearing on
power supply for traction. Suggestions for suitable changes in the Supply Authoritys network may
be made at appropriate level and if necessary concrete proposals initiated for making power supply
100% reliable.

20104 Scrutiny of Bills

a) The Supply Authorities bills should be carefully scrutinized in the Divisional Office with reference
to the Agreement and the tariff. A time schedule should be laid down jointly with the Accounts
Department for scrutiny and passing of the bill so as to take advantage of the rebate admissible, if
any, for prompt payment. Panel charges levied, if any, should be carefully scrutinized and
appropriate remedial measures
[6]
taken to prevent recurrence. If the minimum charge payable is in excess of the amount warranted
by the actual energy consumption, this fact should be promptly brought to the notice of CEE as well
as the operating Department to take special steps to arrange for movement of additional traffic, to
the extent possible, in the affected section, including diversion from other routes.

b) Detailed instructions should be issued locally, jointly with the Accounts Department, listing the
items to be checked prior to passing the bills from the Supply Authorities. An illustrative list is given
below:
i) Arithmetical accuracy
ii) Meter readings shown on the bill tally with those received earlier from the subordinates.
iii) The tariff applied is in terms of the agreement.
iv) The method of computation of the maximum demand for billing purpose is in accordance
with the agreement and that temporary increase in maximum demand on account of
emergency feeding has not been taken into account where this principle has been accepted.

v) The time allowed for payment is in accordance with the agreement.

vi) There is no duplication in billing.

vii) The payee as provided for in the agreement is clearly indicated. The full particulars of the
payee should be advised to the Accounts branch to enable that Branch to issue cheques
accordingly.

viii) Each new bill should be analyzed and compared with earlier bill and the reasons for any
significant departures investigated.

In case of any dispute/discrepancy, the payment be made under protest

20105 Power Factor Improvement

a) Provision of power factor improvement capacitors at 25 KV bus of traction substations should be

planned giving priority to substations (I) which feed large marshalling yards and (ii) where penalty
for low power factor and / or exceeding maximum demand has been stipulated in the tariff.

b) The average monthly power factor is calculated as ratio of KWh and KVAh over a month. Care
should be taken to make sure that it does not go leading while P.F. correcting equipment is used
and is kept near unity. Switched capacitor be used where load violations are wide.

c) The Guidelines issued by RDSO in respect of selection of the KVAr rating should be kept in view
at the time of planning.

20106 Shut-Downs of Traction Supply to be Pre-planned

a) At all grid sub-stations and traction sub-stations owned by the railways, duplicate EHV feeders
are available. Most of the sub-stations also have two sets of traction power transformers and
associated switchgear. Maintenance of equipment and transmission lines should not, therefore,
necessitate total shut-down of EHV and 25 Kv supply at a sub-station. It should be arranged with
the Supply Authorities that on the rare occasions when such shut-down becomes inescapable,
notice should be given well in advance to Sr. DEE/DEE(TRD) stating the reasons for the shut-down
and the anticipated duration. Such shut-downs should be arranged by Sr. DEE/DEE (TRD) in
consultation with the Operating Department which may have to re-schedule trains and take a other
measures as necessary.

b) A double circuit set of transmission lines from the Grid sub-station are run to give supply to
traction sub-station. Therefore, maintenance of the transmission line does not necessitates total
shut-down of [7]
the systems. However, all such shut-downs should be planned well in advance giving the reasons
for the shut-down and anticipated duration.
20107 Operating instructions for Grid Sub-stations
Detailed operating instructions mutually agreed to between the Supply Authorities and the Railway
should be made out for each grid sub-station as well as traction sub-station owned by the Railway
and should be issued to TPC as well as operators at grid stations. These instructions should
contain the following details.

a) Procedure for carrying out switching operations at the sub-station.

b) Procedure for interchange of message of pre-planned or emergency shut downs.

c) Procedure to be followed in case of failure of supply and information to be conveyed by grid

sub-station operator regarding duration of failure and anticipated time of restoration to enable
emergency working to be introduced.

d) Records to be maintained by grid sub-station operator and TPC regarding emergency feed
arrangements.

e) List of office and residential telephone numbers of important grid and railway officials to be
contact in an emergency.

f) Mutual assistance to be rendered for transmission of important messages in the event of

telephone failures at the grid sub-stations or RCC.

20108 Statistical Data Regarding Energy Consumption

In the divisional office, al register should be maintained to record month wise the following
particulars in regard to energy consumption at each supply point:-

a) Energy consumption (Kwh)

b) Maximum demand (Kva)
c) Average power factor (KWH/KVAH)
d) Monthly average load factor per cent
e) Payment for energy
f) Payment for maximum demand
g) Payment towards meter rent
h) Payment of fuel surcharges, if any
i) Payment for P.F. surcharge/penal charge
j) Payment of covering the minimum guarantee load, if any
k) Other payments, if any
l) Total amount of bill under all heads

m) Average total cost per Kwh.

A consolidated statement giving the above details for all supply points should be furnished by Sr.
DEE/TRD to CEE each month by a stipulated date. CEE will in turn furnish a monthly statement in
the prescribed Performa to the Railway Board and Research Design and Standards Organization
(RDSO).

[8]
 Monthly Maintenance

20227 Bonding and Earthing

20228 Oil level in transformers, CBs and CTs etc.
20229 Insulators
20230 Traction Transformers
20231 Operating Mechanism of Circuit Breakers & Interruptors
20232 Isolators
20233 Bus bar, Clamps and connectors
20234 Control and Relay Panels

Quarterly Maintenance

20235 Batteries and Battery Charger

20236 PTs & CTs
20237 Booster Transformers
20238 Auxiliary Transformers

Half Yearly Maintenance

20239 General
20240 Traction Transformers
20241 Isolators
20242 Control and Relay Panels

Yearly Maintenance

20243 General
20244 Lightning Arrestors
20245 Bonding and Earthing
20246 Traction Transformers
20247 Isolators
20248 Bus bars and Connectors
20249 Control and Relay Panels
20250 Batteries and Battery Chargers
20251 PTs and CTs
20252 Special Maintenance Schedules for Minimum Oil Circuit Breakers and Interruptors
20253 Pre-monsoon Checks
20254 Overhaul Schedule for Equipment

[10]
CHAPTER II
 SUB-STATIONS AND SWITCHING STAITONS

20200 Introduction

1. This chapter is divided into 4 sections as under

Section I Organisation : A broad set up of the organisation and duties of Chief Traction Foreman
(Power Supply Installations) are covered.

Section II Operation of Sub-Stations : The important points relating to operation of transformers

and protective devices are covered.

Section III Guiding Notes on Maintenance : The important points to be borne in mind in the
maintenance of chief power supply equipments are covered.

Section IV _ A recommended schedule of maintenance for power supply equipments is given

2. The following documents have been incorporated as Appendices to this Volume.

2.1 Code of Practice for Earthing of Power Supply Installations for 25 KV ac, 50 Hz. Single
Phase Traction System issued by RDSO (Appendix III)

2.2 Guidelines for Relay setting at Traction Sub-stations and Switching Posts issued by RDSO
(Appendix V)

2.3 Guidelines for Provision of Maintenance Depots. Tools and Plants and Transport Facilities
(Appendix VI)

2.4 List of Specifications and for Equipments and Materials for Railway Electric Traction issued
by RDSO Appendix IX)

1. ORGANISATION

20201 Organizational Set up

The Divisional set up of senior subordinates working under Sr. DEE/TRD has been arranged on two
types of patterns.

a) Territorial basis

b) Functional basis

In the territorial set up one Sr. Subordinate is responsible for all the activities of maintenance and
operation over a predetermined section of electrified territory or a sub-division. The functional set
up envisages separate Sr./ Subordinate to be incharge of each activity viz.. sub-station. OHE,
workshop, PSI etc. in a division or sub-division. Duties , however, have been specified here in
relation to particular function. For territorial set up, the CTFO incharge will perform his duties
keeping all functions in view, the next in command viz. TFO being the functional incharge of the
specific activity.

[11]
Remote Control system or protective relay testing being a specialized activity, CTFO (RC) and
CTFO/Test Room usually have a functional jurisdiction over the entire division, with Head Quarters
at the Remote Control Centre and Divisional Repair Shop respectively. The CTFOs in territorial
charge, should keep a constant liaison between themselves since these aspects will have an
element of dual control.

20202 Duties of Chief Traction Foreman, Power Supply Installation

He is the senior supervisor working under the control of DEE/AEE/TRD and directly responsible for
the safe and efficient operation and maintenance of traction power supply installations including
sub-stations (when owned by the railway), switching stations, booster transformers and auxiliary
transformers in his jurisdiction. He shall be thoroughly conversant with all technical details of the
equipment under his charge including their rating, trend of power demand as also correct methods
of their operation and maintenance, in particular, he shall

1. supervise the maintenance of installations under his charge in accordance with the
prescribed schedules to keep them fully serviceable at all times and in a state of good repair:

2. maintain proper co-ordination with the Traction Power Controller, Chief Traction Foreman
(OHE), Supply Authorities and render assistance when required to ensure reliability of power
supply:

3. keep his organistion in constant readiness to deal promptly with any breakdowns and
failures of equipment;

4. ensure that the programme of testing and maintenance of protective relays is adhered to and
ensure that other safety equipment including bonding and earthing are functioning effectively;

5. instruct, train and supervise staff under his control and ensure that they do operate and
maintain the equipment properly and in particular do actually observe all rules and regulations and
safety precautions laid down;

6. depute staff for refresher courses as prescribed, particularly for such staff as are found
deficient in their working;

7. ensure that special instruments and tools provided for maintenance operation and testing of
all installations are properly cared for;

8. keep a close watch on availability of spare parts and other stores required for maintenance
and operation of the installations and initiate timely action to recoup stocks;

9. ensure proper accountal and periodical verification of stores and tools in his charge.

10. Depute staff when required to man sub-stations and switching stations in the event of failure
of remote control equipment.

11. Inspect all installations under his charge at least once a month, with particular attention to
safety aspects;

12. Submit prescribed periodical returns after careful scrutiny to AEE/TRD and Sr.
DEE/DEE(TRD);

13. Keep his superior officers fully informed of all important development and seek their
guidance when required;

14. Carry out such other duties as may be allotted by superior officers from time to time.
15. Carry out inspections as indicated at Annexure 2.01. [12]
 II OPERATION OF SUB-STATIONS
20203 Introduction

Since the electric traction system depends upon continuous availability of power supply, sub-
stations and switching stations have to be kept in proper working condition at all the time. To
ensure this, the transmission lines, the 25 KV feeder lines and traction transformers with associated
switch gear and control and relay panels are duplicated so that if one unit fails, the standby unit can
be brought into service to continue power supply. All switching operations are also centralized and
controlled by remote operation by a single authority, namely Traction Power Controller.

20204 Inspection Book and Log Book at Sub-Stations

An inspection Book shall be maintained at every sub-station in which observations made by

supervisory officials visiting the sub-station for periodical inspections shall be recorded. In addition
a log book should also be maintained to keep a record of the traction transformer oil temperature,
ambient temperature as well as currents and voltages as indicated on the control panel at a fixed
time every morning. If there is any thing abnormal unusual, CTFO/PSI will investigate the cause
thoroughly and take necessary remedial action.

20205 Overload Capacity of Traction Transformers

Traction transformers usually have the following overload capacity:

1. Overload rating : (a) 50% overload for 15 min. and (b) 100% overload for a period of 5 min.:
after the transformer has attained steady temperature on continuous operation at full load.

2. Over an ambient temperature of 45 degree C the maximum permissible temperature rise

shall be as under:

(a) Winding = 50degree C (by resistance method)

(b) Oil = 40 degree C ( by thermometer)
(c ) Current carrying parts = 35 degree C ( BY THERMOMETER)

3. The hot-spot temperature after 50 % overload for 15 min, or 100% overload for 5 min. shall
not exceed 100 degree C for an ambient temperature of 45 degree C.

4. Interval of time permissible between two successive overloads ( after continuous working at
maximum ambient temperature of 45 degree C is 3 hours for both 50% overload for 15 min. and
100% overload for 5 min.

20206 Tap Setting on Traction Transformers

Traction Transformers are usually provided with off-load tap changers ( operated locally or by
remote control ) with taps from + 10% to (-) 15% in steps of 5%. To decide the correct tap setting a
recording voltmeter should be connected at the traction sub-station to the secondary side of a
potential transformer to ascertain the pattern of voltage variation throughout the 24 hours for atleast
3 typical days. Based on the readings from the recording the tap position should be fixed so that the
daily OHE voltage peaks at the traction sub-station lie just below 27.5 KV but does not touch 27.5
KV. This will ensure that the OHE voltage is well above the minimum of 19 KV at the farthest point
on the system even when heavily loaded. Once a year a 24 hours record of voltages available on
the two sides of every neutral section should be taken to make sure that the voltage does not fall
below 19 KV at any time.

Since any change in the inter-connections of the grid system would have repercussions on the
voltage at the traction sub-station, the CTFO/PSI should keep in touch with the supply authorities in
regard to system changes [13]
so that he may arrange to take another set of 24 hour voltage readings if any change has taken
place and to change the tap setting if required.

20207 Tests on Transformer Oil

In order to improve the performance and to prolong the life of the transformers, EHV grade oil is
used. The following two specifications the first one for new oil and the second for oil in service, are
adopted.

(a) IS- 335 Specification for New Insulating Oils.

(b) IS- 1866 Code of practice for maintenance and supervision of insulating oil in
service.
A summary of tests for various characteristics, the requirements to be complied with and methods of
tests as contained in the two specifications is at Annexure 2.03 (A&B). The tests are wide ranging
and should be done once a year. However, some of the tests like Breakdown voltage (BDV) test,
acidity tests, crackle test for moisture, may be carried out in PSI depots or sub-stations once in six
months when samples are drawn for condition monitoring as per para 20216 Procedures for these
test are indicated in IS 1866.

20208 Purification of Transformer Oil

The object of oil purification is to remove all contaminants such as water, carbon deposits, dirt,
sludge, dissolved moisture and gases. The most important quality to be preserved is the di-electric
strength, which is affected by the presence of moisture.

The insulating materials used in the winding are hydroscopic by nature and therefore moisture is
absorbed through defective breathers, gaskets and addition of untreated make up oil. It is essential
to remove these impurities by purifying the oil when the di-electric strength goes below the
permissible limits.

20209 Oil Purification Plant

For purifying the transformer oil, machines conforming to RDSOs Specification No. ETI/PSI/103
may be used. These are normally operated from 240 V single phase supply taken from the 100
KVA Station transformer provided at the sub-station. Supervisory officials in charge of maintenance
of transformers should make themselves familiar with the suppliers instructions in regard to the
operation and maintenance of the oil purifying equipment.

20210 Insulation Resistance During Drying Out

Readings of temperature and insulation resistance should be recorded every two hours, from
commencement until the full operation is completed. If the readings are plotted on a graph, the
appearance will be as shown in Fig. 2.01.

It will be observed that there are four distinct stages:

A. Initially the insulation resistance drops down to a low value because of rise in temperature of
the oil upto about 75 degree C.

B. Insulation resistance will continue to remain at a low level despite temperature being
maintained at a high level until most of the moisture from the windings and oil has been driven out.

C. The insulation resistance will thereafter rise gradually and level off, indicating that all
moisture has been driven out and the drying out operation has been completed. At this point oil
circulation should be discontinued.

D. As the oil cools off, the insulation resistance will rise much above the leveling off point at the
end of stage . This is because the insulation resistance value doubles for a fall in temperature of
about 10 degree C to 15 degree C.
[14]
transformer may have to be pressed into service for the duration of the peak load. Such parallel
operation of traction transformers may sometimes also incidentally result in reduction of the total
losses thereby effecting economy. Secondly, it will also result in higher OHE voltage, since traction
transformer impedance is now halved as the transformers are identical.

If a sub-station is persistently overloaded and an adjacent sub-station is appreciably underloaded,

the possibility of shifting the neutral section may be considered.

20213 Operation of Differential Protection

Apart from operation on account of internal faults in the transformer, the differential relay could also
operate either because of current in-rush on account of magnetization of the core at the time of
switching on or because of spill current caused by lack of perfect balance between secondaries of
EHV and 25 KV current transformers. The causes for such mal-operation may be defective
harmonic restraint filters or wrong CT ratios and should be eliminated.

20214 Buchholz Relay

The Buchholz relay assembly is provided on transformers to detect evolution of gas caused due to
internal faults. After first commissioning, the upper assembly of the relay may sometimes be found
to operate causing the relay to trip. Analysis of the composition of gas collected will indicate the
nature of fault. If it is mere air bubbles the transformer is sound. For details of tests manufacturers
write up may be referred to. It is always a wise policy to get the de-electric strength of the oil tests,
measure the insulation resistance and carry out ratio test.

III Guiding Notes On Maintenance

20215 Introduction

1. For better utilization of traction assets, outage of any traction equipment from service should
be minimum without compromising on safety of the equipment and personnel. Monitoring of
condition of the equipment by reliable means is essential for following system of need based
maintenance i.e. directed maintenance. However, till such time reliable condition monitoring
techniques are introduced, the present system of preventive maintenance has to continue.
2. Recommendations of Original Equipment Manufacturer (OEM) and guidelines issued by
RDSO, time to time, shall be kept in view while defining the scope and periodicity of the schedules.
3. The tightening torque for fasteners of various sizes is given in Annexure 2.08.

20216 Transformers

1. Condition Monitoring
In oil filled equipment like transformers, normal deterioration or ageing of insulation is caused by
thermo-chemical reaction with participation of heat, moisture and oxygen. This results in formation
of soluble and insoluble products which accumulate and deteriorate the properties of oil and
cellulosic insulation. Whereas the oil can be reconditioned to restore functional properties, no such
treatment is possible for the cellulosic insulation, which suffers from reduction of mechanical and di-
electric strength. The condition of the insulation, therefore, needs to be checked by suitable
methods.

The thermal and electrical stresses caused during short circuits, overloads and over voltages in the
system result is gas formation in appreciable amount and deterioration of di-electric properties and
lowering of flash point of oil from 145 degree C to somewhere between 50 degree to 80 degree C in
extreme cases. In the case of incipient faults, the gases being soluble, are absorbed in oil. The
Buchholz relay cannot respond during early stages of trouble and by the time these devices operate
the damage is done. Dissolved gas analysis (DGA_ provides an important means in the art of
condition monitoring of power transformers and other oil filled equipment. Of the various methods of
gas [16]
analysis Gas Chromatography (GS ) is one of the most sensitive, efficient and rapid method,
eminently suited for detection of incipient faults and for monitoring of growing faults which are not
always revealed by established routine tests etc. In order to timely detect the deterioration of
insulation, oil sample shall be drawn annually and subjected to gas chromatography.

Guidelines for condition monitoring of traction transformers by Dissolved Gas Analysis technique
are appended at Annexure 2.04.

2. Overhaul Of Transformers.
a) Overhaul of a transformer is normally undertaken either if it is faulty or at the end of 7-10
years by way of periodic maintenance. This can be done in the Central Repair Shop which is a
covered shop having full facilities including a core lifting bay with a crane. Before commencing the
work ensure that spare gaskets of proper quality are available. Drain out the oil, disconnect at
leads, remove manhole covers where required. The EHV and 25 KV bushings are then carefully
removed out and stored well protected in a safe place. Then remove the core by means of the
lifting hooks and place on shop floor over a trestle in a large receptacle into which oil can drain out.
b) If the transformer has been opened up because of any internal fault, make a careful note of
colour of transformer oil, arc-marks, carbon deposits, charring of insulation, condition of the
windings, unusual odour and other abnormalities which would all help in ascertaining the cause of
the failure. If a coil has been burnt out, the whole transformer will have to be completely dismantled
and then the damaged coil replaced with a new coil. In the case of the traction transformer, the
replacement of the damaged coil is best done in the manufactuers works where necessary facilities
and staff with the requisite skill are available.
c) Arrange for the interior of the transformer tank to be thoroughly cleaned of all accumulated
debris, sludge, etc. and wash with fresh oil. Remove the drain plug, lightly polish the valve seat and
renew the oil-tight gasket round the spindle so that when assembled the plug is fully oil tight; the
same remarks apply to the oil sampling valve, if provided. Opportunity should also be taken to plug
or weld up any small blow holes through which oil seepage was observed earlier. Finally paint the
exterior of the tank if necessary after thoroughly cleaning it up of all paint work, rust and traces of oil
and dirt.
d) If the coil assembly is lifted up after 5,. 10 or more years of service, considerable amount of
sludge formation would have occurred on all parts of the transformer i.e. at the bottom of the tanks,
metal work of the transformers, windings and inter-spaces between windings. All these should be
scrapped off carefully with a wooden or fiber wedge without causing any damage to the windings.
Traces of the sludge left over in inaccessible places are best removed by directing a thin jet of
transformer oil under pressure using small oil purifier. At the same time the old surface
contamination should be brushed and washed down, until the clear surface of the winding is
exposed.

e) Care should be taken to protect the windings against ingress of moisture particularly during
inclement weather. Care should also be taken by wiping off body sweat with a towel. The windings
should also be kept warm by surrounding the open windings by a number of infra-red lamps or by
other means.

f) Fully push home the wedges between the coils and take up the slackness of end-plates by
tightening up the bolts and locking them. These are provided on traction transformers to hold the
windings tightly together to withstand the high mechanical forces generated at the time of short
circuits. Shrinkage and settlement usually take place within the first six months of the
commissioning of a transformer. The coils are also liable to suffer displacement due to short circuit
forces. If the coils are not held tightly in position, it will lead to repeated movement of the coils as
well as layers and turns which will in turn cause abrasion and wear of insulation and ultimately
failure. It is, therefore, sometimes recommended that the first available opportunity should be taken
to have the wedges fully home and tighten up the pressure screws where they are provided.

[17]
g) Finally put back the core assembly inside the tank, assembly the bushing check tightness of
all internal connections, fit the top, provide new gaskets, fill pure oil and dry out as detailed in para
20208 to 20210. Experience has shown that tools like spanners and foreign objects like washers,
pieces of cloth, etc. are sometimes inadvertently left behind in the transformers, which present
hazard of short circuits. It is, therefore, important that al tools, etc. used in the overhaul work should
be listed out at the beginning and accounted for at the end of the work.

When overhauled transformers are to commissioned the same procedure as detailed in Chapter IX
for new transformers should be followed;

Each railway should plan, taking into consideration the resources available with them to carry out
the POH and repairs of the transformer and decide the agency to execute the work.

2. Investigation into causes of Failures of Transformers.

In most cases the causes of the fault can be surmised by careful observation of the condition the
windings, e.g. displacement of the turns or coils, coil insulation (brittle or healthy), evidence of
overheating carbon deposit or flash marks on the core, supports, the inner surface of the tank or
cover. The following notes may be of help in identifying the cause.

a) Failure due to lightning discharge or overvoltages - This is characterized by breakdown of

the end turns close to the line terminal. There may be a break in the turns or end lead, and also
flash marks on the end coil and earthed parts close to it, but the rest of the coils will be found to be
healthy.

b) Sustained overloads The windings in one or all phases would show sings of overheating
and charring; the insulation would be very brittle and would have lost all its elasticity.

c) Inter-turn short, inter-layer short, or inter-coils short - The same signs as for indicated for
sustained over load would be noticed, but only on affected coils, the rest of the coils being intact.
This is likely if the differential relay or the Buchholz relay has operated.

d) Dead short circuit This can be identified by the unmistakable, lateral or axial displacement
of the coils. The coils may be loose on the core, some turns on the outermost layer may have burst
outwards and broken as if under tension. If, in addition to these signs, the windings are also
completely charred, it is conclusive evidence that the short circuit has continued for an appreciable
period, not having been cleared quickly by the protective relays.

e) If the upper chamber of the Buchholz relay alone has tripped, check the insulation of core
bolts, by applying a voltage of 230 V to 1000 V between the core and each bolt. If it fails, renew the
insulating bush. Observe also all the joints, and tap-changer contacts, for over heating and arcing.

f) If the oil shows a low BDV, it does not necessarily mean that it has caused the breakdown.
At high voltage ratings, excessive moisture content in the oil may result an internal flashover
between the live parts and earths, which will leave corresponding tell-tale marks.

20217 Circuit Breakers and Interruptors.

The following types of circuit breakers and interruptors are now in use.

Circuit Breakers:

a) 220/132/110/66 KV Double pole

- Minimum oil type
- SF6 type [18]
b) 25 KV single pole

- Minimum oil type

- SF 6 type
- Vacuum type

c) Interruptors

- Bulk oil type

- Minimum oil type
- SF6
- Vacuum type

Oil type circuit breakers/interruptors require considerable attention for maintaining satisfactory
condition of the oil. In case of minimum oil type equipments frequent replacement of oil is
necessary on account of service conditions. To overcome these limitations, SF-6 type and vacuum
type circuit breakers and interruptors are now standardized.

Manufacturers detailed instructions may be referred to for installation, commissioning, operation

and maintenance for all types of breakers/interruptors. RDSOs additional instructions on
maintenance and modifications to the circuit breakers/interruptors should also be followed. Some
tips for the maintenance of circuit breakers and interruptors, in general, are given in the succeeding
paragraphs.

20218 Guidelines for Maintenance of Circuit Breakers and Interruptors.

A. Minimum Oil Circuit Breakers.

1. Oil

When a circuit breaker trips the arc is extinguished by the oil and, therefore, the oil gets carbonized
and contaminated. Although 25 KV traction circuit breakers are designed for 100 successive
trippings or for short circuit currents upto 4000 A, without requiring replacement of oil, experience
has shown that because of heavy contamination of oil, insulation level comes down rapidly even
with 40 or 50 trippings. A record should, therefore, be maintained by the ATFO, based on TPCs
register/computer print out of the number of trippings of each circuit breaker since last attention.
The CTFO/PSI should keep a watch over these figures and arrange to measure the BDV of oil
samples at intervals to be decided in the light of experience. Oil shall be purified or replaced if the
di-electric strength falls below the prescribed value.

2. Gaskets

During inspections, look for evidence of oil leaking out of bushings, tank body, etc. Slight oil leakage
could occur due to (a) the mating surfaces are not perfectly flat (b) the gasket is not being quite free
from dirt or extraneous matter (c) the gasket is not being properly compressed (d) gasket has lost its
elasticity.

Leaky gaskets shall be attended to or replaced without delay, as they may allow moisture to get in
and contaminate the oil.

3. Bushings

The porcelain exterior surfaces should be maintained in a perfectly clean and bright condition.
Deposits of salt and industrial dust should be removed periodically so that there may be no
possibility of flash-over. where the
[19]
deposits are heavy a wet cloth may be used for wiping it off, falling which carbon tetra-chloride may
be used. After removing the contamination the surfaces should be wiped out with a dry cloth so that
the gloss on the surface is restored.

During inspection the insulator surface shall be very carefully examined all round for any fine
surface cracks so that the damaged insulators may be replaced. If the chipping on bushing sheds is
only very slight, replacement may not be necessary.

4. Internal Insulating Parts

Every time an oil circuit breaker is opened and oil has been drained out, all the interior parts
including the bushing in the minimum oil type units or tank in the bulk of units should be thoroughly
cleaned to remove all traces of carbon or sludge that may have adhered thereto. Thereafter, the
parts should be first cleaned with dry non-fluffy cloth (never with cotton waste), then thoroughly
flushed out with good oil and are assembled.

5. Contacts

It is essential for the contact surfaces to be properly aligned with sufficient area of contact and
pressure between the contacts to ensure that when carrying full-load currents, the contacts remain
quite cool. Badly pitted or burnt-out contacts should be replaced before they cause damage to other
parts. If they are only rough, the surface irregularities should be smoothed out by touching up lightly
with a clean line file taking care not to overdo it. Where the contact mechanism consists of main
and secondary contacts, the main contacts do not normally require any maintenance, because the
current is made or broken only at the secondary contacts. The main contacts should, however, be
inspected for good condition and kept smooth and clean. The adjustment of contacts should be
made in accordance with Makers instructions.

6. Operating Mechanism

Check whether the elastic mounting pads are in good condition and capable of absorbing the
mechanical shocks during operation. The length of the breaker stroke should be measured and
adjusted if necessary in accordance with the Makers instructions book. Ensure that the operating
mechanism functions smoothly and freely through the entire stroke and without binding. Lubricate
all pins and bearing surfaces with light oil and wipe off the excess. Ensure that all cotter pins are
open and locking plate and nuts are in place and properly tightened.

The operating springs are quite powerful and when they are in the charged condition considerable
energy is stored. Serious damage and injury to personnel may be caused if they are released
inadvertently.
Parts which are scored or which show excessive wear should be replaced and adjustment should
be made within the tolerances as indicated in the Makers instruction book.

The circuit breaker or interruptor is guaranteed to work satisfactorily between the specified voltage
limits. During annual inspection check performance of interruptors and circuit breakers to ensure
that they function properly at the lowest specified voltage for the operating coil. Measure and record
the opening and closing times both at normal and minimum voltage.

7. Interlocks

Pay attention to the proper functioning of interlocks, both mechanical and electric, and particularly to
auxiliary contacts, spring tension and screws, bolts, pins, etc. securing the contacts. Check that the
wiring connections at terminal boards are properly secured.

[20]
B. SF 6 Circuit Breakers:

1. Gas System

The SF-6 gas in a pure state is inert, exhibits exceptional thermal stability and has excellent arc
quenching properties as well as exceptional high insulating properties. Physical properties of SF-6
gas are indicated in the Annexure 2.05. There is very little decomposition of the gas after long
periods of arcing. Such decomposition has virtually no effect upon dielectric strength and
interrupting capability. The solid arc product formed by arcing is metallic fluoride which appears in
the form of a fine gray powder which has high dielectric strength under dry conditions as existing in
the breaker. A good quality absorbent is used in the apparatus to remove decomposed gaseous by-
product. During the maintenance record gas pressure and temperature. Supply the gas if pressure
is less than the prescribed value. Check setting of gas pressure switches.

2. Interrupting Unit

Clean the surface of the porcelain and other parts. Contacts should be inspected and replaced if
necessary.
Renew the absorbent taking care that exposure of the absorbent to the atmosphere is minimal.
The breaker should be evacuated as soon as possible.

3. Operating Mechanism

Check stroke from closed position to completely opened position and over stroke from completely
opened position to stopped position. Check prescribed clearances. Relubricate moving parts.
Check that pressure gauge is working correctly. Check pneumatic system for tightness.

The housing should be checked for water penetration and rust. Ensure that fasteners are not
loosened. Check connections of control circuit wires for tightness.

C. Vacuum Circuit Breakers

Guidelines as indicated above in case of the other two types of circuit breakers in respect of
operating mechanism and its housing and other components are generally applicable in case of
vacuum circuit breakers also except the interrupting chamber and pneumatic circuit. As regards
interrupting chamber (vacuum bottle) no maintenance as such is required to be carried out.

20219 Lead Acid Batteries

A battery is considered to be very vital equipment in the power supply installations and therefore, its
proper maintenance is imperative.

On electrified sections batteries and battery chargers are installed at the following locations:-

1. Traction Sub-Stations

110 V 200 Ah. Lead acid cells for control, protection and indication circuits.

2. Switching Stations

110 V or 72 V, 40 Ah. Lead acid batteries for operation of circuit breakers and interruptors and
motor operated isolators.
3. Remote Control Equipment
Batteries of suitable voltage and capacity at remote control centre, traction sub-station and
switching stations.
[21]
To reduce number of batteries at TSS/SS the remote control equipment is now being connected to
the battery of TSS/SS

In all cases, mains operated battery chargers are provided with facilities for either trickle charge or
boost charging. The rating of the battery charger should related to the capacity of the battery.

20220 Guidelines for Maintenance of Batteries.

1. As the entire system of protection at a sub-station depends upon a sound battery it should
always be in proper condition. It should under no circumstances be disconnected when the sub-
station is in operation.

Batteries should be maintained keeping in view instructions of the manufacturer by a trained staff.
The points to be observed during the inspections are summarized below

a. General condition of the battery room and cells

b. Specific gravity of electrolyte in the cells
c. Charging current
d. Cell voltage
e. Condition of the plates and extent of deposits
f. Inter-cell connectors and main battery terminals

A detailed history of every battery should be separately maintained in which all relevant information
is periodically entered. Fortnightly specific gravity readings should be taken and recorded in
appropriate forms.

Smoking or the use of open flames or tools which may generate sparks is strictly forbidden in the
battery room. The battery room should be well ventilated and dust free and should have acid
proffing done on the walls and flooring. It should be kept isolated from other electrical equipment.
Appropriate fuse protection for short circuit in the wiring between the battery and distribution switch
board should be provided.

2. Specific Gravity

The specific gravity of the electrolyte should be maintained at about 1.210 at 27 degree C and when
it drops to 1.150 the cell may be considered discharged. These values vary with the type of battery,
temperature, age and working conditions.

Specific gravity is related to electrolyte termperature. For the purpose of test requirements, the fully
charged specific gravity shall be 1.20 + 0.005 corrected to 27 degree C. Temperature correction
hydrometer readings of specific gravity shall be made as follows ( Ref. IS 1652)

a) For each 1 degree C above 27 degree C add 0.0007 to the observed reading and

b) For 1 degree C below 27 degree C deduct 0.0007 from the observed reading.

When the battery is first commissioned the specific gravity of the all cells would be almost equal.
Subsequently during periodical inspections, variations in specific gravity may be observed due to
unequal rate of evaporation. This should be corrected by adding distilled water. In no
circumstances should concentrated or diluted sulphuric acid be added to any cell except when acid
is known to have spilled out. Distilled water alone should be used for topping up the level.

Hydrometer readings taken when a cell is gassing freely gives the specific gravity of a
mixture of gas bubbles and

[22]
electrolyte and not the true specific gravity of the electrolyte. The readings should therefore be
taken after allowing all bubbles to subside. Hydrometer of reputed make should only be used.
Hydrometers of 300 mm length are necessary to give required accuracy. Two hydrometer should
always be maintained in a station and they should be periodically checked to see that they read
alike.
3. Pilot Cells
One of the cells in each row of the battery set should be selected and kept as the pilot cell.
Readings should be taken on these cells with sufficient frequency to indicate its state of discharge
and charge and serve as a guide to the condition of the other cells. The pilot cell when once
selected should not be changed unless the cell has to undergo special treatment or repairs in which
case a note should be made immediately on record sheets. The height of the electrolyte in the pilot
cell should invariably be kept at a fixed point (say 12mm) above the top of plats by adding distilled
water every fortnight, if necessary.
4. Trickle Charging
Lead acid batteries are very sensitive to overcharging as well as cover discharging. If over charged,
the positive plates will shed their active material quickly. If kept in discharged condition for long, the
plates will suffer sulphation evidenced by appearance of whitish deposits on the plates. Prolonged
charging at a very low rate after emptying the electrolyte and filling the cell with distilled water is
sometimes useful if the sulphation is very light. However, there should be no occasion at all for any
battery set used in stationery traction installations to be sulphated, as they are continuously on
trickle charge. A long life for the battery is achievable if the battery is kept floating on a battery
charger so that the terminal voltage of each cell is maintained close to 2.15 V.

This can be achieved if the battery is kept on a very low rate of charge, say, 1 milli-ampere per Ah
capacity of the battery. The exact rate of charge should be fixed having regard to the normal and
intermittent rates of discharge over a period of 24 hours, so that the battery is always kept in fully
charged condition and never overcharged or over-discharged.

When a battery is being properly float-charged very small gas bubbles (about the size of a pin head)
rise slowly from the plate to the surface of the electrolyte in batteries, that are being overcharged the
bubbles are much larger and reach the surface at a higher rate.
5. Cell Voltage
The voltage of cell at the end of charger is not a fixed value but will vary depending on the age of
the battery. The temperature, specific gravity of the electrolyte and charging rate. The voltage of
new cells at the end of a full charge will be about 2.5 to 2.75 V when it is receiving charge at the 10
hour rate. This gradually decreases as the age of the battery increases until it comes down to 2.4 V
with normal temperature and charging rate.

No cell should ever be discharged below the point where the cell voltage reaches 1.85 V as
measured when the cell is discharging at the normal 10 hour rate.

It should be noted that the voltage of a cell gives an approximate indication of its state of charge ( or
discharge) only when it is being discharged, say at the 10 hour rate, and not when the cell is an
open circuit.

Sulphated plates, lug corrosion, partial short circuit due to cracked separators and other defects of a
lead-acid cell cause a noticeable drop in the terminal voltage with current flowing in the cell. This
drop varies with the amount of current flowing and in order to get voltages that can be compared
from month to month, the voltages should be taken with the same current flowing in the cell. The
cell testing voltmeters in use should be periodically checked and recalibrated, if necessary. When
not in use they should be kept in a safe place.

6. Condition of Plates and Deposits

The active material in the positive plates in healthy cells in use for more than 12 months (when fully
charged) should
[23]
be chocolate in color and negative plates light or bluish grey according to age. The chief indications of weak
cells are badly coloured plates, irregularity in gassing or entire failure to gas and a fall in voltage and specific
gravity below that of other cells.

In new batteries, flakes of brown scale will be seen getting detached from edge of positive plates. This
formation of scale is normal. Until all this scale is dispersed, the plate cannot be considered as stabilized.
Sometimes pieces of this scale may lodge across adjacent negative plates and cause a partial short circuit.
Such flaked pieces should be gently dislodged with a thin piece of wool and allowed to fall to the bottom of the
cell. This scaling occurs only on the edges of the plates. The removal of the scales should be done very
carefully so that the plates are not damaged.

Examine carefully the physical condition of the plates such as cracks, distortions, accumulation of whitish
deposits, etc.

The color of the deposits gives a good indication of the state of health of the cells. Whitish deposit indicates
undercharging leading to discharged condition. In healthy cells, the deposit is brown in colour but excessive
shedding of active material for the positive plates indicates overcharging of the battery. If this is noticed,
reduce the rate of charge immediately. If all the cells in a battery show whitish deposits immediate action
should be taken to give a boost charge at an appropriate rate and then to increase the trickle charging rate
sufficiently to keep the battery in a healthy condition all the time. Weak cells should be immediately examined
for any possible short circuit or metallic contact between positive and negative plates. The short circuit should
be removed and the cell should then be given special additional charging by cutting it out and putting it back
again when a healthy condition is regained, after it is attended to.

7. Inter-Cell Connectors

The inter-cell connectors of the battery should be examined to ensure that they are clean and tight, making
perfect contact with cell lugs and that no corrosion is taking place. Light viseline should be applied to prevent
corrosion.

Inspection of copper inter-row connectors should also be made for any signs of copper sulphate corrosion
which should be cleaned up. Acid-proof paint or enamel should be applied to all exposed copper work in the
battery room and any flaking of paint work given prompt attention.

20221 Protective Relays

1. Each electrified division shall have specialist staff attached to the Central Repair Shop trained in the
maintenance overhauling, testing adjustment and calibration of protective relays as well as indicating,
intergrating and recording instruments. Such specialist staff shall hold competency certificate No. TR-7 as
explained in Chapter XII.

2. The Central Repair Shop should be fully equipped with necessary apparatus, instruments, tools and
equipment for overhauling, testing and calibration of relays.

3. Each Supervisor responsible for maintenance and testing of protective relays should maintain a
register in which full details regarding each relay should be entered. The details to be recorded are the type
and serial number, PT & CT ratios, range of settings available, characteristic curves (where applicable),
location where installed, schematic diagram of connections, normal settings and details of calculations for
fixing the normal setting. Details of tests as well as repairs carried out should be entered in this register from
time to time. These particulars should also be maintained in the office of Sr. DEE/TRD.

4. No alterations in the settings of protective relays should be carried out without the written
authorization of Sr. DEE/TRD, who will submit proposals including detailed calculations for changes required,
if any, for prior approval of CEE. Guidelines for setting of relays are given in the Appendix V.

5. The procedure for commissioning of protective relays has been given in Chapter IX.

[24]
6. The normal maintenance attention required for relays in service is generally as under

a) It is essential to ensure that the cover gaskets are in good condition and the fixing screw quite tight,
so that the instrument is dust-tight.

b) Manual operation to confirm that the relays do operate the trip circuits in the manner prescribed.
These tests should be carried out by atleast at the level of AEE once in a year for all relays. Simultaneously
visual checks on relay connections, condition of the trip battery, trip and alarm circuits, and also the dust-
tightness of protective covers should be made. The relay cover should then be sealed. A record should be
maintained showing the date and time this is done.

On each occasion when the seal is broken subsequently the reasons should be recorded in the log book.
c) Distance protection relay may be tested for calibration once in a year with primary injection set.

d) Secondary injection test - These should be done annually preferably before onset of busy season,
making use of portable testing equipment and at the settings approved by the competent authority. Apart
from testing the operation at the normal setting tests should also be carried out at other settings to make sure
that the relay has the required characteristic.

e) Overhaul bench tests and calibration : These are necessary once in ten years of when a relay is not
found functioning correctly. This work should invariably be carried out only in the Central Repair Shop by
highly skilled technicians fully conversant with all details of construction and adjustment.

The bench tests and final calibration should be carried out after overhaul of the moving parts and
measurement of coil resistance and other data. Transport of the relays to and from the Central Repair Shop
also requires utmost care including locking of the moving parts and careful packing and handling. When
laboratory tests are fully satisfactory, the relays should be sealed and date of overhaul painted on the outer
cover of the relay.

20222 Guidelines for Maintenance of Switching Stations

The maintenance required for equipment in switching stations is more or less similar to that for traction sub-
station equipment, except that traction transformers, circuit breakers and current transformers are not present
and area is much smaller. However, the only additional but important item which requires attention is
condition of the return feeder connection to all the rails (at the feeding posts). These return feeder
connections are liable to be damaged by Permanent Way gangs in their normal work of packing and
maintaining the permanent way. Supervisory officials, therefore, should stress the importance of these from
the electrical point of view to the PWIs so that they in turn may warn their maintenance gangs not to damage
the connections. In addition, the supervisory officials shall, during their periodical inspection, make it a point
to inspect the return feeder rail connections and ensure that they are in excellent condition.

IV MAINTENANCE SCHEDULES

20223 Schedules of Inspection

1. In order to achieve high reliability and ZERO DEFECT, and to ensure effective checks on the
maintenance work minimum schedules of inspections to be carried out each month by the TRD officers and
Sr. Subordinates in charge of operation and maintenance of PSI equipments, are indicated at Annexure 2.01.

The schedule of inspections as indicated is the minimum quota to each official per month and should be
independent of other tasks. They will not be of routine nature but shall be carried out in depth to identify:

i) Deficiencies and short comings.

ii) Lack of skill amongst staff.

[25]
iii) Inadequacies in maintenance facilities.
iv) Constraints experienced
v) Conditions of enviorment, which lead to poor quality of work if any.

2. The inspecting officials should adjust their inspections in such a manner as to cover all of the
installations in their jurisdiction within the stipulated periods and stagger the inspections among
themselves to avoid over inspections of the some installations repeatedly in a very short time and
neglect of other installations. A check list in brief for various inspections is given in the Annexure
2.02.

3. The items of attention listed hereunder at any particular periodicity are over and above those
mentioned in the previous schedule. This should be kept in view while carrying out maintenance
work.

4. The periodicity of the items of attention listed in the following paragraphs may be modified to
suit local requirements with the approval of CEE.

5. As regards new equipments, if schedules have not been drawn up, tentative schedules may
be evolved, based on the Original Equipment Manufacturers guidelines and RDSOs
recommendations, keeping in view the local conditions also and followed with the approval of CEE.

6. Schedules for maintenance of SF-6 type circuit breakers as recommended by one of the
manufacturers are indicated in the Annexure 2.06. Schedules for maintenance of vacuum circuit
breaker as recommended by one of the manufacturers are indicated in the Annexure 2.07.
Schedules as indicated in the following paragraphs are for minimum oil circuit breakers.

20224 General
1. No work of any kind shall be commenced on or in the vicinity of live equipment unless
power supply to the particular part has been switched off and all other prescribed safety measures
taken.

2. To guard against the possibility of unauthorised interference and pilferage from unattended
sub-stations and switching station, all electrical department staff shall be vigilant and watch for any
such activity when they are in the vicinity. Surprise checks coupled with periodical inspections will
also act as deterrents.

3. The TPC shall once a day check up communication to each of the grid sub-stations and
obtain the maximum demand and energy consumption for the previous 24 hours and enter the
figures in a register. Whenever inspecting staff visit the sub-station or switching stations, they shall
contact the TPC on the telephone.

FORTNIGHTLY MAINTENANCE

20225 General Inspection by a PSI Supervisor

1. Go round the whole area of the sub-station ; inspect for general cleanliness, proper
drainage, road and rail access. The surface of the roadway and pathways in the sub-station should
be firm and sufficiently elevated to prevent water logging. Remove any undergrowth of vegetation
around the outer periphery; cut any tree branches likely to come in the vicinity of live lines.

2. If lubricating or transformer oil is stored, inspect for security and fire risk and see that no
combustible material is in the vicinity.

3. Examine all Caution, Danger, Shock Treatment and other boards, whether they are
clean and well secured. Inspect fire extinguishers, fire buckets and First Aid Boxes, if they are intact
and serviceable. [26]
4. Inspect structure and plant foundations for any sinking or cracking. Go round the structural
work for checking tightness of various bolts and nuts.
5. Inspect all indication lamps on control panels for correct working.
6. Carry out inspections as indicated at Annexure 2.01.

20226 Battery

1. Check all cells generally in accordance with para 20220.

2. Take specific gravity and cell voltage of pilot cell and record in register. If any significant
change is noticed specific gravity and voltage for all cells should be taken to identify any weak cells.
Then top up with distilled water exactly to the correct level for every cell.

3. Check operation of battery charger and note charging rate in register.

MONTHLY MAINTENANCE

20227 Bonding And Earthing

Visually inspect all earth connections and see that they are in order and that every equipment has
duplicate earths. Tighten connecting bolts and nuts as necessary. Where the sub-station and
feeding post are close by ensure that sub-station structures are properly bonded with the feeding
post and the track by two independent connections.

20228 Oil Level in Transformers, Circuit Breakers, CTS etc.

Check oil level in sigh gauge glass and examine all joints, valves, plugs etc for oil leakage in each
equipment; rectify leaky parts if found and restore the oil level.

20229 Insulators

Clean all insulators with dry cloth and look for any flashover marks, cracks, chippings. Insulators
which are badly chipped should be replaced. Minor chippings can be rendered impervious to
moisture by a light coating of Araldite or similar epoxy resin.

20230 Traction Transformers

1. Clean externally the tank, conservator, radiator, bushings, oil level indicator, gauges, etc with
dry cloth.

2. Make a note in the Register of the maximum temperature of transformer oil on dial indicator;
reset indicator.

3. Check explosion vent diaphragm for any damage and presence of oil

4. Check silica-gel breather. If turning pink in appearance, replace it with dry gel (blue color)
and recondition the old silica-gel. If the silica-gel is too wet, check di-electric strength of transformer
oil.

5. Check for gas collection, if any, in Buchholz relay.

6. Check for oil leakage on transformer body, conservator tank, oil drain valve and foundations.
If leaking, take corrective action by tightening the bolts; replace gaskets, if necessary.

7. Check if heater in the marshalling box is functioning properly, and if all terminal connections
are in order. [27]
20231 Operating Mechanism of Circuit Breakers and Interruptors.

1. Open the cover of control box. Examine the interior and remove the accumulated dust, if
any part of the interior is badly rusted indicating entry of moisture, find out the cause, plug
the holes and repaint the rusted parts. Check in particular if the weather-proof gaskets are
in good condition; if not, replace them to make the control box water-tight and dust-tight.
Examine if the leading in pipe connections are properly bushed, sealed and water-tight.
Check if all pins and checknuts are in place. Check also tie-rod nuts for tightness.
2. Operate the mechanism at least twice manually. Have it operated on remote control from
RCC; keeping the control door open, observe whether the mechanism functions smoothly
without any rubbing or obstruction, and also if the shock absorber functions properly when
circuit breaker is tripped.
3. Examine the commutator of the motor and clean with muslin cloth. Examine carbon brushes
and replace if necessary.
4. Check breather and breather holes for clogging.
5. Check gear-oil level in the mechanism and replenish it, if required
6. Check if heater is functioning properly
7. Check interlocks of the equipment and associated isolators.
8. Check local position indicator and remote semaphore indicator for operation. Observe for
the correct operation of recording counter.

After complete checking, close the cover and test the breaker for operation under remote, local and
manual control.

20232 Isolators

1. Manually operate isolator several times and observe if it operates smoothly and correctly.
Check interlocks and integral lock, lubricate moving parts as necessary with appropriate lubricant.

2. If isolator is motor-operated, check commutator of motor and clean with dry mull cloth, and
check carbon brushes for proper bedding and wear. Check if motor is working smoothly, clean limit-
switch and auxiliary switch contacts and check tightness of wiring connections. Examine contactor
box and signal box; clean thoroughly and lubricate all gears, shafts, bearings contact etc.

20233 Busbars, Clamps and Connectors

Immediately after switching off the power supply and earthing the lines, feel by hand all connectors
and clamps on busbars and equipment terminals which carry heavy currents to see if they are too
hot. If any connection is too hot, it indicates poor contact. Open up the connector; carefully clean
the contact surfaces, touch up the high spots on the contact surfaces so that the mating surfaces
bed well together; apply a very light coat of viseline, refit and tighten up. Wherever applicable,
replace bimetallic strip.

20234 Control and Relay Panels.

1. Make a note of flag indications, if any, then reset.

2. Check if all indicating and recording instruments are working normally and the pointers are
not sticky.

3. Note and record in the Register the ranges of voltage and current variations during a 15
minute period at the time of the day when inspection was carried out. Abnormal voltage or current
should be noted for corrective action.
4. Clean the panels externally. [28]
QUARTERLY MAINTENANCE

20235 Batteries and Battery Chargers

1. Take specific gravity and cell voltage of every individual cell and enter in the register.

2. If the battery is not in a fully charged condition, boost charger should be given as required
and trickle charging rate increased to the extent required. This should only be done by a
supervisory official after investigating the causes for excessive discharge.

3. Make a general examination of battery charger. Check earth connection to the body.

20236 PTs and CTs

These should be maintained generally on lines similar to that of traction transformers except for
items which do not obviously apply. In addition, for PT check the fuse holders on the LV side to see
if they are in order.

20237 Booster Transformers

a) Replace or recondition silica-gel breather, if necessary.

b) Check earthing connections from bottom of structure to the earth electrodes or to the rails,
Check the availability of duplicate earth strip and its proper connection.
c) Check all caution boards, name plates and anti-climbing devices for proper condition
d) Check foundation for any sinking or cracking : Check all structure bolts and nuts for proper
condition.

Annual maintenance and periodical overhaul are to be carried out, generally as indicated for the
traction transformer.

20238 Auxiliary Transformers

1. Measure insulation resistance of transformer winding and record values alongwith

temperature.

2. Test a sample of oil for BDV

3. Check that the 25 KV fuse-holder out freely on raising the spring latch. Check rod gap
setting. Measure earth resistance of neutral conductor.

Annual maintenance and periodical overhaul are to be carried out, generally as indicated for the
traction transformers.

HALF YEARLY MAINTENANCE

20239 General

CTFO/PSI should visit the grid sub-station and ascertain whether any significant change in the EHV
grid network has occurred during the past six months or are expected shortly.

20240 Traction Transformers

1. Test oil sample from tank bottom for crackle test, acidity and BDV,. If BDV is below the
prescribed value, oil should be dried out.
2. Check whether the rod gap settings on bushings of transformers are in order, as per Makers
drawing. [29]
3. Measure and record insulation resistance of all windings to earth and other windings with a
2500 V megger, alongwith temperature of windings and ambient temperature.

4. Check all alarm and trip devices for proper functioning.

20241 Isolators

1. Observe for any signs of overheating and check the wipe of contact blades. Clean blade tips
and fixed-contact fingers and lightly wiseline the contact making surfaces.

2. Clean all articulated joints, sliding and bearing surfaces thoroughly.

3. Check all split pins, lock nuts and check nuts for proper condition.

4. Check for correct setting and alignment of arcing horns.

5. Operate the isolator slowly, check for simultaneous operation of the blades on the poles and
correct alignment of blade tips in the fixed contact jaws of the ples. Adjust if required to ensure that
the blades are fully horn between the contacts when handle is in closed position.

6. Check locking arrangements.

20242 Control and Relay Panels.

1. Check tightness of all connections, remove cobwebs and wipe off accumulated dust with dry
cloth.

2. Check if tap and time settings of the relays are in order.

3. Examine fuses for signs of overheating or aging, springiness and cleanliness of contact
making parts. Clean up and lightly wiseline to ensure proper contact.

YEARLY MAINTENANCE

20243 General.

1. Inspect the fence all-round the sub-station and bonding between metal fencing panels and to
earth. Put a drop of oil in the hinges of all doors. Repaint any of the structural parts as necessary.

2. Open all the trench cover and clean them completely. Clean all culverts and remove
cobwebs; check possibility of lizards or other inspect gaining entry into enclosed control equipment,
and make them insect-proof.

3. Arrange for painting of walls and metal-works as necessary.

4. Check all explosion vent disphragms for any damage.

5. Check rod gap setting.

20244 Lightning Arrestors

1. Check earthing terminals and earth strips for proper condition. Check connection to the line.

2. Where lightning arrestors are provided with discharge counters, record the counter reading.

[30]
20245 Bonding and Earthing

1. Check physically the soundness of bonding and earthing connection to every electrical
equipment, structural steel, lightning arrestor etc. and inter-panel connections.

2. Record earth resistance to body of electrical equipment as well as to all parts of the fencing
and structural steel work.

3. Check if the terminations of the overhead shield wire covering the whole sub-station are in
good physical condition and properly bonded electrically to the structures.

4. Check and record resistance of each group of earth electrodes, after disconnecting it from
common earth system. Improve, if necessary.

5. Check condition of connections to the burried rails.

20246 Traction Transformers.

1. Send samples to approved laboratory for all tests listed at Annex. 2.03B (IS 1866) including
dissolved gas analysis.

2. Check oil level in bushing

3. Inspect bushing gaskets for leaks and tighten bolts.

4. Move the tap-setting switch up and down the full range a few times so that by self-wiping
action good contact is assured. Set the tap finally at the correct position making sure that tap-
indication corresponds to position of main contacts.

5. Paint transformer tank on such parts as required.

20247 Isolators

1. Smoothen burrs, if any on the blade tips and fixed contact fingers with fine emery paper and
smear wiseline.

2. Measure clearance of blade in open position and record and adjust crank mechanism, if
found necessary.

3. Check the adjustable stop set-screws for proper condition and correct positioning.

4. If the isolator is motor-operated, measure and record insulation resistance of motor windings
and contactor coils using a 500 V megger.

20248 Bus Bars and Connectors

Measure with a Ductor or other low resistance measuring instrument the contact resistances of all
connections which are carrying heavy current.

20249 Control and Relay Panels

1. Carry out maintenance on relays as detailed in para 20221.

2. Check and clean up control switches and push-button contacts for burnt or corroded marks;
polish the surfaces. Check also if the contact springs have the correct springiness.
[31]
20250 Batteries and Battery Chargers

IF the battery is not in a healthy condition or if there is excessive accumulation of sediment, the
whole battery should be replaced with a new set.

Battery Charger

Open out the covers of the battery charger and blow out all dust. Check tightness of all
connections, bolts,
Nuts and screws. Measure and record the insulation resistance of the transformer windings of the
battery charger with 500 V megger.

20251 PTs and CTs

1. Test oil samples if possible.

2. Check rod gap setting, if provided
3. Measure insulator resistance.
4. Check conditions of fuses of PTs and terminal connections for CTs.

20252 Special Maintenance Schedules for Minimum Oil Circuit Breakers and Interruptors.

This schedule will apply to minimum oil circuit breakers and interruptors with the following proviso:

132 KV CBs - 6 trippings on fault

25 KV CBs - 30 trippings on fault
25 KV Interruptors - 250 openings on normal current for minimum
oil type and 500 openings on rated current
for bulk oil type.

a) Open the extinction chamber, examine the contact-rod arcing-tie, upper and lower contact
fingers and fixed arcing-contacts for burring or putting. Check contact springs for loss of temper,
breaks or other deterioration; replace wherever necessary. Remove any beads of fused metal from
arcing-tips and clean pitted surfaces. Change the contacts when the wear reaches the limits
prescribed by the manufacturer. Tighten up all bolts and current carrying parts. Check contact rod
for correct alingment and setting.

b) Test oil samples for BDV. If it falls below the prescribed value the oil should be purified or
replaced.

c) Clean the explosion chamber with dry and clean cloth. Remove the carbon deposits if any;
wash out all traces of moisture from all parts with fresh oil having high dielectric strength and refill
with good oil.

d) In addition, the operating mechanism of circuit breakers and interruptors should be attended
to annually as under;-

1. Lubricate bearing surfaces of rollers, bearings and sliding surfaces with good quality
machine oil. Since oil trends to collect dust and dirt, if should be used sparingly and any surplus
should be wiped off with a clean cloth.,

2. See that all links and levers move freely. Operate the mechanism slowly by hand to see that
all parts move freely and no undue friction is noticeable. Observe the mechanism to see that
everything is in working order.

[32]
3. Check all pins, latches, etc. for binding and misalignment. Check latch carefully to see that
is not getting worn so as to cause unlatching from vibration or sticking and failure to trip.

4. Check that the mechanism operates with 80% of the nominal operating voltage. Check and
record the insulation resistance.

5. Observe operation of trip coil during electrical trippings and the plunger for fast action and
freedom from any stickiness. The plunger should have sufficient travel to ensure an adequate
impact that will positively release the breaker latch. Check insulation resistance of the coil.

6. Check if the breaker mechanism operates smoothly and freely without binding. Check that
the contact rod is not binding against its guide.

7. Wash out bearings, pivots, etc. with carbon tetra-chloride if they are dirty, and lubricate very
lightly.

8. Examine the accelerating spring and see that adjusting nuts are locked tight.

9. Measure the length of the breaker stroke and check and adjust in accordance with
Manufacturers instructions.

10. Check opening and closing position of the auxiliary contacts with respect to the main
contacts. Adjust where necessary. Check the condition of the contacts and refinish with fine file if
burnt or corroded. Ensure that good contact is made without excessive friction. Check operating
rods and levers to ensure that they are secure and move freely. Smear auxiliary contact surfaces
lightly with wiseline or petroleum jelly. Drain oil from gear box of the spring charging motor and refill
to correct level with the right grade of oil. Measure the duration for which the motor runs to charge
the spring and compare with Makers instructions.

20253 Pre-Monsoon Check

Before onset of monsoon season, it should be ensured that for every equipment no scheduled
maintenance work is overdue. In the scheduled inspection just preceding the monsoon, special
attention should be paid to the vulnerable points likely to permit ingress of moisture resulting in
reduction in dielectric strength of the equipments and rusting of parts.

20254 Overhaul Schedule for Equipment

1. Transformers in case of an internal fault or once in 7-10 years.

2. Operating mechanism of circuit Once in 10 years or as and when any major part like springs
breaker and interruptors. have To be replaced or the mechanism is sluggish, and
needs shop attention and overhaul.

[33]
 Annexure 2.01
(Para 20202 , 20223)

SCHEDULE OF MONTHLY INSPECTIONS.

SN. Nature of Inspection Sr. DEE DEE AEE CTFO * TFO* ATFO*

1. Traction sub-station 1 1 2 4 4 4

2. Switching stations 1 2 3 4 4 4

3. PSI Depots 1 2 4 - - -

4. Grid Sub-station 2 in a Yr. 1 2 1 1 1

5. Office Insp. 1 1 1 - - -

Notes:

1. These inspections are the minimum quantum per month

2. * In respect of Supervisory staff, the inspections pertain to their respective jurisdiction

3. Check lists of items to be broadly covered are indicated at Annexure 2.02. The maintenance
schedules
Prescribed should also be kept in view.

4. Quota of inspections by HQ officers may be laid down by CEE.

[34]
 Annexure 2.02

(Para 20223)

CHECK LIST FOR INSPECTIONS

1.0 PSI depots including Subordinate Offices

a) OHE/PSI Depots

Check
1. Staff grievance register

2. Quarter Register.
3. Attendance register
4. Cleanliness of depot
5. Upkeep of stores.
6. Stock position in Stores
7. Compliance of audit & account inspection notes.
8. Test & Trial report
9. Availability of latest and specifications
10. Planning and Progress of Section works.

b) Subordinate Office:
Check

1. Attendance register.
2. Compliance of audit & account inspection notes.
3. Compliance of officers inspection notes.
4. Test & Trial report
5. Availability of Drgs. And specifications.
6. Progress & Planning of section works.

2.0 Inspection of Grid Sub-station.

1. Be on look out for any modifications made/being made in the power supply arrangement.
2. Check up if there is any equipment under breakdown which is likely to increase risk of
interruption. In power supply to traction.
3. Note down meter readings and scrutinize and record important data regarding power supply
parameters including daily. MD, variation in voltage, frequency and power factor.

3.0 Inspection of Traction Sub-Station.

a) Switch Yard:
Check

1. For vegetation growth and spreading of pebbles.

2. Painting of fencing and equipments.
3. Condition of cable trenches & trench covers.
4. Condition of approach road.

[35]
b) Power Transformer:
Check
1 OTI and WTI temperature present and maximum readings.
2 Oil level in conservation tank
3 Tap changer position of standby & service transformer.
4 For abnormal humming.
5 Colour of silica gel.
6 For leakage of oil on transformer body, conservator tank, oil drain valve and radiator.

c) Circuit Breaker and Interuptors

Check
1. Control box gaskets for water and dust tightness.
2. Operation by local & remote control.
3. Operating mechanism for smooth operation
4. Oil level and leakage.
5. Closing time of interruptor.
6. Number of trippings since last replacement of oil in case of circuit breaker and counter
reading of interruptor.

d) PT, CT, AT.

Check
1. Leakage of oil

e) Isolator.
Check
1. Locking arrangements.
2. For correct alignment of blade tip in the fixed contact jaws.
3. For correct matching & alignment of arcing horns,

f) Control Panel
Check
1. Fuses for the correct size, overheating or aging sings.
2. For loose connections at terminal boards.
3. Functioning of Alarms and visual indication on control panel.
4. Functioning of auxiliary relays.

g) Battery charger & Batteries.

Check
1. Acid level

[36]
2. Presence of sedimentation
3. Specific gravity & voltage of pilot cell
4. Presence of sulphation and tightness of inter cell connectors.
5. Size of fuses of battery charger.
6. Voltmeter and ammeter readings.

h) Energy meter
Check
1. Recorded maximum demand.
2. Condition of the seal.

i) Earthing
Check
1. Soundness of earth connection to each electrical equipment and structure.
2. Last recorded earth resistance readings.
3. Buried rail connection.

j) Remote Control Equipment

Check
1. General function of relays and selectors.
2. Wiring for loose connection if any.
3. For presence of dust & condition of cubicle gaskets.

k) General
Check
1. Availability of fire buckets, Respiration chart, First Aid Box, Tools & Plants.
2. Working of TPC Phones and emergency sockets.
3. Inspection register and remarks made therein
4. History sheets of various equipments.

4.0 Switching Stations

a) Switch yard.
Check
1 For vegetation and spreading of Pebbles.
2 Painting of fencing and equipments
3 Condition of cables trenches & trench cabins.

b) Interruptors
Check
1. Control box gaskets for water and dust tightness.

[37]
2. Operation by local & remote control.
3. Operating mechanism for smooth operation.
4. Oil level & leakage.
5. Interlocking of interruptors and under voltage relay operation at SP.

c) PT & AT
Check 1. Leakage of oil

d) Isolator

Check 1. Locking arrangements

2 For correct alignment of blade tips, in the fixed contact jaws & alignment of arcing horns.

e) Battery charger & Batteries.

Check
1. Acid level.
2. Presence of sedimentation
3. Specific gravity & voltage of pilot cells.
4. Presence of sulphation & tightness of inter-cell connectors.
5. Size of fuses of battery charger.
6. Voltmeter & ammeter readings.

f) Earthing
Check
1 Soundness of earth connection to each electrical equipment & structures.
2 Last recorded earth resistance readings.

g) General
Check
1. Availability of fire buckets, respiration chart, First Aid Box, Tools & Plants.
2. Inspection register and remarks made therein
3. History sheets of various equipments.

[38]
 Annexure 2.04
Para 20216

GUIDELINES FOR CONDITION MONITORING OF TRACTION POWER TRANSFORMER BY

DISSOLVED GAS ANALYSIS (DGA) TECHNIQUE
(Reference RDSOs circular No. ETI/PSI/M/4 dated 5.2.91)

1.0 Introduction

1.1 Dissolved gas analysis (DGA) is a power ful diagnostic technique for monitoring the internal
condition of transformer as it is capable of detecting faults in the incipient stage, before they develop
into major faults and results in the outage of the transformer. The conventional Buchholz Relay is
universally used in transformers to protect against severe damages. However, its limitation is that
enough gas must be generated first to saturate the oil fully and then to come out or there should be
a gas surge to operate this relay. Moreover, Buchholz Relay is never meant to be a diagnostic
device for preventive maintenance of transformers.

1.2 The DGA technique is very sensitive as it detect gas in parts per million (ppm) of the oil by
use of the GAS Chromatograph, it is possible to check whether a transformer under service is being
subjected to a normal aging and heating or whether there are incipient defects such as Hot Spots,
Arcing, Overheating or Partial discharges. Such incipient faults otherwise remain undetected until
they develop into a major failure.

2.0 Formation of Gases in Oil Filled Transformers.

2.1 It is well known that insulating oil in high voltage equipments can break down under the
influence of the thermal and electrical stresses to produce hydro-carbon gases, hydrogen and
carbon oxides. Gases may be formed in transformers and other high voltage oil filled equipment
due to aging and to a greater extent as a result of faults. The accumulation of gases in transformer
oil may be sudden due to a severe arcing fault or more gradual as in the case of slow deterioration
of insulation. The principle mechanism of gas formation in a transformer tank can be classified as
under:

A_ Oxidation b) Vapourisation, c) Insulation decomposition d) Oil breakdown e) Electrolytic action

2.2 Oxidation
Carbon dioxide is the gas predominantly liberated during the process of oxidation. The process
begins when small quantities of oil combine chemically with the dissolved oxygen in the oil resulting
in formation of traces of organic acids. These acids react with the metal of the transformer, forming
metal based soaps which dissolve in the oil and act as a catalyst to accelerate the process of
oxidation.

2.3 Vapourisation
The vapourisation of oil occurs at about 280 degree C while that for water occurs at about 100
degree C. The false alarm of a Buchholz relay may be attributed to the fact that the condensation of
water vapour takes place when the excess moisture in the tank is vapourized by a heat source.
False alarm can also occur, when hydro-carbons, the constituents of the insulating oil, vapourize.
2.4 Insulation Decomposition
The solid insulants in power transformers are mainly of cellulose or resinous type, viz. Paper, press
board, cotton, resins and varnishes. These substances contain in their molecular structure
substantial amounts of oxygen , cabin and hydrogen. In the temperature range of 150 degree C to
400 degree C the insulation breakdown results in liberation of hydrogen, carbon dioxide and carbon
monoxide. Above 400 degree C the gases formed are relatively less.

2.5 Oil Break Down

The direct break down of oil by arcing results in cracking of the oil. The aromatic contents
breakdown into simple [41]
 hydro carbon gases and hydrogen. Acetuylene and methane are the major constituents. Other
hydrocabon gases may also be liberated due to cracking. If the necessary temperature is
maintained for their stable formation.

2.6 Electrolytic action

Hydrogen and oxygen are liberated during electrolytic action. Presence of minute and small
particles of fibres within the oil leads to electrolytic action. Light hydrocarbon gases may also be
present. If solid insulation is involved.

3.0 Types of Fault Conditions

There are three main types of fault viz. Overheating of windings, core and joints, partial discharges,
and arcing.

3.1 Overheating

Overheating metallic parts heat up the surrounding regions such as paper insulating tapes and oil.
This leads to thermal deterioration of these materials. Thermal degradation of paper produces
carbon dioxide. Carbon monoxide and water. The ratio of carbon dioxide to carbon monoxide is
typically five, but if the ratio falls below three, there is indication of severe overheating of the paper.
Oil degradation produces a number of hydro carbon gases such as methane, ethane, ethylene, and
acetylene. Methane and ethane are decomposition products that appear above 120 degree C
ethylene appears above 150 degree C while acetylene is a high temperature product, appearing at
several hundred degrees centigrade. Some hydrogen is also produced along with the hydro
carbons gases. The proportion of the various hydrocarbons varies with temperature. This is the
basis of the well known Ratio code introduced several years ago by Dorenberg and R.R. Rogers.

3.2 Partial Discharge

The second type of fault condition is partial discharge which occurs due to ionization of oil in highly
stressed areas where gas/vapour filled voids are present or the insulation is continuing moisture.
The main product during particle discharge is hydrogen, though small amounts of methane and
other gases would also be present depending upon thermal digression. The disintegration of oil and
cellulose due to particle discharge is characterized by the removal of the outer hydrogen atoms to
form hydrogen gas. The remaining molecular framework polymerizes and long chain products such
as waxes are formed. Thermal degradation is a more predictable phenomenon which involves the
break up of chemical bonds. Cellulose decomposes ultimately to CO, CO2 and water; oil break up
into lower molecular hydro carbons.

3.3 Arcing

The third type of fault condition is arcing. Arcing can occur between leads, between lead and coil
and between other highly stressed regions weakened by fault conditions. The high temperature
caused by arcing results in the production of acetylene and hydrogen.

3.4 Pattern of generation of gases in transformer is summarized below:

FAULT/PATTERN KEY GAS

Conductor Overheating CO/CO 2 (carbon oxides)
Oil overheating C2 H2 (Ethylene)
Particle discharge H2 ( Hydrogen)
Arcing C2H2 (Acetylene)
4.0 Solubility of Gases.
4.1 The solubility of gases in oil varies with temperature and pressure. While solubility of H2,
N2,CO, O2 in [42]
oil increases with temperature and that of CO2, C2, H2, C2 H4 and C2 H6 decreases with
temperature, solubility of CH4 remains essentially constant.

All the gases become more soluble in oil with increase in pressure. Solubility of gas is one of the
factors contributing to the complexities in formulating permissible levels of gases on the basis of
service life of a transformer. Table I show solubility of different gases 25 degree C and at 1 atm.
The homogenerity or the gases in the oil is dependent on the rate of gas generation, access of the
fault area to flowing oil, rate of oil mixing and presence of gas blanket.

5.Dissolved Gas Analysis (DGA)

5.1 Dissolved gas analysis (DGA) of the oil of a transformer in operation is a specialized
technique to assess the internal condition of the transformer. DGA is performed by Gas
Chromatography. The gases extracted from the oil by a suitable apparatus are transferred to the
Gas Chromatograph system for analysis.

5.2 The knowledge of solubility of Hydro-carbon and fixed gases at different temperatures, in
insulating oils helps in interpretation of gas analysis. The permissible concentration of dissolved
gases in the oil of healthy transformer is shown in table II. The combinations of Gas levels for
different types of faults are shown in Table III while table IV shows the gas composition by volume
under arcing fault with participation of various components of solid dielectrics in a transformer.

5.3 While the absolute concentration of fault gases gives an indication of status of insulation of
transformer, whereas the relative concentration of these gases provides a clue to the type of fault.
For fault diagnosis the method based on Rogers Analysis is adopted.

5.4 Ropgers method:

This method hold good for hydro carbon gasses By evaluating the gas ratios, the type of fault is
detected. Four ratios are used viz. Methane/Hydrogen, Ethane/Methane, Ethylene/Ethane and
Acetylene/Ethylene. The value of ratios can be greater or smaller than unity. The ratio and type of
fault represented by that ratio are given in Table V.

6.0 Data Collection and Analysis.

6.1 It is recommended that DGA be performed irregularly once a year on every transformer upto
4 years of service and thereafter twice a year upto 10 years and the frequency thereafter may be
increased to thrice a year.

Note: Wherever the Buchholz relay operates, the dissolved gas analysis be carried out immediately
after operation of the relay to ascertain the cause of fault.

6.2 The results of the DGA for each transformer should be built into a data and based on the
trend of the gas levels over a period of time as well as the faults, if any, that the transformer had
suffered, an analysis may be done to establish the exact nature of the incipient fault that may be
developing in the transformer.

[43]
 TABLE I

SOLUBILITY OF DIFFERENT GASES IN TRANSFORMER OIL AT 25 DEGREE C 1 atm

Gas Volume %
With reference to volume of oil

Hydrogen 7
Oxygen 16
Nitrogen 8.6
Argon 15
Carbon Monoxide 9
Carbon dioxide 120
Mathene 30
Ethane 280
Ethylene 280
Acetylene 400
Propylene 400
Propane 1900
Butane 4000

TABLE II

RANGE OF GAS LEVELS

(All concentrations are in PPM)

Gas 0-4 years 4-10 years 10 years.

Methane 10-30 30-80 30-130

Ethane 10-30 30-50 30-110
Ethylene 10-30 30-50 50-150
Acetylene 10-16 10-30 10-40
Hydrogen 20-150 150-300 200-500
Carbon Monoxide 200-300 300-500 500-700
Carbon Dioxide 3000-4000 4000-5000 4000-10,000

[44]
.
 ANNEXURE 2.05
PARA 20218

PHYSICAL PROPERTIES OF SF 6 GAS

1. Molecular Weight 146.07

2. Melting point -50.7 degree C

3. Sublimation Temperature -60.8 degree C

4. Critical Temperature 45.547 + 0.0003 degree

5. Critical Pressure 38.55 Kgf/Cm2

6. Critical Density 0.730 g/Cm2

7. Dielectric constant at 25 degree C 1 atm 1.002

8. Thermal conductivity at 30 degree C 3.36 x 10

9. Density at 20 degree C:

Kgf/Cm2 Gm/lit.

At 0 : 6.25
At 1 : 12.3
At 5 : 38.2
At 10 : 75.6
At 15 : 119.0

(47)
 Annexure 2.06
Para 20223

MAINTENANCE OF SF 6 CIRCUIT BREAKERS

1.1 Schedules

The maintenance and check execution standard depends upon the working conditions of the CB.
The checks to be carried out, their frequency and scope are broadly as under:

Type of check Frequency Scope

Patrol Inspection Every Week The patrol inspection is an external check of the
Circuit breaker in live condition for irregularities.

Ordinary Inspection After every The ordinary inspection is inspection performed by

1000 operation turning off the circuit breaker for a relatively short
time for simple inspection and servicing with emphasis
on functional checks e.g. visual check of irregularities
and cleaning of dust and dirt.

Detailed Inspection After every The detailed inspection is an inspection performed by

3000 operation turning off the circuit breaker for a relatively long time
to dismantle and inspect the mechanism for
irregularities for the purpose of continuously
maintaining the performance

Incidental Inspection - The incidental inspection is performed when inspection

And repair are necessary due to the detection of an
irregularity during patrol inspection or during operation.

1.2 General

Attention should be paid to the following points during ordinary and detailed inspection.

a) Switch off control/compressor motor supply. Discharge all the air in the air receiver through
the drain valve.

b) The circuit breaker is to be inspected in the open position unless otherwise specified in these
instructions. At the open position of the breaker the safety pins for preventing closing and opening
must be inserted. On completion of the inspection, the safety pins must be removed.

c) Good quality grease should be used adequately.

d) Circlips and split pins which are removed must be replaced with new ones.

e) RemoveO rings must be replaced with new ones. While handling and placing O rings in
their grooves care should be taken to avoid dust falling on them.

[48]
 Chapter III
OVERHEAD EQUIPMENT
20300 Introduction

1. This chapter is divided into five Sections as under:-

Section I - Organization : A broad description of the duties of 3 important categories of staff in

OHE Section is given. Here also, in territorial distribution of work, the CTFO in charge have all
activities under his control, and TFOs next in command will be in charge of functional activity.

Section II Guiding Notes on Maintenance : The important points to be borne in mind in the
maintenance of the main items of OHE are enumerated.

Section III Maintenance Schedules for OHE : A recommended schedule of maintenance for OHE
is given.

Section IV Safety Rules for OHE : The essential safety rules applicable to OHE staff are given.

Section V - Forms and Registers : The records to be maintained in regard to OHE maintenance
and recommended performance for these are given.

2. The following relevant documents have been incorporated as Appendices to this Volume.

2.1 Principles for Layout Plans and Sectioning Diagram for 25 kV ac Traction issued by RDSO
(Appendix I).
2.2 Code for Bonding and Earthing for 25 KV ac 50 Hz. Single Phase Traction System issued by
RDSO (Appendix II)\
2.3 Regulations for Power Line Crossing of Railway Tracks issued by Railway Board (Appendix
IV)
2.4 Guidelines for Provision of Maintenance Depots, Tools and Plants and Transport Facilities
(Appendix VI)
2.5 Model Circulars (Appendix VII)
2.6 List of Specifications and for Equipments and Materials for Railway Electric Traction issued by
RDSO (Appendix IX)
2.7 Diagrams of General Arrangement and Fittings a reference booklet issued by RDSO
(Appendix X).

1. ORGANISATION

20301 Duties of Chief Traction Foreman CTFO (OHE)

He is the senior supervisor working under the control of Sr. DEE/DEE (TRD) and directly
responsible for the proper maintenance of OHE including the 25 KV feeders and return feeders from
the traction sub-stations to the feeding posts. He should be fully conversant with the layout and
sectioning of OHE in his jurisdiction as also the rules and procedures laid down for efficient
maintenance of OHE and safe working on OHE.

In particular he shall:

1. supervise the maintenance of installations under his charge in accordance with the prescribed
schedules, to keep them fully serviceable and in a state of good repair.
2. Plan in advance the requirement of power blocks for OHE maintenance based on the work to be
done in consultation with his section supervisors and ensure the completion of the work within
the time allotted.
INDIAN RAILWAYSAC TRACTION MANUAL VOLUMEIIPART1[58]
3. Carry out detailed inspections of OHE under his control by push trolley or motor trolley to cover
the entire section once in 3 months.
4. Scrutinize daily the reports on foot patrol and other defects on OHE, as well as reports from
section supervisors and inspection reports of officers and arrange prompt rectification of defects
pointed out and report compliance to Sr. DEE/DEE/AEE (TRD)
5. Check the work by sectional gangs under him to ensure that quality work is done and that
compliance with prescribed schedules is adhered to .
6. Keep the organization for attending to breakdowns in constant readiness to act promptly and
expedite restoration whenever there is a breakdown.
7. Instruct and train staff under him in the correct methods of maintenance with special reference
to safety precautions.
8. Arrange to send his staff for training courses as required.
9. Ensure that special testing instruments, tools and equipment including the OHE inspection cars
and breakdown vehicles, provided for maintenance of OHE are properly cared for and
maintained in proper condition.
10. Keep a watch on availability of spare parts and stores required for maintenance of OHE and
initiate timely action to recoup stocks.
11. Ensure proper accounting and periodical verification of the stores and tools under his charge.
12. Submit the prescribed periodical returns to DEE/AEE(TRD) and carry out their instructions
issued, if any, on the basis of such returns.
13. Keep his superior officers fully informed of each and every important development and seek
their guidance when required.
14. Carry out such other duties as may be allotted to him by his superior officers; and
15. Carry out inspections as indicated at Annex. 3.01.

20302 Duties of Field Supervisors.

The field supervisors in charge of OHE (ATFO, chargeman, inspector etc.) will be under the
CTFO(OHE) and each supervisor will be responsible for the following.

1. maintenance of the OHE and allied installations in his jurisdiction in accordance with the
prescribed schedules.
2. Submission of the requirements of power blocks for OHE maintenance, in co-ordination with
permanent way maintenance as far as possible, so as to take maximum advantage of traffic
blocks.
3. Detailed inspection of OHE under his charge by push trolley or on foot as indicated in para
20322 and 20323.
4. Scrutiny of daily foot patrol and other reports of defects and take prompt action to remedy the
defects brought out.
5. Close supervision of the maintenance gang under his control to ensure a high standard of work
and compliance with prescribed schedules.
6. Keeping the organisation under his control in readiness to deal with breakdowns.
7. Guidance to the maintenance staff for the proper execution of work in accordance with standing
instructions.
8. Ensuring that tools and equipment under his charge are properly cared for and maintained in
proper condition
9. Keeping watch and taking necessary action to recoup stores and spares required for his
jurisdiction.
10. Preparation and submission of periodical reports and returns to superior officials as laid down:
11. Keeping CTFO(OHE), AEE(TRD),DEE(TRD) and Sr. DEE(TRD) informed of all important
developments and seeking their guidance when required.
12. Carrying out any other duties allotted by superior officials.
13. Carrying out inspection indicated at Annex. 3.01.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [59]

20303 Linesman

1. All linesmen should have requisite educational qualifications to enable their working independently to
take power blocks from TPC, deal with messages in connection with power blocks and also to submit
written reports to their supervisor in regard to patrol and inspection work assigned to them. However, until
it is possible to have all Linesmen with the requisite educational qualifications, it will be necessary to
authorize only selected linesmen to deal independently with taking of power block and issue of messages.
Literate Linesman to be authorized to take power blocks independently should be trained and certified.

2. Every linesman should be conversant with the safety rules pertaining to his work and be capable of
independently attending to minor repair and adjustment work on OHE. For this purpose he would be
required to carry his tool box, telephone etc. with him wherever needed.

3. A linesman should be able to carry out operation at switching stations on local control in an emergency
under instructions from the TPC.

4. Linesman shall look for the common types of defects on OHE when they are deputed for patrol work and
to report on defects noticed during such patrols to the Section Supervisor (Para 20322)

5. Every linesman should develop the ability to carry out temporary repair in the event of breakdowns so as
to restore traffic as quickly as possible and to deal with repairs necessary for all types of breakdowns of
OHE.

II GUIDING NOTES ON MAINTENANCE

20304 Introduction
1. For better utilization of traction assets, outage of any traction equipment from service should be minimum
without compromising on safety of the equipment and personnel. Monitoring of condition of the
equipment by reliable means is essential for following the system of need based maintenance i.e. directed
maintenance. However, till such time reliable condition monitoring techniques are introduced, the present
system of preventive maintenance has to continue.
2. Recommendations of Original Equipment Manufacturer (OEM) and Guidelines issued by RDSO, from
time to time, shall be kept in view while defining the scope and periodicity of the schedules.
3. The tightening torque for fasteners of various sizes is given in the Annexure 2.08.

20305 Out of Plumb Masts

Inspite of the care taken in design and erection, OHE masts do sometimes get out of plumb. This occurs
largely on embankments, due to erosion of earthwork on the outer side of the mast on account of poor
drainage or excavations in the vicinity or due to sinking of foundations onnew embankments. The extent of
earthwork initially provided at the back of foundations on embankments is shown in Structure Erection
(SEDs). OHE maintenance staff should, during patrolling and inspections, make a particular check of the
condition of earthwork has been or is likely to be eroded away, the Engineering Department should be
approached to strengthen the embankment, and the matter pursued until it is satisfactorily completed.

Masts which appears to be out of plumb should be checked with a plumb bob. Since the normal height of the
contact wire is 5.60 m above rail level, the extent of deflection of the masts at this height can be conveniently
found by measuring the deflection at a height of 1.85 m above rail level and multiplying this figure by 3. If the
mast is out of plumb, by more than 3 cm upto 5 cm, it should be kept under watch after making sure that there
is enough earthwork all round. To identify such masts requiring watching, a yellow bend of width 5 cm should
be painted at a height of 1.85 m from rail level.

Masts which are out of plumb in excess of 5 cm can be set right by releasing the OHE and pulling the mast
by a Tirfor. To facilitate this, the foundation must first be exposed on the side to which the mast is to be
pulled by the Tirfor., and the rear under side of the foundation should be packed and rammed with pieces of
stone until the foundation is fully supported. If necessary the newly packed part may be strengthened by
pouring in cement

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [60]

Any other method considered appropriate as per site conditions may be adopted.

RDSOs report No. ETI/OHE/55 on Tilting of OHE masts, Causes and Remedies may also be
referred to.

20306 Rail Level and Setting Distance

Structure Erection (SEDs) show setting distance or implantation of the OHE masts i.e. distance of
the nearest part of mast from the centre line of the nearest track as well as the height of the contact
wire from rail level at each location. These are with reference to alignment and level of the track at
the time of erection of OHE. Before electrification work is taken up, it should be ensured that the
track alignment and level are finalized. This is particularly so in the case of yards under remodeling.

Any change in alignment due to slewing of tracks will affect the setting distance and consequently
the stagger of the contact wire. At locations where the setting is critical i.e. close to the minimum
permissible value, slewing of track may result in infringement of the moving dimensions with
consequent danger of accidents. Change in rail level due to variation in ballast cushion or packing
up or packing down of the track will also result in change in contact wire height. Though provision
exists in the cantilever assembly for adjustments of the stagger and height, such adjustment are not
to be made unless absolutely necessary. It is best to maintain the position of OHE and tracks as in
the SEDs.

General Rule (1976) 17.06 stipulates as under:

Alteration to track
Before any alteration to alignment or level of electrified track is commenced, due notice shall be
given to those responsible for the overhead equipment so that the overhead equipment may be
adjusted to conform to the new conditions:

If follows, therefore, that any alterations of the alignment of the track on electrified sections shall
only be made with the prior knowledge and concurrence of the Sr. DEE(TRD) so that he may
arrange to correct the SEDs to the extent required. No alterations to the track affecting OHE
parameters may be carried out without obtaining specific approval from Sr. DEE(TRD). Whenever
any permanent changes are effected, the SEDs should be revised and a note made of the
circumstances and the authority under which the revision has been made.

To facilitate periodical checking, rail level and setting distance should be painted at the base of each
OHE mast face soon after commissioning, preferably in black letters. A horizontal line would
indicate the rail level. The setting should be marked in correct to the second decimal place.
Repainting of the these markings will ordinarily be required once in two years. Where pollution due
to brake shoe dust etc. is severe, repainting may be required more often.

During yearly maintenance of OHE, rail level and setting distance should be checked and compared
with the original figures. Any variations above 30 mm is setting distance and 20 mm in rail level
should be advised to the PWI for correction. No change in setting distance and rail level should be
allowed if such change results in infringement of moving dimensions.

It is essential to have a joint annual check of rail level and setting distance by the Chargeman/OHE
and APWI.

In addition to the marking on the masts, a register should be maintained by CTFO(OHE) to record
the annual measurements of implantation at critical locations over his jurisdiction. A similar register
should be maintained by each Chargeman for his own section (see proforma 03-8 in Section V)

Limits for mast setting distances are indicated in Appendix I.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [62]
20307 Contact Wire Hard Spots and Wear

Hard spots are points on the OHE where contact wire wear is likely to be higher than at normal
locations, due to less flexibility in the OHE. Smoke pollution aggravates wear at hard spots. The
usual spots where the contact wire is likely to show more wear are

1. Support points at curves.

2. Section insulators.
3. Splices
4. Turn outs
5. Central mast of 2 span uninsulated overlaps of unregulated OHE>
6. At approaches to tunnels and over line structures.
7. Locations where smoke pollution is pronounced, namely, tunnels with steam traction and at the
ends of platforms where steam locos halt for a long time under OHE.
8. Pull offs

At such hard spots, it is important to keep a watch on wear of contact wire by measuring and
keeping a record of contact wire thickness periodically. It is essential to concentrate on these spots
during annual measurement of contact wire wear.

20308 Sparking During Current Collection

Sparking occurs when there is loss of contact ( or improper contact) between the pantograph and
the contact wire. The common causes attributable to the OHE are:

1. Incorrect tension in regulated OHE due to maladjustment or sluggish operation of regulating

equipment;
2. Inadequate tension of contact wire in the case of unregulated OHE;
3. Deposit of soot on contact wire due to steam and diesel traction and the resulting roughness of
contact face during current collection;
4. Kinks in contact wire.

If OHE on the main line is unregulated the tension in the contact wire should be checked and
adjusted if need be once in 2 years. The speed being low in yards and sidings, the adverse effect of
incorrect tensioning will be less pronounced and re-tensioning at longer intervals of 3-4 years will be
adequate (para 20330)

Deposits of soot on account of steam and diesel traction may cause trouble due to sparking at
points where steam engines halt for long periods. Particular note should be made of such locations
and cleaning done at shorter intervals. The importance of cleaning of contact wire before
introduction of electric traction is dealt with in Chapter IX.

Kinks detected during patrolling and inspection should be straightened or/removed without delay.
After re-tensioning it is particularly necessary to inspect the section for kinks.

The periodic current collection tests (para 20324) would reveal points where sparking takes place.
Apart from investigating and rectifying the cause of such sparking, it is also important that the
roughened surface of the contact

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [63]

wire be attended to, failing which, there will be further deterioration, with successive passage of pantographs
resulting in reduced life of contact wire.

20309 Contact Wire Wear

Hard drawn grooved copper contact wire of 107 mm 2 cross sectional area when new is used in the 25 kV
electric traction system. With a proper maintenance of the OHE the contact wire is expected to have a life of
about 30 years, with average traffic density and conditions of pollution.

The thickness of new contact wire is 12.24 mm. It will be necessary to replace the contact wire when it has
worn to a thickness of 8.25 mm corresponding to a cross sectional area of approximately 74 mm2. At this
point 2 mm clearance shall be available between the bottom most point of the dropper clip, parallel groove
clamp as well as contact wire splice and the pan of pantograph. Any further reduction in cross sectional area
will result in the current density in the contact wire splice and the pan of pantograph. Any further reduction in
cross sectional area will result in the current density in the contact wire under certain conditions exceeding the
permissible limit of 4.7 A/mm2 apart from reduced factor of safety under tension. In siding and lines with a
low traffic density, a lower thickness limits of 8 mm may be adopted.

It is important to measure and record the wear of contact wire at the known hard spots (para 20307) and at a
few selected locations where heavy wear may be expected, so as to keep a watch on the rate of wear.
Observations have indicated the wear of contact wire between starter and advance starter is high where the
train picks speed, specially in suburban sections. In addition to the known hard spots, the wire thickness may
be measured at one or two points between each pair of stations where speed is maximum. These
measurements should be taken at the time of yearly maintenance and recorded in a register. When the
average wire thickness has reached approximately 10 mm, the number of points where measurement is taken
may be increased and one location in each tension length may be covered in addition to the known hard
spots.
Measurements of contact wire thickness in the vertical direction should be made with a micrometer, preferably
one fitted with a ratchet screw adjustment to ensure that the pressure between the jaws when taking
measurement does not exceed a particular value. Considerable care is required in using the micrometer.

The measurement will be meaningful only if in successive years the thickness is measured at the same point
at each location. It is only then that the values recorded can be directly compared. A 75 mm wide band may
be painted on the mast fact with black paint. If the location is identified in this manner and a convention
followed that measurement should be taken say 20 mm before the swivel clip in the direction of motion. It can
be ensured that in successive years, measurement will be taken at identical points. The measurements must
be taken personally by a supervisor well acquainted with the use of micrometer. Registers should be
maintained in the office of the ATFO(OHE) for his jurisdiction and CTFO(OHE) for the entire division in
proforma 03-4 given in Section V.

If any isolated point the contact wire reaches the condemning limit of thickness, a splice should be introduced
at the point.

20310 Splice Fittings

The splice in OHE becomes necessary when a small length requires replacement as a result of excessive
wear or restoration after breakdown.
The splice fittings commonly in use are
1. splice for single contact wire to identification No. 1080 or 1080-1
2. splice for double contact wire to identification No. 1280
3. splice for Catenary to identification No. 1090
4. splice for feeder wire to identification No. 1100

The main components are made of aluminum bronze and the studs of contact wire splice are of stainless
steel. Samples of splices from each batch of supply are required to be subjected to special tensile tests in
addition to the normal tests for quality of material, in view of the need for ensuring reliability of these important
fittings.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [64]

A splice should, as far as possible, be located at a distance of not less than 5 m from the support in
the direction of traffic to avoid a hard spot on the OHE. Not more than 15 splices shall be used in
one tension length. The distance between adjacent splices should, as far as possible, be more than
100 m.

In new construction normally no splice shall be provided. Under exceptional circumstances a

maximum of two splices may be permitted.

The main points requiring attention during inspection of splice fittings are

1. Careful examination for cracks or other casting defects or abnormalities.

2. In case of Catenary splice fitting tightness of the right hand and left-hand joint sockets.
3. Check to see if any slipping of the ends of two contact wires has taken place. When viewed
through the top window, there should be no gap between the two contact wire ends.
4. Tightness of the stainless steel studs.

Contact wire splices should not ordinarily be re-used. If they are re-used at all, new brass ferrules
for contact wire splice to Id No. 1080 should invariably be used to ensure that worn serrations of the
ferrules do not result in insufficient grip on the contact wire.

Over-tightening of the stainless steel studs of contact wire splice fittings is harmful. Tightening
should only be done to the extent possible with a standard spanner. No extra leveraile by means of
a pipe etc. should be used.

Registers should be maintained in the Offices of Sr. DEE(TRD), AEE(TRD), CTFO(OHE),

TFO/ATFO(OHE) and OHE Section Chargeman showing the location and date of installation of all
splice fittings under their jurisdiction. These registers should be brought up-to-date by taking an
inventory of splice fittings during yearly maintenance and POH.
203011 Section Insulator Assembly
1. Section Insulators assembly is used to provide electrical isolation between two elementary
sections which are otherwise continuous. They are used mainly on cross overs, diamond
crossings and turnouts for loops and sidings to isolate section from main line. They may be
used on main lines to form neutral sections in heavily graded sections, suburban sections and at
inspection pits on secondary lines as well as lines for sheds for maintenance and inspection.
Rules regarding the location of section insulators are contained in Appendix I; the speed
permissible at these locations is also indicated therein.

2. The section insulator assembly is shown Fig. 3.02. The assembly comprises of a strain
insulator with two runners connected to one of contact wires. The bottom of the runners is at
the same height as the contact wire on the other side, and so shaped as to allow a smooth
passage of the pantograph underneath it. The two runners overlap with the contact wire on the
other side for a short length to ensure that there is no interruption in the current drawn by the
locomotives as it passes underneath the section insulator. The flexibility of the OHE is reduced
where a section insulator assembly is provided.

3. The essential points to be checked during periodical maintenance are as under-

a) The weight of the section insulator should be fully taken up by the droppers so that the runners
are at the same height as the adjacent contact wires both longitudinally and transversely.
Fasteners are provided, at both the contact wire ending clamps, at the ends of the contact wire
and link assembly and section insulator cross beam assembly, for effecting the adjustment
accurately. When correctly adjusted, there should be no sparking when a pantograph
negotiates it. The runners if bent or damaged should be either replaced or straightened out.
The runners as well as the contact wire should be smoothened by filling off globules of copper
which might have formed due to arcing. The distance between the contact wire and the runner
on either side should be not less than 220 mm.
INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [65]
and application of silicone grease should be decided based on the extend of smoke pollution in the
area ( para 20314)

b) The PG clamps holding the stiffeners at both ends should be checked to ensure that the
stiffeners do not work loose.

20312 Short Neutral Sections Assembly.

1. Short neutral sections assembly incorporating light weight contact wire insulator of composite
type ) resin bonded glass fibres core protected with wear resistant ceramic beads) has now
been adopted as standard. Ease of installation even on flat curves and difficult locations,
substantially reduced maintenance and other advantages are gained by introducing short
neutral section. Conversion of existing overlap type neutral sections to short neutral sections
may be done where it is not yet done. Short neutral sections should also be introduced in lieu of
insulated overlaps opposite to the feeding posts at sub-stations. (Boards Ref. 86/RE/501/1N/S)
dt. 16/22.7.1987.)

2. The general construction, design and other requirements of short neutral sections shall conform
to RDSOs Drg. Nos. (I) ETI/OHE/SK/551-Arrangement of Neutral Sections for Conversion with
Short N.S. (ii) ETI/OHE/SK/552-Arrangement of short N.S. at Existing Feeding Post.

3. The essential points to be checked during periodical maintenance are as under:

a) cracked beads.
b) Electrical erosion of coating
c) State of cleanliness of insulators.
d) Burning of arcing horns and arc traps
e) Pantograph hit marks on the under side of compression ferrules and end sleeves of the contact
wire insulators to ascertain need for adjustment to be runners.
f) Freedom of movement of telescopic anti torsion droppers.
g) Elastomeric bellows for cracks
h) Insulation resistance.

20313 Jumper Connections.

The following types of jumper connections, using standard copper conductors and PG clamps, are
in common use in 25 KV OHE.

1. In-span jumpers of approximately 50 mm2 cross section for electrical continuity between contact
and Catenary wires, at intervals not exceeding 400m.

2. Potential equalizer jumpers of approximately 50 mm2 cross section at insulated over laps and
neutral sections to keep the portion of OHE between the cut in insulators and the nearer
anchorage at the same potential as the adjacent run of OHE.

3. Continuity jumpers of cross section 105 mm2 to provide electrical continuity between the two
portions of OHE at uninsulated overlaps and between the main line OHE and turn out/cross over
OHE at turn outs/cross over.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [67]

4. Jumpers of cross section 105 mm2 or 150 mm2 between feeders and OHE at feeding points.
5. Jumpers of cross section 50 mm 2 provided between out of run. OHE and anticreep wire as an
anti theft measure.

Jumper connections play a vital part in maintaining continuity of supply. On account of the up and
down movements of the contact wires, the jumper connections are bent to some extent every time a
pantograph passes through. With repeated bendings the strands of the flexible jumper connections
are liable to get broken in course of time on account of fatigue. To guard against this possibility,
special attention should be devoted to the jumpers during periodical maintenance.

The essential requirements for reliability of jumpers are

1. Sufficient length and adequate looping to provide flexibility so as to prevent failure on account of
repeated up and down movements and movements on account of elongation and contraction of
OHE due to temperature variations.
2. Adequate cross section to carry the normal currents and possible overloads due to shut downs
on adjacent lines, as well as faults.
3. Proper bonding and in soldering of the ends.
4. Proper seating and tightness of connections at PG clamps.

Failure of continuity jumpers will result in discontinuity of the OHE and consequent serious
interruption of traffic. Though failures of potential equalizer jumpers may go unnoticed, such failures
can result in electrical accidents. Also, unscheduled attention to such jumpers will necessitate
power-block on both the adjacent elementary sections, which may be quite difficult to arrange
without repercussion to traffic. Proper attention to jumpers during scheduled maintenance is,
therefore, very important. Jumpers, particularly continuity jumpers, with broken strands should be
invariably replaced, failing which the reduced cross-section may cause overheating and eventual
failure. Broken strands are most likely at the point of entry into PG clamps, possibly due to sharp
edges in the clamp. PG clamps should have properly rounded off edges to prevent the cutting of
strands. The clamps should be checked for signs of overheating and proper tightness.

It should, however, be remembered that a PG clamp should not be interfered with unless there are
signs of overheating or damage.

20314 Environmental Effect on OHE

Atmospheric Pollution

The atmospheric pollution has caused a large number of insulators flash over in certain areas such
as Howradh and Assansol in Eastern Railway. Ahmedabad, Vadodara,. Surat and Valsad sections
of Western Railway and Madras-Gudur section of Southern Railway. The flash over mainly occur in
the early morning in winter before sun rise and in the pre monsoon period, specially when monsoon
are delayed. The pollutants provide a creepage path resulting into flash over of insulators and
consequent tripping of the 25 Kv and EHV circuit breakers. Pollution can be classified, broadly into
the following categories.

I_) Saline Pollution : caused by salt deposits in coastal areas. The adverse effect get magnified in
foggy, humid and light rain conditions, resulting in series of flashovers.

ii)_ Chemical and Industrial Pollution : Waste gases from industries hydrochloric acid, sulphuric
acid, hydrofluoric acid fumes etc. and minute particles of urea, cement etc. affect insulators of the
electrified tracks in the vicinity of these industries.
These conditions not only effect the insulators, but also affect the steel parts including mast, which
corrode rapidly and need frequent attention. Special steps are required to be taken throughout the
year, suitably modifying the insulator cleaning schedules to ensure trouble free service.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [68]

1. Insulators

Although insulators supporting OHE are by the side of supporting masts, they are subject to
settlement of carbon deposits, smoke pollution due to steam trains, oily deposits on account of
diesel engine and cement or other industrial dust as mentioned earlier. If these deposits are not
removed at regular intervals, they are liable to become hard and difficult to remove in course of
time, and by reducing the insulation of the OHE greatly, lead finally to a flashover. Further, a dirty
insulator of a section insulator can result in a dangerous potential in a section made dead.

The remedy lies in cleaning the insulators at regular intervals. Where there is no pollution, cleaning
need be done only once a year or even at longer intervals. Where pollution is not appreciably high,
the interval may be three months or longer depending upon the degree of pollution in the area.
Generally in heavy industry areas more frequent cleaning of insulators may have to be done.

Cleaning is done by wiping the surface with a piece of dry cloth. A wet cloth may be necessary if
the coating is hard. If the deposits are oily, petrol may be used for cleaning. If this too in ineffective
where encrustation has become hard due to continued neglect, the coating may have to be
removed by rubbing with a wet coir rope using a suitable detergent. After removing the deposits,
the surface of the insulator should be washed well with water, wiped with dry cloth and polished until
the normal glaze is restored.

The periodicity of cleaning of insulators in polluted locations should be laid down by local
instructions. The affected section should be divided into various zones based on the degree and
nature of pollution
And periodicity of insulator cleaning fixed suitably. The cleaning will be required more frequently in
foggy weather compared to dry or rainy season. The periodicity may be reviewed based on effect of
special measure,

Other steps for reducing flashovers due to pollution _

i) Application of High Voltage Insulting Silicone Compound
The frequency of manual cleaning can be substantially reduced by application of silicone grease or
similar anti tracking compounds. Application of high dielectric strength anti acidic varnish has also
been found to be useful under certain conditions. The surface of the insulator is cleaned and then a
light coat of the material is applied so that a dust and water repellent surface is produced.

ii) Use of longer creepage path insulators

Use of Insulators of longer creepage path will reduce frequency of cleaning.

The problem can be tackled in many ways mainly to reduce the frequency of cleaning, which can
be established by constant endeavor in trying out what is best for a specific section over a period of
2 to 3 years.

2. OHE Structure and Fittings.

Due to effluents discharged by the factories which are close to the railway tracks, the atmosphere
gets surcharged due to presence of corrosive fumes in the effluents. Such cause corrosion of steel
structures and OHE parts. In order to safeguard against this problem, remedial action as under
should be taken.
a) Matter should be taken up with the factories and the Board of Control of Pollution of that area,
they should ensure that the discharge of the factories is well within the limits laid down by the
Board.
b) A special check at regular intervals should be conducted to see that the corrosion does not
affect the performance of the components.
c) Chlorinated paints may be tried on the steel structures to off set the effect of pollution on the
steel structures.
INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [69]
20315 Clearances in Tunnels and Other Overline Structures.

If the OHE construction as well as the tunnels and over line structures are not modified subsequent
to the electrification, the clearances provided at the time of erection will remain unaltered. It is,
however, important to check the clearances during the annual maintenance, compare the values
given in as erected and take corrective action as required.

20316 Regulating Equipment

1. There are three types of regulating equipment in use at present viz. The winch type, pulley block
type and 3 pulley type. With all the three types of equipment the chief task of maintenance is to
ensure that the counter weight is free to move up and down in the guides without any chafing or
obstruction. If the movement of the counterweight is obstructed, the tension of the OHE will not
be correctly regulated resulting in poor current collection. The counterweight should not come
down so low so as to touch the muffing in summer, nor should if strike the guide fixture at the
top during winter.

During yearly maintenance of the pulley block type of equipment dimension X (i.e. the distance
between the centres of the movable and fixed pulleys) and Y (i.e. the distance between the bottom
of the counterweight and the top of the muffing) should be checked against prescribed values and
adjusted as required according to the tension length of the OHE and prevailing temperature. Small
adjustment can be effected by using the adjusters provided. In the event of appreciable stretching
of the contact and catenary wires, particularly a few months after installation, it will be necessary to
cut small lengths of contact and catenary wires at the terminations to get correct alignment and
adjustment.

In the winch type equipment, corresponding to dimension X in the pulley block type dimension Z
i.e. the distance between the centres of the movable pulley and the winch drum is required to be
measured.

To facilitate checking, the position of the bottom of the counterweight corresponding to the lowest
and highest temperature should be marked on the masts by means of black bands of width 20mm.
The position of the counterweight at ambient temperature of 35 degree C may be marked by a red
band which can be seen during trolley inspection readily. The bottom of counter weight should
coincide with the band mark.

2. The usual defects to be looked for in the pulley block type of equipment are

a) damage to pulley grooves by the stainless steel rope due to misalignment of the equipment and
the catenary wire being not vertically above the contact wire at the termination;
b) seizing of the needle bearings due to drying up of lubricant and consequent jamming of the
pulleys;
c) jamming of guide pulley due to lack of lubrication and consequent grooving of the pulley. This
can be checked by pushing up the counter weight and allowing it to descent due to its own
weight;
d) damage to neoprene washers provided between pulleys resulting in ingress of dirt and water
into the needle bearings;
e) bent sliding rods obstructing the movement of the movable pulley;
f) blocking of grease nipples.

These defects except for replacement of the guide pulley and attention to blocked grease nipples
are not capable of being attended to in-situ. The complete equipment should be replaced with a
spare one and the removed equipment taken to the workshop for attention.

The main pulley and guide pulley bearings of the pulley block type equipment should be lubricated
using approved type of grease which will be able to withstand 60 degree C without drying.
INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [70]
Another important check required for the pulley block type equipment is to see that that the stop
nuts provided at the end of the guide rods are intact. These are provided to prevent the movable
pulley coming off the guide rods in the event of breakage of the stainless steel rope.

3. The common defects to be looked for in the winch type equipment are :

a) Over riding of stainless steel rope and grazing of grooves.

b) Breakage of strands of stainless steel wire rope.
c) Seizure of pulley bearing.
d) Tilting of anti falling device.

Stainless steel ropes should be examined periodically with a magnifying glass for putting and other
signs of corrosion.

Regulating equipments should be checked periodically for free movement with the help of a spring
balance. If pull required for a visible movement of counter weight exceeds 10 kgf. The regulating
equipment should be overhauled.

Whenever a panto/OHE entanglement takes place the regulating equipments of all the concerned
OHEs should be checked thoroughly, particularly if any of them was overhauled more than two
years earlier.

Until such time a grease capable of retaining the properties for 4 years becomes available, all
regulating equipments should be overhauled every two years. Priority should be given to those
which cover the more vulnerable locations.

During overhaul of regulating equipment special attention should be paid to the shape and
dimensions of the winch frame arms (right and left) as they have a direct influence on the angle of
incidence of the stainless steel wire rope on the winch drum.

Whenever a regulating equipment is dismantled, the condition of the bearing grease should be
checked. If it is found to have lost its oil content and exhibits the consistency of hard soap, the
source and type of grease used initially should be investigated.

The condition of rubber or felt seals provided to prevent the ingress of water into bearings should be
checked and if they have deteriorated, the quality and source should be investigated and remedial
steps taken. All seals should invariably be replaced during periodical overhaul unless their condition
is found to be good enough to work satisfactorily for another four years.

4. Most of the points mentioned above are also applicable to pulley type regulating equipment
which is now standard.

20317 OHE Inspection Car (Tower Wagon)

1. OHE inspection car has a key role in the maintenance of OHE and for attending to break downs.
The satisfactory upkeep of the car is, therefore, or utmost importance. ATFO (OHE) should
ensure that the car under his control is maintained satisfactorily and is available at all times for
attending to OHE and for use in the event of break downs.

Each car should carry necessary tools for maintenance of OHE and attending to breakdowns, such
as tackles, straining screws, clamps, ropes a minimum of two ladders as well as an adequate stock
of insulators, lengths of contact and catenary wires and other OHE fittings. An approved list of tools
and equipments to be carried in each care should be issued by DEE(TRD). ATFO(OHE) should
ensure that tools and equipment as per the approved list are always available in the car.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [71]

2. A monthly mechanical inspection of the bogies and running gear of each car shall be done by a
nominated TXR of the Mechanical Department, headquartered close to the OHE depot where
the car is normally stabled. For each car on a Zonal Railway, the TXR responsible for monthly
mechanical inspection will be nominated and a joint circular to this effect issued by CME and
CEE laying down his duties.

The ATFO(OHE) in charge of the car will advise the TXR concerned the date on which it is required
to be inspected and running repairs carried out. Such advise shall be given at lest 48 h. in advance.
ATFO(OHE) should ensure that this monthly advise is issued regularly and the car is offered for
inspection and attended to every month. The TXR will arrange for examination of bogies., running
gear, underframe, under gear fittings and axle boxes only, in accordance with IRCA rules, Part-III.
He will also arrange for stenciling the date of monthly examination on the sole bar of the car. The
POH of the car shall be done at an interval of 3 years in an EMU shop/electric loco shed/Electric
workshop, as decided by CEE. (Ref. Boards letter No. 84/Elec/140/4 Vol. I dt. 1.3.90)

3. The day to day maintenance of the diesel engines and driving gear of the car will be the
responsibility of the ATFO(OHE) concerned. The OHE inspection car drivers should carry out
the daily maintenance. Specialist staff conversant with the maintenance and overhaul of diesel
engines and driving gear should be available on each division for attending to monthly and six
monthly maintenance of the diesel engines and driving gear. If it is more convenient and
depending upon the work load, two or three divisions may be grouped together for the purpose
of posting such specialist staff.

4. Taking into account the total number of OHE inspection cars and the need for relief of such cars
for purpose of POH etc. in each Zonal Railway, one or more spare OHE inspection cars may be
provided as necessary.

20318 Salient Features of OHE Inspection Cars.

The salient features of the OHE inspection cars presently in use of on Indian railways are as under

1. Mark II 4 wheeler manufactured by Kanchrapara Workshop/E. Rly.

i) Diesel engine 83 HP (Simpson make)

ii) Axle load 6.8 tonnes
iii) Pay load 3 tonnes
iv) Speed potential 40Km/h
v) Transmission Gear box system
vi) Brake system Vacuum

2. Mark III 4 wheeler manufactured by Jamalpur workshop/E.Rly.

i) Diesel Engine 185 HP

ii) Axle load 16 tonnes
iii) Speed potential 75 Km/h
iv) Transmission Hydraulic/Hydro mechanical
v) Brake system Compressed Air Brakes.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [72]

3. OHE Inspection Car 8 wheeler

i) Diesel engine Single 530 HP or twin 285 HP

ii) Transmission Volts Hydraulic Transmission
iii) Axle load 16 tonnes
iv) Pay load 10 tonnes
v) Speed potential 110 Km/h on level tangent track
30-40 km/.h on 1 in 60 t rising gradient while hauling
a loaded bogie flat wagon of 60t
vi) Brake system Compressed air brakes
vii) Paying out facility on one drum each of contact and catenary wires
viii)Small workshop fitted with drilling machine etc.
ii) Two staff cabins with toilet
iii) A small kitchen ,storable space for tools,spares, and traction mast etc.
iv) Adjustable lifting and swivelling platform
v) Observation dome To watch pantograph and contact wire interaction
during motion.

20319 Rules for Operation of OHE Inspection Car.

General

i) Authorization:

No OHE inspection car may be operated by any person unless he is specifically authorised to do so
after he has been trained and examined for his knowledge of the rules prescribed ( chapter XII)

ii) Scope

The following rules shall govern the working of an OHE inspection car fitted with a pantograph for
the purpose of inspection of OHE either during commissioning of completed sections of OHE or
during periodical inspections carried out by the OHE inspection car maintenance staff. All staff in
charge of operation of OHE inspection are shall make themselves fully conversant with and act
according to the special instructions given below:

iii) Movement

The movement of OHE Inspection Cars on tracks will be governed by all the rules governing
movement of trains.

Driving

j) OHE Inspection Car shall be driven only by an authorized person, and no person shall be so
authorized unless he has knowledge of the section (Road and Signals) on which the car is to
operate and is conversant with the operation and maintenance of car. He should also be in
possession of competency certificate for the purpose.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [73]

ii) The OHE Inspection car shall be driven at a speed not exceeding 10 km/h when checking
contact wire level and stagger. This shall be done by running on the first gear. Riding on
the clutch for this purpose is prohibited.
iii) If the OHE inspection Car is driven for other than recording operations, the speed should not
exceed the designed speed subject to the speed restrictions imposed in the section.
iv) In every depot, at least two OHE staff shall be trained and issued with competency certificate
to drive an OHE Inspection Car in the event of an emergency.

Panto graph Operation.

i) The pantograph mounted on the roof of the OHE Inspection Car is electrically bonded to
the underframe by means of a cable connection. This cable connection should be checked
before starting any operation for checking and adjustment of OHE.

ii) The pantograph should normally be kept in the fully lowered position and clamped securely
by means of the special clamp provided for the purpose. No string, cord, etc. shall be used
for the purpose.
iii) Before any person goes up to the roof of the OHE Inspection Car for commencing inspection
and adjustment, the section of the OHE concerned shall be made dead and earthed on
either sides. Additional earths shall be provided where necessary. After earthing the OHE,
an additional earth shall be provided near the OHE Inspection Car on the OHE of the track
on which it is standing. An authorized person not lower in rank than a linesman shall then go
up on the roof and remove the clamps to release the pantograph.
iv) Under no circumstances should the OHE inspection car be worked with the pantograph
raised without an earth on either side of it on the section of the OHE in which it is to be
worked.
v) In order to ensure that the pantograph does not enter a section where the OHE is live the
OHE inspection car shall be protected on both the sides with banner flags and other signal
flags.

The Driver shall always stop the OHE Inspection Car ahead of all turn outs, cross overs, insulated
overlaps and section insulators first and then proceed only after ensuring that the section ahead is
dead and earthed. Banner flags shall then be removed for the purpose of admitting the OHE
inspection car into the section ahead.

vi) At the end of the Inspection and checking, the pantograph, shall be lowered and clamped by
an authorized person not lower in rank than a linesman working on the roof after earthing the
OHE of the track on which the OHE inspection car operating. The earths on the OHE near
the OHE Inspection Car shall then be removed after all persons working on the roof have
come down.

Operation of Lifting and Swivelling Platform

a) The lifting and swivelling platform shall ordinarily lie in the fully lowered position along the length
of the OHE Inspection Car.

ii) The swivelling platform shall be raised or lowered only when the OHE Inspection Car is
stationary.
iii) The platform shall be moved out of the normal position only when the OHE Inspection Car is
stationary.

iv) The OHE Inspection Car shall be moved only after the platform has been put back in the
normal position.

v) If the OHE Inspection Car is to be moved with the platform raised, it may be done at a speed
not exceeding 5 km/h.
INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [74]
 III MAINTENANCE SCHLEDULES FOR OHE

20320 Schedule of Inspections

1. In order to achieve high reliability and ZERO DEFECT OHE, and to ensure effective
checks on the maintenance work a minimum schedule of inspections to be carried out
each month by the officers and Senior Subordinate in charge of operation and
maintenance of OHE and associated system, is indicated at Annexure 3.01.

2. The schedule of inspections is the minimum quota for each official and should be
independent of other tasks. They will not be of routine nature but shall be carried out in
depth to identify.

b) Deficiencies and short comings.

ii) Lack of skill amongst staff.

iii) Inadequacies in maintenance facilities

iv) Constraints experienced

v) Conditions of environment leading to poor quality of work.

3. The inspecting officials should programme their inspections in such a manner as to cover
the widest areas in their jurisdiction over the year and so stagger the inspections as to avoid
over inspections of the same section repeatedly, in a very short time while neglecting other
areas. A check in brief for various inspections is indicated at Annexure. 3.02

20321 General

The OHE is subject to dynamic oscillations due to the constant contact and movement of the fast
moving pantograph coupled with wind pressure. It is necessary to maintain the OHE in perfect
condition through proper checks on its geometry and all parameters adopted in the design.

The following schedules of maintenance for the OHE are required to be followed to ensure good
current collection as well as safety of installations and personnel

I) Foot Patrolling
ii) Trolley inspection
iii) Current collection Tests
iv) Special checks
v) Annual Maintenance and OHE Inspection Car Checks.
vi) Periodical Overhaul
vii) Re-tensioning of Unregulated OHE.

2.The importance of OHE arises from the fact that it is extensive, with a very large number of
insulators, fittings and other parts; failure of any one of which may result in dislocation of
train services for appreciable periods until the defect/breakdown is rectified. The adjustment
work is particularly important at cross overs and at overlaps spans since any departures
from the standards laid down could cause entanglement of the pantograph with the OHE,
with serious repercussions. The need for a thorough detailed inspection of every part of the
installation, mast by mast need not therefore be over-stressed.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [75]

 3. The periodicity of schedules laid down below apply to the majority of installations. The
periodicity may however, be modified by CEE, where local condition so warrants.

4. As regards new equipments, if schedules, have not been drawn up, tentative schedules
may be evolved based on the Original Equipment Manufacturers guidelines and RDSOs
recommendations, keeping in the view the local conditions also and followed with the
approval of CEE.

20322 Foot-Patrolling of OHE

The object of foot-patrolling is to made visual inspection of every part of OHE (including feeder line)
so that any defect and abnormalities noticed are recorded and reported to the maintenance gangs
for attention.

2.An experienced OHE linesman (accompanied by a Khalasi if deemed necessary by local

conditions) should be deputed to patrol the section on foot by day, so as to cover every part of the
section including years once a fortnight and suburban sections once a week. If this patrolling is
done thoroughly, many of the defects will be noticed at the incipient stage, before they develop into
major defects. ATFO or Chargeman should foot patrol the section once in six months.

3. The Linesman on foot patrol should be equipped with signal flags, an emergency telephone
instrument and essential tools required for attending to defects on the spot e.g. spanners for
tightening bond connections.

4. The Linesman on patrol duty should particularly look for the following

a) Chipped or damaged insulators.

b) Displaced fittings and droppers
c) Excessive sagging or hogging of contact wire
d) Whether equalizing plate is tilted
e) Free movement of auto tensioning device and position of counterweight with reference to upper
and lower limits of movement marked on the mast.
f) Presence of protective screens, caution and warning boards and Anticlimbing devices.
g) Structural soundness of height gauges at level crossings.
h) Bird nests and pieces of stray wire likely to cause short circuits and branches of trees likely to
infringe the OHE..
i) Defective bonds and earth connections.
j) Defects in return conductor connecting booster transformers and its connection to rails. Oil
leakage if any from BT and AT.
k) Any obstructions including tree branches in the way of free movement of pantograph and trains.
l) Signs of heavy sparking when trains pass.
m) Isolators blades being fully in and for signs of sparking or overheating of isolators as also
condition of locks
n) General condition of switching stations en-route.

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI [76]

o) Tilting of masts especially on high banks and masts with sand core foundations.
p) Number plates
q) Any other abnormal/unusual situation

5. Major defects noticed by the Linesman which endanger safety shall be reported forthwith to
TPC through the nearest telephone. Full details should be given to enable the TPC to decide on the
course of action to the taken and if required to regulate train movements in the affected section.

6. The Linesman should himself attend to and rectify such of the minor defects (e.g. loose bond
connections) which can be rectified by him on the spot without special assistance. To facilitate this,
he shall carry with him a few essential tools. Other minor defects should be noted by him in his
diary and entered by him in a Register (see para 20351) maintained for the purpose in the
depot/sub depot. The roster of patrolling Linesmen should be so arranged that they will be able to
return to the depot sub-depot for submission of report as above before going off duty for the day.
Where this is not convenient, the Linesman must report the defects on telephone to the depot/sub-
depot followed by a written report in the register on the next day . The supervisor in charge of the
depot/sub-depot will carefully scrutinize the Register and take prompt action to rectify defects
reported, making suitable entries in the Register.

7. Testing of Emergency Telephone Sockets: During patrol duty, the Linesman will speak to
TPC from every emergency telephone socket in route. Such calls from patrolling Linesmen should
be recorded in a Register by the TPC indicating the date, time and serial number/location of the
socket tested. Defective sockets should be reported promptly to the S&T Department for
rectification.
A proforma for Linemens Foot Patrol Report is given at Annexure3.03
20323 Trolley Inspection of OHE

Inspection of OHE by push trolley is essential except in sections where use of trolley is prohibited.
The object of such inspection is to enable supervisors and officers in charge of OHE maintenance to
observe closely the OHE under their charge and should be carried out during day time. The depot
in charge (TFO or ATFO)_ should inspect his entire section once a month. CTFO/AEE(TRD) should
inspect their respective sections once in 3/6 months respectively by push trolley or motor trolley as
convenient. Sr. DEE/DEE(TRD) also should cover his entire section at least once a year by push
trolley or motor trolley.

2. Apart from trolley inspection as above, officers and senior subordinates shall travel by the cabs
of locomotives and EMU trains as often as possible but atleast once a month to observe the general
condition of OHE and to get a first hand knowledge of operating conditions.

20324 Current Collection Tests

It is necessary to carry out periodic tests to detect points at which contact between the contact;Are
and pantograph is unsatisfactory resulting In sparking. Such current collection tests are performed
at night.

A mirror can be fixed in front of the look-out glass of the rear cab of a locomotive and adjusted so as
to get a reflection of the rear pantograph which is normally in service. A person travelling in the cab
can then observe through the mirror any sparking which may take place. The location where the
sparking is observed and the severity of the sparking should be immediately noted down and the
OHE at the location got checked up as soon as possible to find out and eliminate the cause of
sparking.

The current collection tests as above should be carried out by the depot-in-charge (TFO or ATFO)
once in 3 months over his entire section. The CTFO/AEE (Trd) should accompany the depot-in-
charge during such tests alternately so as to cover their sections once in 3/6 months respectively.
DEE (trod) should accompany the depot-in-charge so as to cover his jurisdiction once a year.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [77]
The form in which a record is to be maintained Is indicated in para 20349.

20325 Special Checks

While the majority of items require attention only during Annual Maintenance and Periodical
Overhaul, items listed below will require more frequent attention as indicated against each -

1. Insulators: Generally insulators need cleaning once a year along with the annual maintenance
schedule. At locations subject to smoke pollution on account of steam locus or pollution due to
industrial dust, the frequency of cleaning will have to be fixed based on the extent of such pollution.
Where pollution is heavy, cleaning may have to be done more frequently. With the application of
silicone grease, the interval for cleaning at such locations can be extended significantly.

2. Section Insulators: Section insulators on the main lines such as at neutral sections and
passenger yards should be attended to as under once in three months -
(a) Clean insulators and replace badly chipped or even slightly cracked insulators.
(b) Check runners for flash-marks.
(c) Check level of the assembly and adjust as required.
(d) Check foe excessive contact wire wear near anchor clamps.
(e) Tighten properly the PG clamps of droppers and stiffeners.
(f) Check that pantograph passes underneath the section insulator smoothly.
3 Isolating switches at Yards/Loading sidings: The continuity and soundness of earth connections
should be
checked once a month.

4. Bi-metallic clamps: These should be checked for tightness and signs of overheating once in 3
months.
5. Earth Connections: Apart from general inspection of bond and earthing connections during foot-
patrolling, all such connections should be specially checked for continuity and soundness of
connections once in six months. Particulars of all earthing connections (other than structure bonds)
should be entered in a Register station-wise for each section and the dates of six-monthly
inspection entered therein (see para 20351).
6. Feeders: Foot-patrolling of 25 kV feeders should be carried out every month. During this check,
the Linesman shall also check that safety guards provided under the feeders properly earthed, if the
clearances are adequate and caution notice boards are in position.
7 . OHE supported on steel girder bridges should be examined as frequently as possible
depending upon traffic conditions.
8. Bird nests: Vigil should be exercised especially during the nesting season and the nests removed
as soon as
possible.
9. Pre-monsoon checks : Some of the items to be attended are -
i. Checking condition of insulators specially that of section - Insulators at major yards having
mixed type of traction;
ii. Over-line structures for any water leakage on the OHE and PVC insulators at major yards having
mixed type of traction;
iii. Trimming of trees branches;
iv. Condition of embankments with respect to stability of masts; Rod gaps.
v. Rod gaps

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [78]

20326 Annual Maintenance and Checks by OHE Inspection Car
1. This schedule must be carried out by Inspection Car. During the schedule, fittings are not
generally dismantled, but all fittings which are found defective must be replaced. In addition
clearances, heights, staggers etc. should be checked and corrected.

2. The details of work to be carried out during this schedule are as under-

(a) Masts, portals and cantilever supports:

(i) Check rail level and setting distance against markings on the masts and entries in the Register.
Variation above 3Omm in setting distance and 2Omm in rail level should be notified to the PWI for
correction. Variations, even within the above limits, should not be permitted if the Schedule of
Dimensions are infringed.

(ii) Check all steel parts and remove rust, if any, from painted steel work. Rusted portions, after
cleaning, must be given two coats of zinc chromate primer followed by aluminum paint.

(iii) Check all anchors for tightness of bolts, nuts and checknuts and pins, Lubricate all turn
buckles/adjusters and pulleys.

(iv) Examine the base of each structure to ensure that muffs permit drainage of water. Clean the
muffs removing any muck or dirt. Cracked or damaged muffs must be recast.
(v)Check all bonds thoroughly. Defective bonds must be rectified and missing bonds provided,

(Vi) Check and tighten all G.I.bolts and nuts.

(vii) Check all galvanized pipes and fittings. Where galvanization is found to be chipped off, the
fitting of pipe should be replaced. Minor chippings may be repaired using 'cold galvanizing paint'.

(viii) Examine register arm and all hooks and fittings for cracks. Check for cracks on steady arm
tube also.

(ix) Clean all insulators and carefully check for cracks and broken sheds. If more than 2 sheds are
broken or there is any crack on the core the insulator should be replaced.

(X) Check and adjust heights and staggers on the basis of setting distance and rail level marked.
Close co- ordination with Permanent Way Inspectors is required for keeping the permanent way at
the correct location.

(Xi) Check presence and condition of caution notice boards, number plates, coasting boards, etc.
Paint the boards as required. Ensure that they are all well secured.

(xii) Ensure that the drain holes in the tubes are free and not clogged.

(b)Contact and Catenary Wires:

(i)Check carefully condition of contact and catenary wires, particularly for kinks and twists in contact
wire and broken strands of catenary wire. Any stranded conductor (catenary wire etc.) should be
spliced if more than 20 per cent of the strands are broken.

(ii) Check condition of PG clamps and jumpers after opening the clamps and tighten properly.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [79]

(c) Droppers:

(i)Check droppers and tighten bolts wherever required.

(ii)Make droppers vertical.

(d)Turn outs

(i) With OHE Inspection Car running on main line check up if pantograph glides smoothly under
the loop line OHE..

(ii)With OHE Inspection Car running on loop line check up if pantograph glides smoothly under
the main line OHE.

(iii) Check stagger of both the OHEs at turn cuts. (It shall not normally exceed 300 mm).

(iv) Check that the main line OHE of overlap type turn out is about 50 mm below that of the
turnout OHE.
(v) Check up cross contact bar, if any, for displacement and distortion. Check up for hit marks, if
any.
(vi)Check up for hit marks ,if any.
(vii) Check up rail level and setting of the obligatory mast.

(viii) Check up for hard spots near rigid droppers, if any.

(e) Section Insulators Assemblies:

(i) Clean insulators and replace chipped or cracked insulators.

(ii)Check runners for flash-marks, hit marks and proper adjustment.

(iii)Check for excessive contact wire wear near anchor clamps.

(iv)Check the level of the assembly and adjust if necessary.

(v)Tighten PG clamps of droppers and stiffeners.

(e) Isolators:

(i) Check number plates for cleanliness and security.

(ii) Check number plates for cleanliness and security.

(iii)Check correctness of operation, alignment of contacts and arcing horns. Check earth
continuity where applicable.

(iv)Lubricate moving parts and locks.

(v)Check interlocks where provided.

(vi) Check that the distance between male and female contacts in open position is 38Omm to
50omm depending upon the type of isolator.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [80 ]

(g) Short Neutral Section Assemblies

Carry out all checks as indicated in para 20312.

(h)Overlaps:

(i) Check height and stagger of OHE In the overlap section.

(ii) Check whether the normal minimum clearance of 500mm is available between the two OHEs
In an insulated overlap and 200mm in an uninsulated overlap.

(iii) Check whether the lifting of out-of run OHE is correct.

(iv) Check that parallel running of contact wires In the overlap for a minimum 2m In the panto
sweep region

(i)Contact Wire thickness:

Measure and record thickness of contact wire as detailed in para 20309.

(k)Neutral Sections:
Carry out all checks as for an insulated overlap in case of overlap type neutral sections and as
for section insulators in the case of section insulator type neutral section.

(l)Overline, Structures/Tunnels
(i) Check and record horizontal and vertical clearances and adjust OHE as required.
(ii) Check for any flash-marks on the under side of the bridge structures.
(iii) Check that the prescribed height of contact wire is available,
(iv) Check that the gradient of contact wire on either side does not exceed 3mm/m.
(v) Check that smoke screens are properly secured and have adequate clearance from OHE. If
not, get these attended to by Engineering Department.
(vi) In tunnels get necessary repairs done by Engineering Department.
(vii) Check rail level mark on sides of tunnels.

(m)Level Crossings

(i) Check height and gradient of contact wire.

(ii) Check condition of road surface and clearance of height gauge (a black band may be
marked on the uprights at a distance of 4m from bottom face of the boom to facilitate measurement
of clearance.)

Regulating Equipment:

(i) Check 'X' and 'Y' dimensions in the case of pulley block type equipment and 'Z' and 'Y'
dimensions in the case of winch type equipment against prescribed values for the temperature at
the time of checking. Make use of turn-buckles to adjust as required.
(ii) Check that the compensating plate is vertical. If not, adjust as required.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [81]

 (iii)Lubricate pulleys and other moving parts.
(iv)Check if 20mm wide bands in black colour are painted on the mast to indicate upper and
lower limits of movement of counter weight.
(v)Check condition of stainless steel wire rope for any signs of corrosion and breakage of
strands.
(vi) Check condition of grooves on the drum of winch type regulating equipment.

(o) Bonds & Earthing Connection.

(i) Check all bonds and replace defective or missing bonds. Paint all bonds.
(ii) Inspect earths and record earth resistance. Earths having resistance of over 10 ohm should
be attended to.

(P)Masts:

Check verticality of all masts with plumb-bob and take remedial action as required (see para
20305).

(q)Sites affected by accidents:

Such sites should be specially checked and attended to.

(r)Feeder Lines:

(i)Check guard wires at road crossings, if any.

(ii)Check earthing of towers.
(iii)Measure and record earthing resistance of towers.
(iv)Clean insulators and replace those which are cracked or chipped.
(v)Check the jumper connections, strain clamps, PG clamps and bi-metallic strip.

PG clamps:
(i) Check and clean oxide from surface.
(ii) Apply corrosion inhibiting compound.
(iii) Tighten to the prescribed torque.

30327 Integrated Blocks

The annual maintenance schedules can best be organized by adopting the system of Integrated
Blocks. In this. scheme, a 3 to 6 km block (Jumbo Block) is taken by introducing single line working
in the off peak traffic hours between any two stations. Simultaneous work is carried out by
permanent way, signal OHE/PSI staff during day light hours. This saves considerable time for taking
and returning blocks, which forms a sizeable proportion of a short duration block. Effective use of
available man-power can also be made by using extra gangs depending upon the nature of work.
Such work may be organized for 2 or 3 days a week in selected sections and instructions issued in
advance by appropriate planning.

20328 Re-tensioning of Unregulated OHE

The re-tensioning of unregulated OHE in accordance with the tension-temperature chart should be
done ordinarily at the end of 6 months from the date of erection and again at the end of 12 months.
Thereafter the tension should be checked up once in 2 years and retensioning done as required.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART (82)

20329 Periodical Overhaul

1. The aim of POH is to recondition and restore the installation in the condition it was when it was
first commissioned, whereas preventive maintenance has for its objective to take care of the wear
and tear during norma l service and forestalling possible failures by regular inspection and prompt
attention. The POH should be thorough and cover every part of the installation.

The tests to be done at the time of commissioning of new OHE have been detailed in Chapter IX.
The work involved during 4-year POH is somewhat greater in scope than the pre-commissioning
tests, since after years of service many parts would have suffered wear and tear, of which
necessary adjustments will have to be made or repairs done to make good the wear, or the
irreparable items replaced.

The POH of OHE should be planned on a programmed basis so that every part of the installation
receives detailed attention, repair and overhaul at an interval of 4 years. For programming POH, the
entire section in each Division should be divided into smaller sections. POH gangs may be provided
with camps at convenient locations so that heavy materials do not have to be carried from depot or
sub-depot every day. Gangs can move to the site of work in convenient trains or by other means of
transport.

As far as possible, gangs for the work should be earmarked so that a uniform standard of is
achieved. All POH work should be done under the direct supervision of a supervisor not lower in
rank than an ATFO/TFO.

To summarize, the object of POH is to make a thorough inspection of the OHE and to replace such
of the worn- out or damaged parts by those, which have been reconditioned earlier in the
maintenance depots and kept ready. The parts removed are sent to the maintenance depots for
dismantling, thorough examination, re-conditioning if possible and re-assembly for use again as
required.

Maintenance charts, prepared in different colours may be made indicating the type of schedule each
section has to undergo. The same chart can be used to indicate the progress of work and special
works to be done to exercise check over the tasks and targets.

2. In addition to the items detailed under annual maintenance, the following items should be
attended to during POH:

(a) Masts, portals and cantilever supports:

(i) least one complete cantilever assembly per 10 track-km (this may be modified by CEE if
considered necessary) should be removed and taken to the,workshop for dismantling and detailed
examination of various components after thorough cleaning. This test check would reveal the extent
to which other cantilever assemblies have to be examined.
(ii) All regulating equipment should be replaced by previously overhauled ones and the removed
equipment should be sent to the workshop for overhaul.
(iii) As the bracket is articulated, check the position with reference to the axis of the mast. The
position will vary with temperature and distance from anti-creep. The register arm and steady arm
should as far as possible be in the same plane as the bracket.
(iv) Check adjustments of cantilever assemblies, their slope and displacements at every structure
for compliance with the 'as erected' SEDs.

(b) Catenary and Contact Wires:

(i) Dismantle all jumper connections, clean the conductors, (with emery paper in case of copper or
bronze conductors and metallic brush in case of aluminium conductors) clips etc. If the pieces show
signs of overheating, this may be because either they are not tightened properly or the clips are
deformed and
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [83]
contact surface is insufficient. In the latter case they should be replaced. In case of the contact wire,
it is the groove that has to be cleaned with either a fine metallic brush or emery paper. The use of
scraper or file is forbidden. Replace frayed or damaged jumpers.

(i)Remove kinks if noticed.

(c) Insulated and Uninsulated Overlaps:

(i) Check the position of contact wire respect to tracks to comply with SEDS.

(ii)Ensure that insulators of anchoring wires are crossing the plane of OHE in correct position as per
plan.

(d) Overline Structures: Check the height and gradient of the contact wire and tally the same with
'as erected' .

(e)Tunnels:

(1) Check the height and gradient of the contact wire and adjust as per SED.
(ii)100 per cent OHE fittings In tunnels should be replaced with new or previously over-hauled
fittings and the removed fittings taken to the Workshop for detailed examination.

(f)Turn outs:

Check the position of the contact wires with respect to the track for compliance with SED.

(g)Overhead Cross-feeders, Return Conductors and 25 kV Feeders:

(1) Examine wires for frayed strands, overheating, pinching or corrosion, especially at suspension
clamps and PG clamps. Tighten junction sleeves.

(ii)While tightening PG clamps ensure that all joints are properly coated with veseline.

(iii)Check tension in wires and adjust if necessary.

(iv)Other overhead wires such as bypass feeders and earth-wires should be inspected. The
insulator attachments should be dismantled, overhauled and put back in position. The insulators
should be cleaned at the same time.

(h)General:

(i)During POH, fittings, which do not provide prescribed margin of adjustment and proper fitting
should be replaced.

(ii)All fittings on masts should be checked against "as erected" drawings and any variation should be
recorded. and reported to Sr. DEE for changing the drawings.

(iii)The position of splice should be recorded in the relevant lay out plans.

(i)Work to be done in Workshops:

(i) Aluminium bronze fittings, bolts and nuts should be cleaned and carefully examined if necessary
with a magnifying glass. Particular care should be taken to see that the threads are in good
condition. Fittings which have developed cracks should invariably discarded.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART [84]

(ii) All G. I. fittings and pipes should be examined for deterioration of galvanization. Minor chippings
may be repaired by using cold galvanizing paint. (Sand or emery paper should never be used for
cleaning).
(iii) in case of a major OHE break down, it is advisable to remove the bracket assemblies in about 8
to 10 spans on either side and examine them critically for cracks, twists, bends or other defects
which may cause failures later on.
(iv)The regulating equipment should be dismantled and every part should be cleaned. Bearings
should be fitted back after lubricating. Rubber washers/rings should be replaced where necessary.
Any grazing or rubbing on pulleys should either be repaired if possible or the damaged equipment
should be replaced. All lubricating holes should be free for passage of grease. The stainless steel
rope should be closely examined for damage to the strands. Particular attention should be given to
the end fittings on the stainless steel rope. Only approved type of lubricant should be used for
regulating equipment components.
20330 Rehabilitation of OHE
Depending upon the condition of the fittings, rehabilitation of the OHE may be undertaken after a
period of 20 year. CEE may decide the assemblies to be replaced after a special drive for condition
monitoring.

20331 Transmission Lines

1. General
The overhead lines should be inspected periodically to detect any faults and necessary repairs
should be done immediately.

2. Patrolling of Overhead Lines from the Ground

Patrolling of all overhead lines should be done before and after the monsoon. The frequency of
patrolling of the overhead lines for the rest of the period will depend on local conditions. The
patrollers should write the inspection notes and pass them on to the maintenance gang for carrying
out repairs. The patrollers, should be equipped with Inspection books, , tape and binoculars. The
main points to be noted while patrolling are as follows:

a) Structures:- Leaning structures; deformed members; buckled structures; missing fasteners and
members; accessories removed; protective coatings like galvanizing or paints disappeared;
suspension and strain insulator attachments damaged.

b) Foundations - Signs of external damage; settled and washed out soil below normal ground level
over foundations within uplift frustum perimeters; tilted stubs; cracks or breaks in chimney top;
slippage oil stubs from encasing chimney concrete; uneven settlement of footings; disappearance of
gravel blanket protection; backfill embankment and its covers (rip-rap or revelment); damage to
retaining walls, abutments and breast walls and disappearance of external earth backing retaining
walls below designed lines.

c) Insulators and Fittings:- Damage to insulators, heavy surface pollution, missing locking devices
like nuts, washers and pin, burnt out fittings, deflected strings, damage to protective coatings. The
cracked insulators, bird droppings, dense spider webs, kites with threads hanging on the insulators
string.

d) Conductors and Jumpers:- strands cut and opened up; loose jumpers out of shape and causing
infringement of clearance of live wire to earthed metal parts, dead birds, fallen branches or fallen
trees on conductors.

e) Earthing Equipment:- Damaged, broken or missing earthing strips.

f) Right of Way and Clearance:- Shrubs and trees within right-of -way causing obstruction and
infringe-
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART [85]
rnent of clearance of bottom conductor to ground ; objects within line clearance excavation. In no
circumstances, however, clearance measurements should be taken from live line.
3.Foreign Objects:- Construction works near lines causing infringement in line safety or electrical
clearance; birds' nests on structures; use of structure for applying permanent support or pull to other
objects; huts newly constructed underneath lines, and embankments/fencing. -

3. Inspection of Overhead Lines from Tower Tops

Many breakdowns including slipping of conductor due to loose clamps, cracks in insulator porcelain,
defects in insulator fittings, conductor, earthwire and accessories and their attachment points on
structures can only he dispensed or seen by going on top of every structure. This inspection should
be carried out by taking a shutdown of the line at least once in six years. Along with such inspection,
repairs should also be carried out. Any replacement as required should also be made.

4. Special and Emergency Inspection

A special inspection of the overhead lines should be carried out after severe wind/hail storms,
quakes, snowfalls, forest fires, floods or heavy rains. Such inspection should be done after sabotage
too. The purpose of such inspection is to detect any damage or breakage on line and to effect
necessary repairs.

When an overhead line is subject to fault often, it should be inspected to ascertain the nature of
fault, such as too much sag, tree branches touching the line, etc. and to find out remedial measures
required with a view to avoiding their recurrence.

5. Maintenance Tests and Measurements

Insulation resistance of line should be measured at convenient interval particularly at the time when
the line is shutdown for repairs or maintenance. In regard to measurements of earth resistance of
metal structures, it should normally be carried out annually, however, local circumstances and
experience may dictate increase or decrease in this interval but it should not be less than once in
two years.

The clearance and shape of the jumpers should be checked at an interval not exceeding 3 years.

6. Line Repairs Tools

The following special tools, apart from tools required for maintenance of civil works of the lines,
should be kept handy and in working order:

a) Conductor jointing tools,

c) Bolted come-along clamps,

c) Winches,
d) Aerial trolleys

e) Aerial rollers,

f) Thermometers,
g) Dynamometers,
h) Level and theodolite,
i)Measuring tapes
k) Linesman's ratchet,
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [861
m)Pull-lift device of adequate capacity,
n)Wire ropes, and
p) Spanners

IV. SAFETY RULES FOR OHE

20332 General

1. The following rules are supplementary to the General and Subsidiary Rules and the instructions
contained In Volume 1.

2. Printed boards containing instructions regarding treatment of persons suffering from electric
shock should be exhibited in every OHE maintenance depot, equipment room, switching station,
cabin, OHE Inspection Car shed, loco shed, OHE Inspection Car and wiring train and also in offices
of SM, ASM, CYM, AYM and HTXR.

3. First Aid Boxes should be kept at every switching station, maintenance depot, in OHE Inspection
Car, breakdown vehicle and wiring train. 1

4. Ropes, come-along clamps, tirfor etc. should be tested once in six months at least, in the
presence of an ATFO, and record of such tests maintained in each depot.

20333 Documents to be kept with OHE Supervisors for Work on OHE

1. The ATFO (OHE) or other official supervising OHE work shall have with him a complete set of
structure erection drawings, lay out plans, sectioning' diagram and general supply diagram etc.
pertaining to the overhead equipment under his charge. He shall also have with him Station Working
Rules for the stations between which he is working. He shall, in addition, keep with him all useful
information regarding the running of trains over his section.

2. It shall be the responsibility of the TFO/ ATFO (OHE) or in his absence the senior-most official
in-charge of the work to ensure that all safety rules prescribed are actually observed by the staff
when carrying out work on traction installations. It shall be the duty of the supervisor to remind the
staff periodically of the various safety rules to be observed at work site.

20334 Permit to Work

Before commencing work on any part of the dead OHE or within 2m of live OHE, a permit-to-work
shall be obtained from TPC or other authorized person as detailed in Chapter VI.

20335 protection of Staff against Traffic Movements and Protection of Trains

1. The supervisory official in-charge of work on OHE shall observe relevant provisions of GR and
SR for protection of trains before work on OHE is commenced and for the whole time the work is in
progress.

2. Measures laid down in the Chapter VI shall be observed by all concerned to prevent accidental
energization of the section under power block on account of electric train movements.

20336 Earthing before Commencement of Work

1 All metallic parts within reach (either directly or through tools etc.) shall be earthed, after they are
made dead.

2. Each working party shall be protected by at least two independent earths, one on each side of a
working party.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART [87]
3. If the distance between the working parties exceeds 100m intermediate earths shall be provided
in such a manner as to ensure that the distance between earths does not exceed 100m.

4. Even when earthing is provided by isolator switches with earthing heels, additional temporary
earths as above shall also be provided.

20337 Procedure for Providing Temporary Earths

The following sequence of operations shall be carried out while providing temporary earths on OHE

1. Men shall be posted on both sides of the site of work to warn the working party of any
approaching train on the same track and adjacent track(s).
2. The permit-to-work shall be obtained prior to commencing work to make sure that power supply
has been switched off.
3. For providing temporary earth on the OHE or other equipment after it has been made dead, only
discharge/ earthing pole assembly specially designed for this purpose alone should be used. The
cable shall be flexible and should have adequate cross-section (40 mm') to be able to withstand
short circuit currents.
4. Fix the earthing-clamp securely to a mast at least one span away on one side of the work site
after making sure that the mast-to-earth rail bond of this mast is intact. Alternatively, the clamp may
be fixed to the bottom flange of one of the traction rails, taking the cable under the rails.

In single-rail track-circuited sections, the earthing clamp should be fixed to the traction rail i.e. non-
track-circuit rail; on double-rail track-circuited sections the earthing clamp should be fixed to the
mast.

The mast-end or rail-end clamp of the discharge /earthing pole assembly should be checked for
tightness just before connecting the top clamp on to the OHE as the earthing clamp fixed to the rail
or mast in advance could have worked loose.

5. Hook securely with a snap action the top clamp of discharge/ earthing pole assembly to the
OHE conductor close to the mast/structure and tie the earthing pole to the mast/structure. Never
hook on the top hook of the earthing cable to the OHE, till the other end has been first connected to
earth.
6. The earthing clamps should always be fixed to the traction rail or mast / structure first and then
the top clamp should be hooked to the OHE to be earthed.
7. Repeat operations 4 and 5 for the second temporary earth on the other side of the working party.
8. After temporary earths have been fixed on the OHE on both sides of the work site, staff may
proceed with the maintenance work.
9. After work is completed and men, materials and tools have been removed and the OHE is clear,
the above earthing rods may be removed in the reverse order i.e., first remove the hook on the OHE
and then the clamp fixed to the rail or mast/structure. After warning all staff that supply will be
restored and that they should keep away from live equipment, the permit-to-work may be returned
and supply restored.

20338 Precautions in Regard to Discharge/Earthing Pole Assembly

1. The continuity of the cable connection between the top clamp and the earthing clamp should be
checked once a fortnight.

Cable should be renewed if more then 20% strands are broken. During use, cable should be
continually examined for fraying and breakage of strands.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [88]

Discharge/Earthing pole assembly should be Inspected by TFO/ATFO once a month.

2. During accidents when slewing the OHE and in similar circumstances, the discharge/ earthing
pole assembly should be provided at a location where it is not likely to be interfered with during
crane working or due to work on the permanent way.

20339 Work on OHE or any Conductor having a Sectioning Point

When work is to be carried out on OHE or conductors, which are not electrically bonded, following
additional precautions are required.

i) The two sections of conductors or ends of conductor which may have snapped may be at
different potentials. Each end should, therefore, be separately earthed at two points after switching
off supply to both parts,of the OHE or conductor.
11) This precaution should also be observed when working on or in the vicinity of a sectioning point
and cut-in insulators.

3. Neutral Sections should be treated as live equipment and earthed separately at two points on
either side of the work party before commencing work.

4. , When work is to be carried out on an isolator, both sides of the isolator should be earthed at two
points or more conveniently, isolator jumpered temporarily.

20340 Protective Helmets

At the work-site, staff are advised to wear helmets to protect their heads against any tools or
equipment which may drop down accidentally, as well as to minimize head injury in case of
accidental fall from a height.

20341 Safety Belt

Staff working on structures or a ladder are advised to protect themselves against an inadvertent fall
by wearing a safety belt for supporting themselves by a rope sling.

20342 Rules for use of Ladders

1. It shall be the responsibility of the supervisor to ensure that ladders are stored in a protected
enclosure, properly maintained and reconditioned as often as required.

A ladder should never be in such a position so as to likely to fall on a live part.

2. Ropes used with ladders should be of cotton or jute. Use of metallic ropes is prohibited. A
ladder should be held by one person on the ground to prevent slipping, while the top end should be
tied to the supporting structure or conductor to keep.lt in position and prevent it sliding away.

3. Ladders should never be allowed to fall on or rest against the contact wire.
4. If the nature of the work involves risk of the conductor breaking into two parts (due to opening
out of sleeves or splices) the ladder shall not be rested against the conductor. Trolley ladders shall
be used in such cases.
5. More than one person shall not normally be allowed on a ladder as far as possible.
6. Climbing on a ladder with wet or slippery foot-wear is forbidden.
7. Ladders should not be used for transporting materials.
8. A rope should be used to pass tools or any equipment to the men working on a ladder.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [89]
9. No one should stand directly below a work spot under a ladder.

20343 Other Important Precautions to be taken while Carrying out Works on OHE

1 The useful cross section of a conductor shall not he reduced while making joints.

2. Any contact with conductors, which are not specifically earthed, is forbidden.

3. The strength of the anchoring rope should be not less than that of the cable to be anchored.

4. Temporary anchoring of conductors should only be done by using stranded flexible steel cable at least of
the same tensile strength as the cable to be anchored. Use of two cables of different strengths joined together
is prohibited. Use of cotton, jute or other non-metallic ropes for anchoring is forbidden.

6. Structure bonds and cable connections of the structure to earth shall be maintained in proper condition.
No heavy materials should be stacked on the rail bonds; transverse bonds between two rails of the same
track as well as rails of different tracks shall also be maintained in proper condition.

7. Where rails to which structures are connected are replaced, the structure shall be connected to the new
rail immediately after it has been laid.

20344 Procedure for Effecting Shut-Down for Work on Auxiliary Transformers

Power supply to auxiliary transformers is effected through fuse-switches on the 25 kV side and the LT Side is
controlled through fuses or double-pole iron-clad switch-fuses. Isolating fuse switches should be opened out
and fuses removed both on the HT and LT sides and the transformer earthed before starting work.

20345 Work on Overhead lines Running Parallel to Electrified Tracks

No work on any span of any overhead line (LT power line or other line) running parallel to an electrified track
where the minimum distance between the nearest conductor of the overhead line and the centre-line of the
nearest electrified track is less than 8m, should be done without switching off power from the 25 kV traction
line (in addition to making dead and earthing the overhead line on which work is to be carried out, in the
normal manner) excepting for the following specific items for work :
1 . Replacement of lamps, if below line.
2 . Painting of structures / poles upto a distance of 2m from the live wires of the power line.
3 . Reinforcement of foundations where such reinforcement does not involve any prior weakening of the
foundation at any time during the work.
4. Replacement of aerial fuses.

20346 Isolation of Booster Transformers

To isolate a booster transformer for maintenance or other work, the following sequence of operations should
be carried out
1. Where no isolator is provided a permit-to-work should be obtained for both the elementary sections, the
BT should be disconnected from the OHE and the OHE made through by jumpering.
2. When an isolator is provided to disconnect the BT primary winding from 25 kV lines, power must be
switched off from both the elementary sections to which the BT is connected after which the isolator should be
opened to disconnect the BT from the OHE and to make the OHE through.
3. The secondary winding of the BT should be disconnected from the return conductor and the return
conductor made through by jumpering.
4 . The return conductor should be earthed at the location where the BT has been disconnected; and the mid-

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [90]

point rail links on both sides of the BT should be opened so that booster cells on either side will
extend over a longer section temporarily.
5. With the OHE and return conductors made through, 25 kV power supply may be restored

It should be noted that during the period when a BT has been disconnected from service, the
interference on adjacent communication circuits will be enhanced. In view of this the defective BT
should be replaced with a good BT with the least possible delay.

20347 Isolators

Isolating Switches on the 25 kV system shall not be opened or closed when current is passing
through them. Normally, isolators should only be opened or closed, after power supply to the section
has been switched off by opening the appropriate interruptor (see para 20600 & 20601).

20348 Petroleum Sidings

The following arrangements/precautions would be necessary: -

Arrangements

i) An equipotential link between the petroleum sidings installation earth and the track via a switch
ii) Setting up of neutral zones (insulating joints) in the track to avoid any risk of propagating stray
current.
iii) Setting up of neutral zones/sections in the contact wire similar to loco inspection pits.
iv) The tracks must be provided with longitudinal bonds on both the rails as well as transverse bond
(30 m intervals). All masts and metallic structures in the vicinity of the track/ sidings should be
provided with structure bonds. Copper rivets should be used for bonding.
v)10 ohm earths must be connected to the petroleum siding on each side at the insulated joint.

Precautions
c) No oil tanker Is. permitted to stable under live OHE for inspection purpose.
ii) Fuelling to be done by side filling arrangement only.
iii) Pipe lines in the vicinity of the track should be properly earthed.
iv) Minimum 2 m electrical clearance from live OHE of the adjacent track or only other structure
nearby must be maintained.
v) During filling/loading and unloading of petroleum products the isolators at the neutral section of
OHE should be kept open to ensure that the OHE is dead and earthed.

V. FORMS AND REGISTERS

20349 Records to be Maintained

In Chapter VI the recommended proforma for Power Block and Permit-to-Work messages have
been given.

Particulars of other essential records to be maintained in regard to OHE maintenance are given
below

1. Daily Report of OHE Maintenance to be submitted by the Supervisor in-charge of field work to
ATFO. This should be in proforma No. 03-1 appended.

The form in which reports are to be submitted by the ATFO/CTFO to AEE (TrD) and SR.DEE / DEE
(TrD) may be laid down locally by each Division.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [91]
 2. Register for Foot-Patrol Reports: The reports regarding foot-patrolling (para 20322) should be
entered by the Linesman in a Register to be maintained for the purpose by each Section Supervisor.
The Register shall be generally as shown In proforma No. 03-2 appended.
3. Cantilever Assembly Maintenance Register as per proforma No. 03-3. This should be
maintained by each depot/sub-depot.
4. Register of Contact Wire Thickness Measurements: This Register shall be maintained in
proforma No. 03-4.

8. Register of Clearance under over line Structures as per proforma No. 03-5.

9. Register of Earth Resistance Measurement as per proforma No. 03-6.

7. Register of Current Collection Tests shall be maintained in proforma No. 03-7.

8. Register of Regulating Equipment shall be maintained by each depot/sub-depot for its

jurisdiction. This Register should have a page allotted for each Regulating Equipment. Particulars of
adjustments carried out, amount of catenary and contact wire cut etc. shall be recorded in this
Register, indicating the dates on which these items of work have been done, as per Proforma No.
03-10.

9. Register for Isolator Switches shall be maintained by each depot/sub-depot indicating dates on
which the isolators have been Inspected and the details of work carried out, as per Proforma No.
03-1 1.
10. Register for Turn cuts and Cross-overs shall be maintained by each depot/sub-depot. This
should indicate the dates on which each turn out/cross-over has been checked for adjustment and
particulars of work done, as per Proforma No. 03-12.

11. Register of Vulnerable Foundations: This should contain details of checks carried out on
foundations at vulnerable locations, such as on over bridges,,embankments susceptible to erosion
etc., as per Proforma No. 03-13.
12.Register for Feeder Lines shall be maintained by concerned depots/sub-depots to indicate
particulars of patrolling of 25 kV feeder lines and maintenance carried out on such feeder lines.
13.Register of Critical Implantation: The annual check of Implantation at critical locations (para-
20306) shall be recorded in this Register as per Proform'a No. 03-8.
14. Register of Level Crossings: This should contain dates on which height of contact wire at Level
Crossings as well as that of the height gauges at Level Crossings have been checked. See
Proforma No. 03-14.
15. Register of Splices as referred to in para 20310 as per Proforma No. 03-15.
16. Register of OHE Break-downs: Each depot/sub-depot should maintain particulars of OHE break-
downs occurring in its jurisdiction in Proform'a No. 03-9. For each break-down a page should be
allotted. Reference to detailed reports submitted should also be given to facilitate investigations
subsequently.
Registers may also be maintained for any other additional items in the proformae prescribed by
CEE.
The registers should be of A-4 size. As they are required for permanent record they should be cloth-
bound. The nomenclature of the register should be shown on the cover in 6 mm block letters.

The Supervisor of the depot/sub-depot will be held responsible for ensuring that these registers are
maintained up-to-date. Officers and Senior Supervisors during their inspections should scrutinize
these registers and initial a few important entries.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART [92]

Annexure 3.01 (Para 20301,2,4) 20320

SCHEDULE OF MONTHLY INSPECTIONS

Sl . Nature of Inspection SR.DEE DEE AEE CTFO* TFO* ATFO*

No.

1. Locomotive Cab 1 1 2 2 2 2
2. OHE Inspection Car 1 2 3 4 4 6
3. Push Trolley 1 2 2 4 4 4
4. OHE Depot 1 2 4 4 - -
5. Station 1 1 2 4 4 4
6. Night Inspection - 1 1 2 2 2
7. Office Inspection 1 1 1 1 1 1

Notes:'
(1) These Inspections are the minimum quantum per month.
(!I) In respect of Supervisory Staff, the inspections pertain to their respective jurisdiction.

(iii) Brief checklists of items to be broadly covered are indicated at Annexure 3.02. Detailed
maintenance schedules prescribed should also be kept in view.

(iv) Quota of Inspections by HQ officers may be laid down by CEE

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [93]

 Annexure 3.02
(Para 20302)

CHECK LIST FOR INSPECTIONS

1.0 OHE Depots & Subordinate Offices

(a)OHE Depots
1.Staff grievance register.
2.Quarter register.
3. Attendance registers.
4. Availability of all drawing (latest), SWRs with latest correction slips.
5.Cleanliness of depot.
6.Upkeep of Stores.
7. Stock position of stores.
8. Upkeep of wiring train, OHE Inspection car, ladders, tools etc.

b) Subordinate office:
1.Attendance registers.
2.Compliance of audit & account Inspection notes.
3.Compliance of Officer's inspection 'notes.
4.Test & Trial report.
5. Latest drawings & specifications.
6. Planning & progress of section w
1.0 Station
a) SWR
1. SWRs with latest correction slips.
2. Display of traction working diagram and its correctness at SM room & cabins.
3. Traction KeyBoard and key register for its proper maintenance.
4. Knowledge of traction working of SM/ASM on duty.
5.Validity of the competency certificate of SM/ASM.
b), CLS Board in SM room/cabin
1. AT standby supply.
c) Isolator.
1. Locking arrangements.
2. Correct alignment of blade tip in the fixed pole contact jaws.
3.Correct matching & alignment of arcing horns.
d)General
1. Fire extinguishers, sand/water buckets, Respiration chart, First Aid Box, Tools & Plants.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART I [94]

 2.Working of TPC phones & emergency telephone sockets.
3.History sheets of various equiprnents.
3.0 Cab Inspection
a) Condition of OHE
1 Flashed/damaged insulators
2. Displaced fittings & droppers
3.Balance weight in reference to upper & lower limits marked on masts.
4.Number plates, warning board for rusting & tightness.
5.BT : Oil leakage and deposits of pollutants on Insulators
6.AT : 011 leakage and deposits of pollutants on insulators
b) Obstruction to OHE:
1 . Birds' nests
2. Tree branches near OHE.
c) Cab equipments
1. Emergency telephone.
2. Focussing of head lights & flasher light.
3. Voltage on loco voltmeter at FP & SP locations.
d) Driving technique of Driver
1. Exchange of signals with station staff.
2.DJ opening & closing at neutral section.
3. Observation of caution orders.
e) Night Inspection
1. Incidence of sparking from the rear cab of locomotive.
2. Other items as above.

3.0 Push Trolley Inspection

a) Mast:
1. Implantation at selective locations.
2 Deflection of mast, on leading mast.
3. Areas affected by accident.
4 RC ,to rail connection for any loose connection.
5. Connection bonds and earthing connection.
6 Number plate.
7. Muffing.
b) OHE fittings:
1.The isolator blade is fully in and also for signs of sparking or overheating.
2. Insulators for any chipping/flash marks/damages.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [95]

 3. Displaced fittings & droppers.
4. Application of silicon grease on insulators.
5. Birds' nests, stray wire pieces and tree branches likely to infringe the OHE.
6. Free movement and position of counter weight with reference to upper and lower limits
marked on
the mast.
c)L. C Gate & over line structures.
1. Protective screens at FOB/ROB.
2. Height gauges at level crossings and height.
(f) Booster Transformer & Auxiliary, Transformer
1 . Oil level and leakage of oil.
2 Anticlimbing devices.
3 .Jumper connections.
4. Earthing.
5. Fuses on ATs.
6. Colour of Silica gel.
e) General
1. Signs of heavy sparking on OHE when train passes.
2. General condition of switching stations enroute.
3. Emergency telephone sockets at important locations.

Inspection with OHE Inspection Car

a) Mast, portals and cantilever supports.
1. Structures and galvanized tubes for rust & chipping off galvanization.
2. Cracks on steady arm & register arm.
b) Contact &\Catenary wires
1. Kinks & twists on contact wire.
2 Broken strands on catenary wire.
3. PG clamps, Jumpers.
4 Contact wire wear at selected locations.
5 Height and stagger at selected locations.
c) Section insulators
1 Flash or hit marks on and adjustment of runners.
2 Level of assembly & alignment.
3. Chipped/cracked insulator.

d) Turn -out
l. Stagger of both the OHES.
2. With Inspection Car running on loop line, check up if the-main line OHE passes smoothly
under the
pantograph. .
3 With Inspection car running on main line, check up if the loop OHE passes smoothly under the
pantograph
INDIAN RAILWAYS AC TRACTION MANUAL--,VOLUME 11 PART 1 [96]
Overlaps:

1. Height and stagger of OHE in the overlap section.

2. Whether normal minimum clearance of 500mm is available between the two OHEs in an
insulated overlap and 200mmin the case of uninsulated overlap.

3. Check up whether lifting of out-of-run contact wire is correct.

(f)Overline structures

1. Horizontal & vertical clearances.

2. Flash marks underside of the structures.

3 .Gradient of contact wire on either side.

4. Insulation on catenary wire under the structure.

(g)Level Crossing.
1. Height & gradient of contact wire.

(h)Regulating Equipment:

1. . X-Y and Z - Y values with temperature.

2. Free movement of drum.

3. Lubrication of pulley and other moving parts.

4. Stainless Steel wire rope for opening of strands, broken or rusted strands.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME II PART I (97)

 PROFORMA 03-1
Annexure 3.4 (Para 20349)

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION
Daily OHE Maintenance Report

Date ............
.......................... Depot

Note : - To be submitted to ATFO by the field supervisor' on the same day after completion of work.
l Power Block in sub-sector/Elementary. Section :
(a) Time asked ...........................................................................................................................
(b) Time received ................................................Time returned...............................................

Remarks, if any ..........................................................................................................................

2. Staff utilized Skilled....................................................Semi skilled......................................

Unskilled ..............................................

3. Details of work carried out:

(a) Stay/Bracket/Anchor insulators cleaned from Mast No . -------------------------

-------------------------------------------------------------To Mast No. -----------------------------------

(b) Section Insulator cleaned and checked Nos.. ----------------------------------------------------------

(C) OHE checked and adjusted between Mast No ............................ ....................................

.............. .................................................To Mast No ........................
(d) Height and stagger of contact wire to be measured and recorded
------------------------------------------------------------------------------------------------------------------------------
Height of contact wire Stagger
------------------------------------------------ --------------------

Mast No, Actual As per SED Actual As per

SED
-------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------

(e) Checked and adjusted X and Y at Mast Nos.

-------------------------------------------------------------------------------------------------------------------------------
How adjusted
----------------------------------
Mast No By turn buckle By cutting Length of wire
cut
-------------------------------------------------------------------------------------------------------------------------------

INDIAN RAILWAYS - AC TRACTION MANUAL VOlUME 11 PART 1 [100 ]

(f) Dia. of contact wire checked at location Nos ............. .....
.......................................................
......................................................................................Dia
......................................................................

(g) Clearance checked at location ...........................................................................................

Measurements .............................................................................................................
(h) Insulated overlap at location No ......................................................................................
clearance between OHE ..................................... ................................. (500mm min.)
(I) General condition of contact and catenary wires ...............................................................
Report if any catenary strands are damaged.

4. Work done without Power Block

(a) Muffs cleaned from Mast No ........................................... to Mast No..............................

(b)Bonds checked and tightened from Mast No .................. ..............................

To mast no. ......................................................................

1. Discrepancies ........................................................
2 . Repairs done ..............................................

(c) Rail level and implantation checked from Mast No ....... ........ to Mast No
.......................................
Rail level mark missing ...................................
Repainted .................... .............................

Discrepancies ..................................................

-------------------------------------------------------------------------------------------------------------------------------

Rail level Implantation

------------------------------- -------------------------------------
Mast No. Low by cm. High by cm. As checked As per
SED
-------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------
Station............................... Signature of
Supervisor.................
Dated. ......................
Designation...............

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART I 101

 PROFORMA 03-2

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION
Register for Foot Patrol Report
-------------------------------------------------------------------------------------------------------------------------------
Sr. Date Loaction Nature of BY whom Date of Initials of
No. No. Defect noticed rectification Supervisors
-------------------------------------------------------------------------------------------------------------------------------
Note - One Page to be allotted for each km.

PROFORMA 03-3

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION

.
Cantilever Assembly Maintenance Register

Kilometre ................... Station....................

-------------------------------------------------------------------------------------------------------------------------------
Sl. Location No. Type of Location Date on which attended

No. 1 St Yr. 2nd Yr. 3rd Yr. 4th Yr. 5th Yr.
-------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------
Note - 1. Each km should start with a fresh page.
2. Type of location should indicate BWA (Balance weight), FTA (Fixed termination), IR (In-
run wire),OOR (Out-oE run wire) etc.
3.When POH is carried out on individual cantilevers,.the date should be recorded in red.

PROFORMA 03-4

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION

Record of Contact Wire Wear

-------------------------------------------------------------------------------------------------------------------------------------
--
Location Line Date Thickness of Wear since last
Remarks
Wire, mm. Readings
-------------------------------------------------------------------------------------------------------------------------------------
--

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [102]

 PROFORMA 03-5
.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION
Register of Clearances under Over line Struvtures
FOB/ROB
No..................
Date Contact Clearances of Contact wire Clearances Contact
Remarks
Height Catenary wire height as adjusted height if any,
Above adjusted to as per
Rail level
I End II End I End II End SED
(m) (cm) (cm) (cm) (cm) (m)
-------------------------------------------------------------------------------------------------------------------
................................Line
Span ..................................................
Push up ................................................
Clearance .............................................
As per profile ......................................
Note :- Each line under FOB/ROB to be allotted a separate page.

PROFORMA 03-6

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION

Register of Earth Resistance Measurements

Station.................... Nearest Location................

Earth Pit No...............
-----------------------------------------------------------------------------
Sl.. Date of Resistance in Over all Initials of
Remarks
No. Test Ohms Resistance Supervisors
if any,
-----------------------------------------------------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------------------------------------------------
Note - 1. Half page to be allotted for Each pit.
2. Earth test should be carried out on a dry day preferably in March/April once a year.

PROFORMA 03-7

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION
Register of Current collection tests

Date By whom Loco Train Approx. Loca Obser Action Date

Remarks
Done No. No. Time tion vation taken
-------------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------------
Note :- One page to be given to each block section (up and down lines separately).
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 103
 PROFORMA 03-8

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION

Record of Locations with critical implantation

Sl. Block Location No. Line No. Implantation (m) Date Remarks
No. Section Actual As checked
Per SED
--------------------------------------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------
Note: - One page in the Register to be aflotted for each location

PROFORMA 03-9

.............................. RAILWAY
............................... DIVISION
TRACTION DISTRIBUTION SECTION

Register of Break-downs/ Accidents involving OHE

1.Date of accident/break-down ........................................................................
2.Station .........................................................................
3.OHE Locations affected ........ ...........
4. Details of damages ........................
5. Probable cause ............................................
6. Brief description and remedial action taken ......................
7. Reference to detailed reports sent .............................

8 Rernarks, if any ...... ................................

Note:- One page in the register to be allotted for each case.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [104]

 Profonna 03-12)
.................... RAILWAY
.................. DIVISION
TRACTION DISTRIBUTION SECTION
Tumout and Cross Overs
TURNOUT/CROSS OVER NOUMBERS.......................... SECTION /
STATION.........................
-------------------------------------------------------------------------------------------------------------------------------------
----
Sl. Particulars Date Whether Height of Stagger of
No. of turnout/ checked cross type or ---------------------- --------------------------------
Adjustment Remarks
Cross over overlap Mainline Turnout/ Mainline Turnout/
done,if any
type contact X-over OHE X-over
wire,m. Contact mm. OHEmm
wire,m.
1 2 3 4 5 6 7 8
9 10
-------------------------------------------------------------------------------------------------------------------------------------
-----------
(N.B. Half Page to be alloted for each turnout/crossover)

(Proforma 03-13)
.................... RAILWAY
.................. DIVISION
TRACTION DISTRIBUTION SECTION
Vulnerable Foundations
-------------------------------------------------------------------------------------------------------------------------------------
----
Sl. Date Implan- Height Amount of leaning in Amout of leaning in
Action Remarks
No. checked tation of HRL mark mm at cont.wire level mm at 1.85mm from HRL taken
Noted above rail Towards Away from Towards Away from if
any
Level(+) track(+) track(-) track(+) track(-)
-------------------------------------------------------------------------------------------------------------------------------------
--------------------------------------
1 2 3 4 5 6 7 8 9
10
-------------------------------------------------------------------------------------------------------------------------------------
-----------

Location:
Type of Mast:
Type of Foundation:
Type of Soil:
Whether the foundation situated on embankment/cutting,, bridge, flyover, tunnel etc.
Implantation as per SED:
(N.B\One Page for each masts/location)

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUMEII PARTI[ 106]

 (Proforma 03-14)
.................... RAILWAY
.................. DIVISION
TRACTION DISTRIBUTION SECTION
Level Crossing Gauges
-------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------
Sl. Location Line Date of Height of Condition of Level of Whether manned

II. No. Of level checking contact Height gauge road or

unmanned Remarks
X-ing wire below
Rail level
-------------------------------------------------------------------------------------------------------------------------------------
-------
1 2 3 4 5 6 7 8
9
-------------------------------------------------------------------------------------------------------------------------------------
-------

-------------------------------------------------------------------------------------------------------------------------------------
-------
(Half page for each level crossing)
(Proforma 03-15)
.................... RAILWAY
.................. DIVISION
TRACTION DISTRIBUTION SECTION
Record of Splices

BLOCK SECTION.....................................................
-------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------
Sl. Date when Location Line Date of Observation
Remarks
III. No. Provided in between checking

-------------------------------------------------------------------------------------------------------------------------------------
-------
1 2 3 4 5 6
7
-------------------------------------------------------------------------------------------------------------------------------------
-------

-------------------------------------------------------------------------------------------------------------------------------------
-------

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [1 07]

 CHAPTER IV

REMOTE CONTROL EQUIPMENT

Para No. Subject

1. GENERAL

20400 Introduction

II. FMVFT EQUIPMENT

20401 Transmission Path

20402 Remote Control Switching Equipment
20403 Mimic Diagram Board at RCC
20404 FMVT Equipment
20405 Frequency Allocation
20406 Controlled Post Equipment

111. SCADA EQUIPMENT

20407 General
20408 Transmission Path
20409 Isolating Transformers
20410 Repeater Stations
20411 Microwave Communication
20412 Optical fibre Cable
20413 Master Station Equipment
20414 Mirnic Diagram Board (MDB)
20415 Annunciations
20416 SCADA Software
20417 VDU Display
20418 Transmission and Coding System
20419 Historical Data Storage
20420 UPS and Batteries at RCC
20421 Remote Terminal Unit (RTU)
20422 Storage of Events and Alarrn.
20423 SCADA Equipment Capacity
20424 Modems
20425 Special features in SCADA Equipment

IV. OPERATION AND MAINTENANCE OF RC EQUIPMENT

20426 Duties of CTFO(RC)

20427 Operation of RC Equipment
20428 Investigation of Failures by CTFO
20429 Maintenance Schedule

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART [108

 CHAPTERIV

REMOTE CONTROL EQUIPMENT

I.GENERAL

20400 Introduction

A Remote Control Centre (RCC) is set up near the Traffic Control Office on each Division having
electric traction, -to work In close liaison with the traffic control. The RCC includes the main control
room, equipment room, Uninterrupted Power Supply (UPS) room, Remote Control laboratory and
Battery Room and is the nerve centre of the Traction Power Control.

Types Of Equipment:

The following types of Remote Control Equipment are mainly in use on Indian Railways at present:

(i) Frequency Modulated Voice Frequency Telegraph (FMVFT), Strowger type equipment for
supervisory control.

(ii) Supervisory Control And Data Acquisition (SCADA) systems with Microprocessor based
equipment and/or Computer based equipment.

The FMVFT equipment was in use for all electrification schemes prior to 1980. Being mainly all relay
system, the equipment has become outdated although some Remote Control Centres still continue
to operate on this system. Salient features of the system are indicated at paras 20401 to 20406.

The SCADA equipment based on State of the art technology has come into use after 1980.
Considering the fast growth and development of computer based equipment, newer types with
enhanced capabilities and new makes are being introduced. Addional facilities at each new RCC is
also natural as new features get incorporated.

11. FMVFT EQUIPMENT

20401 Transmission Path

For transmitting control signals from the Remote Control Centre (RCC) to the various controlled
posts underground cable circuits suitable for voice frequency (VF) operation are employed. These
consist of star quads with an attenuation of about 0. 3 dB/km. Isolating transformers are provided on
the cable circuits at Intervals of 10 to 15 km to limit the build up of longitudinal induced voltage on
account of induction effect of single 25kV ac traction. Line losses are made good by VF repeaters
provided by the S&T Department at interval of 30 to 50 km. The maximum gain in the repeater is 20
dB. Depending upon the distance of the RCC or controlled post (TSS/SP/SSP), repeater gain is so
set that signal level at any point is within prescribed limit. Impedance matching transformers of ratio
1120 : 1120 are provided at points where communication cable is tapped for taking connection to
the R.C. Centre or to the controlled posts. Suitable surge arresters are also provided inside the
equipment room at the termination point of communication cable to protect the circuits.

Normally three pairs of conductors are earmarked for Remote Control System, one pair reserved for
telecommand signals from RC Centre to the posts and one pair from the posts to RC centre for
telesignals. The third pair is spare for use in emergency, when any one of the other two pairs
become unhealthy.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [109]

20402 Remote Control Switching Equipment

The RCC switching equipment consists of the following five major units

1..Pulse Generator
2. Send Selector Circuit,
3.Receive Selector Circuit,
4.Check Circuit and
5. Indication Circuit.

All the units are of the plug-in-type and are housed inside the steel cabinet, which is provided with
dust proff front and back doors. A number of such cabinets are provided in the remote control centre
depending upon the number of controlled posts in a section.

20403 Mimic Diagram Board at RCC

The mimic diagram board at the RCC comprises several control panels on which the mimic diagram
is shown. Every apparatus to be remote controlled is represented on this mimic diagram board by a
control discrepancy switch. Hand operated dummy switches similar to but clearly distinguishable
from the control discrepancy switches are provided to represent certain non-remote controlled
apparatus like sub-station isolat,1 ,. The electrified tracks are represented on the mimic diagram by
white perspex strips or metallic strips. Whenever the 2SkV voltage on any portion of the OHE
between two controlled posts fails, or is not available, the corresponding portion of the mimic
diagram lights up. The mimic diagram, however, remains dark under normal working conditions.

Each control discrepancy switch includes a built-in-jamp in a central indicator'bar. If the controlled
equipment is in closed position, the central indicator bar shows continuity of the diagram. If it is
open, the central indicator bar will be at right angles, breaking the continuity of diagram.

Besides.above, fault annunciation vandows on the mimic diagram board are provided for each
controlled post, with suitable inscription to annunciate the following kinds of fault:

1 Station Blocked

2.R.C. Equipment Defective

3.Contact Failure

4.Low volt d. c.

5.240 V a.c. Failure

6. Transformer Alarms
7. Transformer faults
8.Low Volt 110V/72V d.c.
Item 6,7,8 are provided only for traction sub-stations. Item 6&7 are provided separately for each
individual transformer.

INDIAN RAILWAYS-AC TRACTIO MANUAL -VOLUME II PART I 110

20404 FMVFT Equipment
The control signals from the RCC as well as indication signals from the various controlled posts are
transmitted on separate channels within the voice frequency range of 420 to 2460 Hz. at a
transmission speed of 50 baud, with a 120 Hz separation between the channels. Only 18 channels
are thus available for use. Frequency modulation is employed. The oscillator unit on the transmitter
modulates the frequency + 30 Hz (for 'mark') -30 Hz (for 'space') of the channel frequency.

The transmitting level of each channel is -22dB across 1120 Ohm. The normal receiving level can
be, between, -22 dB and a minimum level of -30 dB.

Due to availability of only 18 channels within the voice frequency range of 420 to 2460Hz. with
channel separation of 120 Hz each pair of conductor can control upto 18 independent of grouped
stations, where the number of such stations exceeds 18, one more pair would be required for
purposes of telesignals only.

20405 Frequency Allocation

In view of their operational importance, all the feeding and sectioning posts are controlled
independently by using a separate frequency channel for transmission of telecommands and
telesignals to/from each post. For purposes of telecommand only SSPs are grouped (not more than
3) in order to economize in the number of channels. Telecomn-iands for all the posts in the same
group are transmitted on the same frequency channels. However, the individual controlled post in a
group is identified by inserting a code in the shape of a long pulse or a long pause in the impulse
train generated by the pulse generator in the switching equipment. When posts are grouped as
explained above, only one operation at a time can be carried out in the grouped posts from the
RCC.

20406 Controlled Post Equipment

The switching and FMVFT equipment at each controlled post are housed in one steel cabinet with
dust proof doors. The switching equipment is similar to that provided at the RCC.

The FMVFT equipment has one send channel panel and one receive channel panel. The equipment
works on 24V dc battery power supply. All the panels except the termination panel are of plug-in-
type An amplifier is provided with attenuation pads for level adjustment. The channel panels are of
the same type as those in the RCC.

III. SCADA EQUIPMENT

20407 General

The SCADA equipment at the RCC is called master Station while that of the controlled station is
referred to as Remote Terminal Unit (RTU).

20408 Transmission Path

Underground telecommunication trunk cable is provided for transmitting the signals from and to the
RCC and the controlled Remote Terminal Units (RTU). Three pairs of conductors (One pair for
"Send", one pair for receive" and the third as spare) from this cable are made available for remote
control operation.

20409 Isolating Transformers

To limit the build up of longitudinal induced voltage on account of induction effects of 25 kV traction,
isolating transformers are provided on the cable circuit at intervals of 10 to 15 km. The cable is
tapped at the RCC and each controlled station and 3 pairs of conductors are terminated on a
terminal board. Isolating transformer of impedance ratio 1120 :1120 is provided at the point of
tapping.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 111

20410 Repeater Stations.

Voice frequency repeaters are provided at intervals of 40-50 km to boost the signal and to make
good the line attenuation. The amplifier gain at the repeater station is about 20 dB, with an equalizer
incorporated to compensate upto 0.02 dB/kHz/km. Depending upon the distance,.the repeater gain
is set so that the signal level at any point en-route is within certain prescribed limits.

If the lead is long suitable surge arresters are provided inside the equipment room to protect the
circuits. The metallic sheath of the lead in cable shall also be kept insulated from the earth system
of the switching station to prevent induction effect, the insulated conductor alone being led into
control panels. For the same reason, switching station earthing, LT 240 V auxiliary transformer
neutral earthing and earth of R. C. equipment are all kept separate and distinct and are NOT
interconnected. In addition, the switching station structure should be solidly bonded to the track rails
by two independent connections.

20411 Microwave Communication

In some of the sections on Indian Railways dedicated Microwave channel at carrier frequency of 18
GHz has been provided for the purpose of communication.

20412 Optical Fiber Cable

Optical fibre cable has also been introduced for communication in some sections of Indian Railways,
which is also used for RC equipment.

Details of the interface between the latest communication systems and the RCC/RTU equipment
may be seen in the relevant technical documents.

20413 Master Station Equipment

Hardware Configuration: Dual main micro-computer/mini-computer system, one main and the other
hot stand- by, is provided at the rnaster-station, each system interfaces with its front end
processors, if any, and modem for communication with RTUs and with the man-machine interface
equipment to provide up-to-date network data and to accept commands. Each system has its own
system console and hard and floppy disks along with their drives. Watch dogs are provided for
monitoring the health of the computer system. In case of failure of one computer system, the
standby system takes over automatically.

Two data-logging printers, one on-line and other as standby, are provided, both being connected to
the same on- line computer system. In case of failure of one printer, the other printer automatically
takes over.
Man-Machine-Interface : Work Stations

Two work-stations, one for each of the two operators, each consisting of two semi-graphic colour
Visual Display Units (VDUS) and a key-board are provided 'at the RCC. The key board contains
both functional keys for operations that are repeated frequently and alpha-numeric key for input of
numerical data and text.

Both workstations are connected to the same on-line computer and meet the following
requirements..

(i)Normally control pre-defined and physically demarcated sections.

(ii)In case of complete outage of one workstation, all of its functions can be transferred to the
healthy workstation, so that normal operations can continue.
(iii)Normally one VDU Is on line and the other acts as standby at each work station. However, if so
needed, it is possible to have both VDUs of each work station on lines simultaneously, either of the
two VDUs being used for viewing diagram for telecontrol purposes and the other for viewing alarm,
on-demand trend curves, histograms or any other data.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 112
20414 Mimic Diagram Board (MDB)
A mimic diagram board and its associated mimic driver is provided at the RCC. The MDB depicts
the traction power supply diagram, Indicating the energize/de-energize condition of the sub-sectors
of the catenary, status of the interruptors and CBs at TSS & FP, SSP and SP.
Unlike in the conventional Mimic Diagram Board used in RCCs prior to introduction of SCADA
system (see para 20403) all control operations are carried out from the key board(s) provided at the
workstations. The Mimic Diagram Boards sole purpose is, therefore, to give an overall view of the
traction power supply system to the operator. Size of the MDB is, therefore, very much smaller. It is
the intention to do away with the MDB altogether since the system can be viewed in the VDUS.

20415 Annunciations
Controlled Station
"Remote Station Defective" is annunciated by a LED.
Master Station
The following annunciations by LEDs are provided on the MDB.
(i) Main System "ON"
(i) Standby System "ON"
(iii) Main System Defective
(ii) Standby System Defective
(v) Main UPS Failed
(vi) Standby UPS Failed
(vii) UPS battery low (below 90% of nominal voltage)
(viii) 415 V, ac, 3 Ph, supply to UPS failed

20416 SCADA Software

The operating system used is suitable for multi-user, multi- tasking, net working and real time
applications.

20417 VDU Display

The, application software supports a large number of versatile serni-graphic coloured displays for
issuing telecommands, blocking/deblocking the controlled points, viewing alarm listing, event listing
or for carrying out special functions. For details of these displays, manufacturers Operating Manual
may be referred to. Calling any of the VDU displays is by simple keyboard operation by the
operator, with pre-defined options available for the order and manner in which displays are called.

20418 Transmission and Coding System

The master station equipment normally scans continuously all the RTUs in a pre-defined cyclic
sequence, to update the equipment status, alarms, events and measurands. Exchange of
information between Master Station and RTUs takes place on interrogation by master followed by
reply from RTU. The communication technique is based on Digital Address Time Division
Multiplexing. Every data exchange is based on well defined transmission protocol. Each transmitted
Information contains sufficient parity cheek bits to detect transmission errors.

20419 Historical Data Storage

The SCADA system is designed to cater for historical data storage of traction power supply system
data for a period of one year. This includes:

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [113)

(i)All alarms./events / measurands of controlled stations and all system alarms.
(ii_)Day wise storage of average feeder current and voltage during the day, maximum demand,
maximum and minimum feeder voltage in the 25 kV side, total number of operations of feeder
protective relays viz. OCR, DPR and WPC relays, CB trappings and maximum and minimum OHE
voltage on both sides of the neutral section. A memory capacity of 40 MB is provided for this
purpose in the hard disk, with provision for further expansion of the memory as required.

20420 UPS and Batteries at RCC

Dual Stand-alone UPS System of adequate capacity to supply 240 V a. c. 50 Hz single phase
supply to the SCADA system at Master Station is provided.

Both the UPS work in parallel sharing the load. In case of failure of one, the entire load is
automatically taken over by the healthy UPS without affecting the working of the system.

in case of outage of both the UPS at the same time, the load of SCADA equipment is directly
connected to input mains through a static switch without any break.

A single battery is provided with both the UPS with adequate Ah capacity to provide 2 h supply to
various equipments in case of failure of input 415 V ac. 50 Hz supply.

20421 Remote Terminal Unit (RTU)

The RTU is microprocessor based and includes its associated digital Input/output modules, alarm
input modules, analog input modules, watchdog transducers, memory modules, interposing relays,
summation CTs, power supply unit(s), surge arresters and other items necessary for its proper
working.

20422 Storage of Events and Alarms

All changes (one or more) in the status of the CBS/interruptors / motor-operated isolators and
alarms that may occur between consecutive polling are stored by RTU until they are reported to the
master station. This is to eliminate any loss in reporting to the master station due to intermittent
failures of channel or any other reason. In other words, no event is lost without its being reported to
master station.

20423 SCADA Equipment Capacity

The SCADA equipment is generally designed for the following tele commands, telesignals and
telemetered parameters for a typical TSS, SP & SSP of a double line section:

S.NO. CONTROLLED STATION TELECOMMAND TELESIGNAL MEASURANDS

1. TSS 24 64 8
2. SP 8 12 4
3. SSP 8 12 -

Number of controlled stations (TSS, SP, SSPS) to be controlled from an RCC mall be as per the
requirements of the section.
Speed of Transmission and Update Time
The communication between the master station and the RTUs is at a suitable transmission speed
not exceeding 600 baud. Normal polling time for updating status, alarm and measurands for the
designed capacity is not more than 4 sec for 20 controlled stations and not more then 6 sec for 30
controlled stations. The actual timings may slightly vary depending on communication protocol
adopted and the system design.
NDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [114]
The RCC should be in the middle of the electrif led section if the number of controlled stations
exceeds 30 so that scanning on either side is possible and update time. kept to the minimum.

20424 Modems

(i) The modems (modulator/ demodulators) provided for communication between the master station
and the RTUs utilize frequency shift keying (FSK) modulation and include send, receive and timing
functions. The send and receive functions are independently programmed as required. The modem
works satisfactorily upto an input signal level of -45 dBm.
(ii)The modem also incorporates necessary amplifier having a minimum gain of 30 db to
compensate for any signal variation at different points in the system. Suitable attenuation Is
provided within the amplifiers to adjust the level through trimpot/rotary switch. It has an output signal
level adjustable between 0 and -30 d bm in steps of 1 dbrn.

20425 Special Features in SCADA Equipment

The following additional features are incorporated in the SCADA equipment:

(I). Tripping of bridging interrupters on under voltage at SP in extended feed condition.
(I!) Inter .lock release request facility for circuit breakers/interruptors control at boundary post (for
guidelines for these inter locks see RDSO's letter No. ETI/PSI/RC/SPEC.19 dated 10.3.1989).
(iii) Control of shunt capacitor bank and monitoring of power factor.
(!v) Automatic localization of fault on OHE and isolation of faulty sub-sector.

SCADA systems on Indian Railways are being supplied by various manufacturers. Although the
systems are different, the basic features of the systems are similar. For details of operating
instructions and maintenance, the operating technical manuals of the makers should be referred to.

IV. OPERATION AND MAINTENANCE OF RC EQUIPMENT

20426 Duties of CTFO (RC)
He is the senior supervisor working under the control of DEE/AEE (TRD) and directly responsible for
the proper operation and upkeep of the RC equipment, which are vital for the efficient operation of
the electric traction system. He shall be thoroughly conversant with all the technical details of the
equipment under his control. In particular, he shall perform the following duties.

1.Maintain the RC equipment at the RCC and the controlled stations in accordance with the
prescribed schedules.

2. Keep close liaison with the S&T department as to the sound condition of the cable pairs allotted
for RC operation.

3. Measures periodically the levels of voice frequency signals at controlled stations and arrange with
the S&T department for correction, when required, at their repeater stations.

4. Keep in constant touch with the TPC on shift duty and ensure prompt rectification of defects
reported in the RC system.

5. Ensure proper maintenance of UPS/battery sets for uninterrupted operation of the RC equipment
and the stand by generating set in the RCC.

6. Inspect the RC equipment at every controlled post once in two rnonths.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [115]
Impart necessary training to the staff under him in the special techniques of maintenance of RC
equipment as well as trouble shooting.

8.Ensure that the special instruments and tools provided for maintenance of the RC equipment are
properly cared for.
9.Keep a watch on stocking of spare parts and other stores required for the RC equipment and
Initiate timely action to recoup stocks.
10.Co-ordinate with CTFO (PSI) and CTFO (OHE) or territorial CTFOs for manning the controlled
posts in the event of persisting faults in the RC equipments.
11.Submit prescribed periodical returns on RC equipment to AEE (TrD) and Sr. DEE (TrD).
12.Keep his superior officer fully informed of all important developments and seek their guidance
when required.
13.Carry out such other duties as may be allotted by his superior officers.
14.Carry out minimum monthly inspections as per manufacturers recommendations.

20427 Operation of RC Equipment

The RCC is the nerve center of the traction system, from which full control over every switching
operation on the entire electrified route is exercised. It should, therefore, be kept in perfect operating
condition at all times. No one, other than an authorized official, shall at any time operate the
equipment. The TPC shall, at every change of shift, carry out a lamp test and, once a day give a
general check for all stations and thereby ensure that the indications on the mimic panel are In
order. Any defects observed In operation shah immediately be reported to the CTFO(RC) and the
entry made in the log book of the time defect was reported and the time it was rectified. Any
excessive delay in rectification which militates against operation shall be brought to the notice of
AEE(TRD). Depending upon the nature of the defect TPC shall take adequate precautions against
mal-operation until the defect noticed is rectified.

Should RC equipment of a switching station fall completely, the failure shall be reported to
AEE(TRD) and Sr. DEE (TrD) and arrangements made to man the switching station with trained
personnel to carry out the switching operations, observing the precautions prescribed in the Chapter
VIII 'Breakdowns'.

TPC shall once a day contact on telephone the Operators of each Grid sub-station from which
traction power supply is obtained and ensure that the communication facilities are Intact.

20428 Investigation of Failures by CTFO

As with any other equipment, every failure of RC equipment should be separately registered,
investigated and rectified, making a brief note in the failure report of the action taken as well as
classifying and finally pin-pointing the exact cause of the failure. The failures should be analyzed
every month and any special steps required taken to overcome the trouble and prevent recurrence
should be taken. A 'history sheet' showing the faults that have occurred on different items of
equipment will assist in carrying out detailed investigation of recurring troubles in consultation with
the Manufacturers of the equipment.

20429 Maintenance Schedule

The specific maintenance instructions issued by the respective suppliers of SRC/SCADA systems
should be observed and changes to be made therein may be decided in consultation with the
manufacturers. For the batteries used in the remote control centre and the remote terminal units
(RTUs), the instructions in Chapter 11 for fortnightly maintenance and quarterly maintenance shall
be applicable.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [116]

 CHAPTER V

OPERATION OF TRACTION POWER CONTROL

Para No. Subject

20500 Remote Control Centre

20501 Manning of RCC
20502 Knowledge of Rules
20503 Entry into RCC
20504 Shift Duty
20505 Shift Duty Register
20506 Repair and Adjustment of RC Equipment
20507 Switching Operations to be Deliberate
20508 Liaison with Section Controller
20509 Prompt Attention to Telephone calls
20510 Log Book
20511 Movements of Maintenance Staff
20512 Checking of Time
20513 Alarm Circuits
20514 Emergency Generator Set
20515 Duties of Chief Traction Power Controller
20516 Duties of Traction Power Controller
20517 Failures of Traction Power supply
20518 Failures of Grid Supply
20519 Prolonged Power Supply Failures
20520 Faults on Railway Equipment and Lines
20521 Lowering Pantograph of Defective Locos
20522 Isolation of Faulty Section
20523 Faulty Section to be kept isolated
20524 Advice to Section Controller
20525 Information to Traction Staff
20526 Action to Rectify OHE Fault
20527 Emergency Telephone Working
20528 Breakdowns and Emergencies.
20529 Obstruction of Tracks - Protective Steps to be taken by TPC

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART i [117]

CHAPTER V

OPERATION OF TRACTION POWER CONTROL

20500 Remote Control Centre

The Remote Control Centre (RCC) constitutes the 'heart' of the control system from where the
switching operations over the electrified system are controlled by one single authority i.e., the
Traction Power Controller.

20501 Manning of RCC

The RCC shall be manned throughout the 24 hours. There shall be shifts in each of which there will
be at least one Traction Power Controller (TPC) who shall be in charge and, depending upon the
workload, an Assistant Traction Power Controller (ATPC) to assist him. The CTPC will be directly
responsible for the correctness of all-switching operations and entries in the LogBook. No person is
permitted to operate the control switches except with the specific permission and knowledge of
CTPC. No person shall be permitted to work as a TPC or ATPC, unless so authorized In writing by
SR.DEE (TrD).

20502 Knowledge of Rules

TPC (and ATPC where provided) shall be fully conversant at all times with the rules and regulations
laid down by the Administration as well as with the details of the electrical distribution system. He
shall keep all instructions issued from time to time as well as copies of documents like General and
Subsidiary Rules, Station Working Rules etc. ready at hand. He shall keep all books and records
up-to-date, posting all correction slips on the day of receipt in the appropriate document.

20503 Entry into RCC

No person is permitted to enter the TPC unless he has an authority for the purpose. The TPC and
ATPC who are on duty shall not be disturbed or distracted.

20504 Shift Duty

No interchange of shift duty or variation of hours shall be permitted without the specific sanction of
DEE/AEE (TrD). In case of unavoidable circumstances the staff may make the necessary
arrangement with other shift duty staff before approaching AEE (TrD) for permission. No one shall
leave his post of duty until he is relieved by an authorised person.

20505 Shift Duty Register,

A shift Duty Register shall be maintained in which shall be noted every change of shift duty. Before
handing over charge, the outgoing TPC shall. record in the Shift Duty Register all points (shut
downs, power blocks, defects in plant, any special instructions received, pending message, if any
etc.) requiring the attention of the TPC who takes over. Before taking over of a, shift duty, the TPC
shall scrutinize all the entries recorded during the previous shift in the Shift Duty Register a.,jJ in the
log book, study the entire mimic diagram in the presence of the previous shift TPC and clear all
points of doubt, if any. He should then sign with time in the Shift Duty Register, thereby admitting
having taken over correctly and assuming full responsibility from then onwards.

INDIAN RAILWAYS - A,; TRACTION MANUAL VOLUME 11 PART 1 [l18]

20506 Repair and Adjustment of RC Equipment
1. TPC shall not repair, adjust or any way interfere with any of the RC equipment at the RCC
except for carrying out switching operations. Every defect shall be reported at once to the Chief
Traction Foreman (Remote Control) or the Assistant Traction Foreman (Remote Control), who are
responsible for the maintenance work.

2. No work may be commenced by any person on remote control or power supply equipment at the
RCC or any controlled post without prior intirnation to and approval of the TPC on duty, who shall
record the event in the Log Book. At the end of the work, the TPC should test the equipment on
remote control and satisfy himself that everything is in order.

20507 Switching Operations to he Deliberate

Since all circuit breakers and interruptors are operated through remote control, the TPC will have
control over the switching operations over a wide area. The time required for each operation is of
the order of only a few seconds. Every switching opration should, therefore, be carried out only after
due thought and deleberation. Operation of several switches simultaneously should be avoided as
far as possible as it may lead to wrong operations.

20508 Liaison with Section Controller

While the Section Controller is directly in charge of all movements of trains, TPC is directly
responsible for maintaining the power supply for ali' electrified tracks. For operation of the train
services, it is necessary that the close liaison be maintained between the Section Controller and the
TPC at all, times. The particulars of communication facilities provided for this purpose have been
described in Chapter 11 of Vol 1.

The TPC should also be in touch with the operators at the various Grid Substations.

20509 Prompt Attention to Telephone Calls

Either TPC or the ATPC shall attend promptly to all calls received on any of the telephones at the
RCC, priority however being given to emergency telephone and TPC telephone.

20510 Log Book

The Log Book is a primary minute-to-minute record of every switching operation carried out at the
RCC, every interruptions to power supply, unusual or abnormal occurrences, messages received
over the telephones, special instructions received from superior officers, defects reported in
equipment and action taken to have them rectified as and when they occur, in chronological order.

20511 Movements of Maintenance Staff

It is also the duty of the TPC to keep a track of the movements of all maintenance staff of the
Traction Distribution Branch so that in an emergency he is in a position to summon the nearest
gang/person, as required. It is primarily the duty of the maintenance staff to keep the TPC informed
of their movements - which shall be recorded in a "Register of staff movements."

20512 Checking of Time

The TPC shall check the correctness of the time on the clock at 1600 h of each day when time
signal is received from the Traffic Control Office.

20513 Alarm Circuits

At every change of shift, the TPC taking over shall cheek all the alarm circuits and carry out a lamp
test of the mimic diagram panel wherever this facility exists.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [119]

20514 Emergency Generator Set
A 415/24OV, ac, 50 Hz, 3 phase Diesel Engine Driven Generator Set is provided at each RCC for
feeding of the essential loads in the event of failure of the rnains supply. Each TPC and ATPC shall
be fully conversant with the starting of the Generator Set. It shall be started and worked for an hour
at least once a week if it has not been operated due to failure of mains supply.

20515 Duties of Chief Traction Power Controller

The Chief Traction Power Controller (CTPC) shall perform the following duties:-
1. Study of all failure reports of OHE, switching stations etc. daily specially In so far as they affect
the operation of trains and submit connected periodical reports to AEE (TrD). He shall maintain
complete statistical data relating to operation of RC equipment and ensure that the schedules of
maintenance are carried out regularly;

2. Scrutiny of traffic delays shown against the Traction Distribution Branch and liaison with the Chief
Controller, as necessary, for ensuring the correctness of the records;

3. Maintenance of close contact with the Chief, Deputy and Section Controllers, TPC and ATPC,
TLC, Sr DEE (TrD) and AEE (TrD) and study of all problems relating to train operations, as far as
the Traction Distribution Branch Is concerned, to seek solutions;

4. Scrutinize the Log Book and the Shift DutV Register once a day and ensure that they are properly
maintained and actionas necessary is taken,

5. In an emergency or disorganization be in direct touch with the Traffic Control Office and help in
every way to restore and maintain the train services and take over operation of power control
himself, if required;

6. Ensure that TPCs and ATPCs are adhering to the rules and instructions in force. Study all the
rules in force and suggest amendments, mo difications, corrections as may be found necessary in
practice;

7. Co-ordinate the Weekly Power Block Programme of all traction staff and other departments and
finalize It in consultation with the Traffic Department. Take steps to adhere. to the agreed
programme as far as practicable.

8. Compile periodical statistics from the data collected on SCADA system and as per instruction of
SR.DE TrD including the analysis of failures on the SRC system, and submit thorn to Sr. DEE(TrD).

9. Report daily to the CEEs office all matters as laid down by the CEE.

20516 Duties of Traction Power Controller

He is the official in direct charge of the control of 25 kV power supply for electric traction and shall
be fully acquainted with all the traction power supply In stallations, and sectionalizing arrangements.
There will be a TPC in each shift in the RCC and, depending upon the workload, he may be
assisted by an ATPC. The essential duties of the TPC/ATPC are as under:

1. When taking over shift duty, he should acquaint himself with the prevailing position of the entire
section including working of the RC equipment, condition of all transformers, circuit breakers,
lnterruptors and isolators, sections under power block, any special Instructions to be carriedout,-
movernents of important officials connected with the traction distribution system, position of the
OHE Inspection Cars and break- down vehicles etc.;
2. Maintain continuous contact with the Power Supply Authorities;
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 120
3.Maintain continuous contact with the Traffic Section Controllers in regard to power supply affecting
train movements, imposition of power blocks etc.;

4.In the event of power supply Interruptions or other failures, take prompt action in accordance with
prescribed rules and local instructions for restoration of supply;

5.Imposition of and removal of power blocks as required, following the prescribed procedure and
safety rules.

6.In the event of power supply failures, OHE break-downs, accidents etc. in the electrified section,
advise promptly the concerned Foreman, AEE, DEE/5r. DEE (and other officials in accordance with
local Instructions), and keep them posted with all important developments;

7.Record in the Log Book, on prescribed proforma, full details of all switching operations carried out,
power blocks imposed or refused (or delayed) and other occurrences in the distribution system;

8.Maintain the following registers and records in the proforma prescribed:-

(i) Shift Duty Register indicating points of importance including messages, movements of ODC
involving power blocks and other details to be noted by following 'shifts.
(I!) Record of standing instructions.
(iii) Register of temporary instructions.
(iv) Register of Staff Movements;
(v) Emergency Telephone Testing Register.
(v) Register of train delays due to failures of signal supply.
(vill) Weather forecast register.

9)By 10 h each day submit the following reports to Sr. DEE/ DEE (TrD) and other officials as laid
down in local instructions:-

(I) List of power blocks availed.

(ii) Particulars of telecommunication failures.
(iii) Particulars of RC failures
(iv) Power Supply failures.
(v) Maximum demand and energy consumption at each traction sub-station.
(vi) Condition of traction sub-station equipment
(vii) All unusual occurrences, if any.
20517 Failure of Traction Power Supply

Failure of 25 kV ac, 50 Hz Signal phase power supply can be due to

(a) failure of equipment of Supply Authorities or

(b) failure of railway equipment.

When the indications at the RCC are that failure of power supply is over the entire area fed by one
sub-station, the cause and likely duration of failure should be ascertained immediately from the
Operator of the Grid sub-station.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 121

20518 Failures of Grid Supply
In the event of failure of Grid power supply at a sub-station, if the Operator at the Grid sub-station
advises that he anticipates that the power supply may not be restored in less than 3 min, the TPC
should immediately initiate emergency working extending the feed from the adjacent substation upto
the failed sub-station, as a first step. He should inform the Sr DEE /DEE (TrD), AEE (TrD) and
Section Controller of this situation. He should also keep in continuous communication with the Grid
sub-station, persue and restore supply to OHE as quickly as possible.

20519 Prolonged Power Supply Failures

1. If the power supply Is anticipated to be restored after 10 minutes, as ascertained from the
Operator at the Grid sub-station, or if he is unable to state when power supply is likely to be
restored, TPC shall immediately proceed as follows:

(a) Advise the Deputy/Section Controller that emergency feeding arrangements are being
introduced In the area fed by the particular sub-station. The Section Controller shall then inform the
stations on either side of the concerned feeding post to issue caution orders to every electric loco
and EMU driver entering the affected area to lower pantographs while passing the feeding post,
specifying the structure number at which the Driver shall lower pantograph and the structure number
on reaching which, he may raise it. The Section Controller shall also repeat the information to all
loco sheds, both major and- minor, and to all train ordering stations. After this has been done the
Section Controller shall confirm to the TPC that Instructions for Issue of caution orders for lowering
of pantographs have been issued and emergency feeding arrangements may be made. These
instructions do not apply for locations where short neutral section assemblies have been provided
opposite the feeding post.

(The Drivers of electric and EMU locomotives shall, however, continue to observe instructions
regarding "Open DJ" and "Close DJ" at the neutral sections as usual).

(b) On receipt of the above information, TPC will open the two 25 kV feeder circuit breakers at the
sub- station where supply is interrupted and put "Red Warning Caps"/"Device inhibited tags" on the
corresponding control switches in the RCC.
(C) TPC will then close the bridging interruptors at the neutral Sections on either side.

(D)On restoration of supply from the grid sub-station, "Red Warning Caps"/"Device inhibited tags"
shall not be removed and the feeder circuit breakers shad not be closed until the bridging
intenuptors have been opened first.
2. If emergency feeding is to be continued for long periods, temporary signals for lowering and
raising of pantographs shall be provided.

20520 Faults on Railway Equipment and Lines

Any faults on OHE and 25 kV feeders lines will cause the corresponding feeder circuit breaker to
trip,. thus interrupting supply to the corresponding sector. When this happens TPC shall reclose it
once immediately. If It trips again he shall keep the circuit breaker open and proceed to isolate the
fault. Where auto reclosing feature is provided, the TPC should take action to isolate the fault after
the auto-reclosure scheme locks out. After isolation of faulty section TPC shall release the auto
reclosure lock-out.

20521 Lowering Pantographs of Defective Locos

Before concluding that the fault is on the the OHE and directing the OHE staff to proceed to the
faulty section to rectify the fault, the TPC should first make sure that there is no defective locomotive
or EMU in the faulty section, which could cause tripping of the feeder circuit breaker. If there is a
locomotive in the faulty section he should arrange to have its pantograph lowered to ascertain if the
fault is on the OHE or on the locomotive.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 122

Drivers and rnotormen should lower the pantographs of their units if they have reason to believe that
a fault has developed causing tripping of 25 kV feeder circuit breaker at the sub-station as for
example when 25 kV supply gets interrupted simultaneously with the tripping of the air blast circuit
breaker on the rolling-stock. If this happens more than once, It is most probable that the 25 kV
power supply interruption is due to fault on the loco. In such a case, the Driver should lower the
pantograph and inform the TPC through emergency or other telephone of his observations and
action taken by him so that TPC may take appropriate action. Whenever pantograph on. the loco is
defective, the TPC should ensure from the driver that the pantograph is properly tied down and
secured, and does not come into contact with the OHE.

20522 Isolation of Faulty Section

1. Expeditious isolation of a faulty section Is of the greatest importance. This can only be achieved
if the TPCs are fully drilled in the correct method of fault localization. The method of fault localization
which takes the least possible average time Is the best. It Is best to standardize the procedure with
a "Control Card" for every circuit breaker and keep the card in a serial order so that, when a circuit
breaker trips, the particular card can be picked out and the sequence of switching operations, as
given in the card, carried out in the card till the faulty section is. isolated and power restored to the
other sections. Such control cards ensure correct sequence of operations Irrespective of who is the
TPC on shift duty.

2, Fig 5.01 is a typical control card for a double line section. The basic idea is to divide the section
into sub- sections and find out whether the circuit breaker trips or not after reclosure. The full-line
arrow shows the action to be taken if the circuit breaker holds and the dotted line arrow, if it does
not. Following the arrows action has to be taken to open or close the interruptors and the feeder
circuit breaker till the faulty section is identified.

3. Sr. DEE (TrD) should ensure that control cards similar to the above are carefully prepared and
kept with TPC for every feeder circuit breaker. He should also ensure that all TPCs and ATPCs are
fully familiar with the method of using the control cards. In the case of some SCADA systems, the
fault localization and isolation sequence is automatic. TPC should carefully note the sequence and
the section that is isolated. He should ensure that power supply is available on the rest of the OHE
after a fault-tripping is noticed and try to minimize the length of the faulty section by directly opening
of isolators manually.

4. While control card is generally drawn up after careful thought, yet, there could be reduction in
average time taken to localise a fault by a change in the switching operations. This may be brought
out by any official to the notice of Sr. DEE/TrD.

20523 Faulty Section to be kept Isolated

(A) On Single Line Sections

After the fault has been located, the faulty section shall be kept isolated by keeping open the
concerned isolators. Feed to other elementary sections shall be restored by closing the concerned
interruptors/isolators.

(B) On other than Single Line Sections

After the faulty section has been located in accordance with para 20522, the faulty section as also
the healthy sections on the adjacent lines over the.same route as the faulty section, shall be kept
isolated by keeping open the concerned interruptors. Feed to all other sections shall be restored by
closing of other interruptors/isolators.

Further, the Section Controller shall be immediately informed by the TPC of the faulty and healthy
sections. Feed to the healthy sections isolated shall be restored only on receipt of advice from the
Section Controller of his having taken special precautions as per para, 20524.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 123
20524 Advice to Section Controller
(A) Faulty Section
The Section Controller shall Immediately be informed by the TPC to take all precautions as per Station
Working Rules, as though the particular faulty section is under emergency power block and the Assistant
Traction Foreman or other traction official in the neighbourhood shall be advised to cheek the faulty section.
AEE ffrd) and DEE (TrD) shall also be informed.

Only when the OHE staff are able to Inspect and find out the nature of the fault, it will be possible for them to
say how long It will take to rectify the fault and restore the power supply. The Section Controller shall decide
whether single line working Is to be Introduced or not taking into account the following factors :

(a) The traffic he has on hand,

(b)The anticipated time by which the OHE maintenance staff can reach the site as ascertained from TPC.

(B) Healthy section kept isolated (Para 20523)

On receipt of advise frorn TPC of temporary isolation of healthy section on line adjacent to a faulty section, the
Section Controller shall irnrnediately take necessary action for having caution orders issued to drivers of all
trains due to enter any of the concerned block sections (wdth OHE temporarily isolated, though healthy) to
watch out for possible obstruction arising due to an unusual occurrence on a track with faulty OHE and be
prepared to stop.

In respect of the trains stranded in any of such concerned block sections, it will be possible to issue caution
orders to their drivers only after they reach the next station. Separate Instructions for drivers of such trains to
proceed cautiously upto next station, In case of being detained in block section for no tension in OHE for more
than 5 rnin, are contained in G & SR etc.

20525 Information to Traction Staff

All information regarding any unusual occurrence received from Station Masters etc. shall be given by the
Section Controller to the TPC to assist him to quickly locate faults.

20526 Action to Rectify OHE Fault

1. The Section Controller shall give top priority for the movement of the maintenance staff (by train, OHE
insection Car or motor trolley) to reach the faulty section, it is the duty of all concerned to reach the break-
down site either by rail or by road in the quickest possible time. They should carry with them a portable
emergency telephone and keep in touch with TPC.

2. The TPC after locating the fault shall reduce the section under power block to the elementary section
concerned by arranging either by trained station staff or TrD staff the opening of isolator Switches. They shall,
after Inspecting the fault, inform TPC the tirne expected to be taken for rectifying the same. TPC shall pass on
this Information to the Section Controller.

3. The OHE staff shall then take a permit-to-work and proceed to rectify the fault duly observing the rules for
the purpose.
20527 Emergency Telephone Working

If an Operator at a Grid sub-station Is not able to speak to the adjacent Grid sub-station due to some fault or
failure on their telecommunication system, the TPC shall arrange for the, messages to be transmitted ovp-r
the railway or other telephone, where practicable. Similarly, in case of fault or failure. of telecommunication
system on the railway, the Operator of the Grid sub-station shall arrange to transmit messages, if any from the
TPC to any other

INDIAN RAILWAYS - AC TRACTION MANUAI -. VOLUME 11 PART 1 125

sub-station through the Grid telecommunication system, on a reciprocal basis. Such messages
should be passed only if they are very urgent and related to maintaining continuity or restoration of
power supply.

20528 Breakdowns and Emergencies

The TPC shall always be in a state of readiness to take quick and prompt action to tackle any
breakdown or emergencies. He will keep liaison with not only the field officials at site who are
engaged in restoration of affected section, but also the Head Quarter officials, giving details of the
breakdown to the extent, they are known apart from, help from the neighbouring divisions or Head
Quarters as the circumstances warrant.

20529 Obstruction of Track - Protective Steps to be taken by TPC

On being informed by the Section Controller/Station Master of any accident/incident likely to

obstruct one or more tracks or OHE in a multitrack section, necessitating immediate suspension of
movement of trains and being told by Section Controller to switch off power, the TPC shall
immediately switch off power supply to the OHE of the affected track as also that of the adjacent
tracks over the length of the tra ek affected. The power supply shall be restored only after it is
confirmed to the TPC that the track and OHE are clear of any obstruction and movement of electric
trains is safe.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [126]

 CHAPTER VI
POWER BLOCKS AND PERMITS-TO-WORK
20600 Operation of Isolator Switches

1. Before considering the procedure for obtaining power blocks, attention is drawn to the
precautions to be taken in opening an isolator switch...Manually operated isolator switches are
provided at different points on the main line to sectionalize the OHE into elementary sections and at
large yards to isolate different elementary sections for maintenance of the OHE.

2. The operating handle of every isolator switch shall always be kept locked either in the open or
closed position. Any loss or damage of a padlock or key shall be reported immediately to the OHE
Section Chargeman, Chief Traction Foreman (OHE) and TPC.

3. An isolator switch is not meant for breaking a current, but only to break a circuit when no
current is passing through it. If an attempt is made to open a switch when it is actually carrying
current, severe arcing will occur at the switch contacts and may result in serious consequences
including danger to the operator. AN ISOLATOR SWITCH SHALL NOT BE OPENED WHEN
CURRENT IS PASSING THROUGH IT.

4. Isolator switches on the main line may only be opened provided the corresponding sub-sector is
first made dead by TPC. The person operating the isolator switch shall not open It, unless
specifically asked to do so by TPC by a clear message supported by a private number or after
receipt of a separate permit-to-work for the section which includes the elementary sections on either
the isolator switch. TPC shall ensure that the sub-sector is dead before he orders opening of an
Isolator switch in it.

5. Isolator switches, however, can be closed by a duly authorised person even if the adjacent
lnterruptors are closed (i.e. on load) provided the closure is made swiftly In one motion. It is
imperative that once the fixed and moving contacts have met, the contacts are not separated.

20601 Isolators in Yards and Sheds

(a) Isolator switches provided for isolating sidings and yards and also to feed OHE inside running
sheds, may be opened provided the official concerned makes it certain that -

(a) the entire section is visible; and

(b) There is no locomotive with raised pantograph in the section.

If is not possible to get an assurance of these conditions, the principles of para 20600-4 shall be
followed.

20602 Maintenance Blocks

There are generally two types of blocks required for maintenance work on electric traction
Installations:

(a) Traffic Block: Where a line is blocked against movement of vehicles whether steam, electric or
diesel locomotive hauled. This will be required whenever heavy repair have to be carried out. A
traffic block will be granted by the Section Controller in consultation with the TPC.

(b) Power Block: Where a section of line is blocked against movement of electric locomotive hauled
vehicles or EMUs only i.e., a section where 25 kV electric supply to the OHE is switched off and the
section made dead. Power block will be required whenever light repairs to or maintenance of the
OHE
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 128
has to be carried out and the nature of the work is such that traffic block is not necessary. Power
blocks are granted by TPC in consultation with the Section Controller. Whenever a power block is
granted by TPC, movement of vehicles hauled by other than electric power, i.e., steam or diesel
may be permitted, provided a caution order is issued as per General and Subsidiary Rules drawing
the attention of the Driver to the fact that the OHE staff are working at the kilometerage specified
and he should exercise caution when passing over the section and obey signals displayed at the
place of work.

20603 Power Blocks

1. Power blocks are of three different types:
(a) Emergency power block,
(b) Pre-arranged power block,
(c) Locally arranged power block.

Power blocks on the OHE of "Secondary lines", i.e.-, siding, yards, sheds, etc. arranged by the
Station Master, Yard Master, Shed Foreman or Engine Examiner concerned locally come under
category (c).

2. In all cases of power block TPC shall put red warning caps on control switches corresponding to
interruptors which are kept open for isolating the section. Similarly, warning boards shall be fixed on
all manually operated switches opened locally for isolating the section. This shall be done by the
operator who opens the switches. These red warning caps and warning boards can be removed
only when cancelling the power block. In case SCADA system is in operation instructions issued for
the operation of the system shall be followed.

20604 Emergency Power Block

An "Emergency PowerBlock" shall be arranged by the TPC and25 kv supply to the OHE affected
shall be switched off by him immediately on receipt of an advice of any break-down of the OHE or
Injury to persons or damage to property particularly in the following cases:

(a) The whole or part of the OHE or a feeder or a cable falling down and or persons or animals or
falling trees or vehicles coming in contact with or likely to come in contact with live equipment;

(b) A damaged catenary or contact wire fouling the vehicle gauge;

(c) A damaged electric locomotive getting damaged to rectify which the Driver requires the permit-
to-work;

(d) Derailment or any other traffic accident on the electrified lines, where cutting off of 25 kV power
supply is considered necessary by TPC or the Section Controller, in the Interest of safety. ,

20605 Reporting Abnormalities in OHE

It is the duty of every railway official to report immediately any abnormalities on the OHE such as
are mentioned
in para 20604 or of tracks, masts/ structures or pantographs of locomotives As may adversely affect
safety of trains movements, to the TPC either directly or through any Station Master,
Section Controller or through the nearest available telephone. If the damage is heavy or the moving
dimensions are infringed he should take steps to protect the lines in accordance with General and
Subsidiary Rules.
20606 Request for Emergency Power Block
1. The person who gives the first Information of break-down on the OHE shall invariably give all
essential information. such as his name, designation, kilometerage where the abnormality has been
noticed, its nature and
INDIAN RAOOVAYS - AC TRACTION MANUAL VOLUME]] PART 1 129
place from where he is reporting. He should leave the place only with the permission of the TPC.

2. The reason for asking for an emergency power block should be brief and to the point, but
explicit. Much time and trouble can be saved if the first information given is clear and unambiguous,
to enable the TPC to decide upon the course of action to be taken.

20607 Action to be taken TPC

On receiving the information the TPC shall immediately arrange to switch off power supply to the
section affected (the details of defects being obtained after the supply is switched off). He shall at
the same time advise the Section Controller on duty the section made dead by him. The Section
Controller in turn should arrange with the Station Masters concerned to take protective measures in
accordance with "Station Working Rules".

20608 Precautions after Emergency Power Block is Imposed

Once an emergency power block is imposed, no work on the affected lines shall be commenced
until an authorized OHE official arrives at site and earths the OHE. at two points or more as per
rules. Power supply to the section concerned shall not be restored by TPC until the authorized
official at the site issue a message supported by private number.

20609 Identification of Sectors, Sub-Sectors and Elementary Sections

1. It is vitally important for every Railway official who has occasion to ask for Power block to know
the correct method of Identifying and describing any section of the OHE where shutdown is
required. He should have with him the upto-date Station Working Rule Diagram for the section,
showing all relevant particulars such as station names, position of all isolators, interruptors, circuit
breakers, "up" and "down" tracks, cross-over section insulators, sectors, sub-sectors and
elementary section numbers.
Sectors: These are described by referring to a section of OHE of a track which can be energized by
closing a feeder circuit breaker at the substation/ feeding post. It covers the section between sub-
station/feeding post and adjacent neutral sections.

Sub-sectors: These are described by the names of two limiting switching stations in the order in
which the train moves and adding the name of the track, e.g., Sub-sector Kendposi-Tabu Dn.

Elementary Sections: are referred to by four/five digit numbers. The sections are numbered serially
in the direction of power supply i.e., from the feeding post/substation towards the neutral section or
the terminal point. At each feeding post/sub-station a new series of numbers starts. The first
two/three digits represent the interrupter controlling feed to the section and the last two digits the
serial number of the elementary section. Up line elementary sections have progressively odd
numbers and Down line elementary sections have progressively even numbers. e.g., elementary
section 0202 means the first elementary section from the feeding post/sub-station on the down line,
fed by interrupter 02.

Whenever there is a doubt in the description, the person asking for power block shall state clearly
the track and OHE structure numbers between which work is to be done.

20610 Telephone Messages

All messages relating to shut-down and restoration of power supply, permits-to-work, etc. issued
over the telephone shall invariably be supported by exchange of Private Numbers. The procedure to
be followed is as detailed below -

(a) Every official who has to exchange such messages shall maintain a Private Number book. As
each message is sent, the Private Number used should be scored out in the Private Number sheet,
initialled and dated. The message number should also be recorded. Every Private Number book and
permit-to-
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 130
work form is an important document and should be carefully preserved for a period of one year
unless required for a longer period in connection with an inquiry or investigation.

(b) Every message shall start with the Private Number of the sender and end with the Private
Number of the person who has received it.

(c) Messages should be brief and to the point. They shall be written out in full before they are sent.
The description of the section on which power block is required should be unambiguous as detailed
in para 20609. All messages regarding permits-to-work shall be in the standard form.

(d) The same person who asks for and obtains a power block should also cancel it before power
supply is restored. The persons exchanging the private numbers should identify themselves by
name over the telephone.

(e) The correctness of every massage shall be confirmed by the person who has received it by
repeating it. Each message shall be recorded by the sender as well as by the receiver in message
books maintained for the purpose.

(f)To avoid confusion, use words "Open" and. "Close" shall be used instead of phonetically similar
words such as "Switch Off", "Switch On". Whenever necessary words may have to be spelt out
(e.g.,1 (one) 4 (four) and not fourteen), B for Bombay, C for Calcutta and so on.
1
20611 Procedure for Obtaining Traffic or Power Blocks and Permits-to-work

Officials in the electrified area who require prearranged traffic blocks, power blocks or permits-to-
work in the danger zone of traction equipment, or who require OHE and or bonding staff to be
present at site for scheduled maintenance works, shall deliver at the office of Sr DEE (TrD) not later
than 10 hours on the first working day of the week statements in the prescribed form showing-

(I) the nature of the work and the date on which it is to be performed;
(ii) by whom the work is to be carried out
(iii)location of the work and the section of the lines to be blocked;
(iv)The trains between which the block is required; and
(v)Whether the track will be available for steam or diesel traffic.

2. The requirements of all departments will be co-ordinated in the office of Sr. DEE (TRD) and a
consolidated statement forwarded to the Senior Divisional Operating Manager concerned, by 12
hours on every Wednesday, for inclusion in the weekly programme of traffic and power blocks.

3. Works of an urgent nature shall be attended to by obtaining emergency blocks and permits-to-
work from TPC

4. A weekly programme of work involving traffic blocks, power blocks and permits-to-work shall be
prepared in the office of Sr. DOM and dispatched to all concerned (TPC, TLC, Loco Sheds, Station
Masters/Yard Masters concerned and Traffic Controller in addition to the departmental officials who
asked for the blocks).

5. All the traction sub-stations have two states of traction power transformers and associated
switch gear. Maintenance of equipment of the traction sub-station, therefore, does not necessitate
total shut down of 25 kV supply at each sub-station. Whenever any maintenance or breakdown is to
be attended In the traction sub-station, the permit to work should be obtained by the Supervisor
incharge from the TPC and after completing the work, the permit to work should be returned by the
Supervisor incharge to the TPC. Similiarly at the switching stations
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 131
normally the alternative feed is available to the concerned sub-sector and therefore, does not
necessitate the power block but only a permit to work should be obtained from the TPC and after
completion of the work, the same should be rerturned to the TPC. In case of attending to the gantry
of a switching station, complete block of the switching station is required for which power block has
to be taken from the TPC.
20612 Pre-arranged Power Block
After a prearranged power block has been agreed to be granted and an advice to this effect
circulated to all the concerned, the following gives the detailed procedure to be adopted by the
Section Controller and the TPC for granting the power block. Assume that power block is required
on the Up line between station .......... and .............. on Elementary Section No . ......... at 1
0-00 hours after the passage of a specified Up train (say 'X'): -

1. On the scheduled day about two hours before the block period, i.e., at about 8.00 hours, TPC will
obtain confirmation from the Section Controller concerned that the trains are running to time and
power block will be available as, scheduled, after the Train No. 'X' Up has passed station at about 1
0-00 hrs.

2.The TPC will pass on information to the Chargeman of the maintenance gang that the power
block, as already arranged, will he available in time.

3.The maintenance gang should arrange to leave the depot in time with all materials and tools so as
to be ready at site at about 9. 30 hrs. The OHE staff (in charge of the work) on arrival at site should
immediately contact the TPC and inform him of their arrival.

Any person detailed to open an isolator switch for switching off power supply shall also report to
TPC of his arrival at site at the required location.

The maintenance gang should carry at least two portable telephone sets and the necessary earthing
pole assembly along with them while proceeding to do maintenance work on the OHE.

4. The TPC should maintain continuous contact with the OHE staff at site.
5. As soon 'X' Up clears the Up track between . ....... and .............. Section Controller should inform
Station Master on duty at all stations concerned to arrange for "longitudinal" and "cross" protection
as laid down in Station Working Rules (see paras 20621 to 20626).

6. The Station Master shall ensure that the protection as specified In the Station Working Rules is
carried out and confirm it to the Section Controller with exchange of Private Numbers.

7. The Section Controller on receipt of assurances from the concerned Station Masters will advise
TPC that the power block may be given.

8. If the power block message is given by TPC In the prescribed printed form the Section Controller
will sign the same and send it to the TPC; if it is given over the telephone, the Section Controller will
grant the power block through a message with exchange of Private Numbers.

9. On receipt of the above message TPC will open the interruptors concerned and issue messages
to the field staff for operation of the required isolators. On receipt of the confirmatory message that
the isolators have been opened, TPC will close the interruptors restoring power supply to all parts,
except over the particular elementary section where work has to be done. He WILL then issue a
permit-to-work message in the prescribed form to the authorized person in charge of the
maintenance gang.
10.After obtaining permit to work, the authorized person may use a flag signal (Yellow flag) to direct
the nominated staff to discharge and earth the OHE at two or more points.
11.The maintenance gang will start the work after taking necessary safety precautions to protect
themselves,

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 132

viz., by earthing , display of banner flags etc. as detailed in General and Subsidiary Rules. ,9

Note: On sections with automatic signalling, the signals may be at danger due to earthing of OHE
with the rails during the period of the power block. The Station Master shall issue necessary
authority as per rules for steam, and diesel trains when these are permitted to be moved over the
section under power block.

20613 Restoration Of Supply After a Permit-to-work is Returned

On completion of the work, the person who received the permit-to-work shall ensure that -

(a) all men and materials have been withdrawn from the electrical equipment and its vicinity,
(b) all earths provided for the protection of the working parties have been removed; and
(c) all staff, who have been deputed to work, are warned that the power supply is to be restored.

He should then inform TPC by a message, supported by Private Number, that the work, for which
the permit- to-work was issued, has been completed, the men and materials have been withdrawn
from the specified section, the earths have been removed and power supply may be restored to the
section. This shall constitute cancellation of the permit-to-work previously obtained.

20614 Work by other than Authorized Persons

1.If work is to be carried out on or adjacent to any, part of the electrical equipment by other than
'authorized' persons such work shall not commence until the person in-charge of the work is in
possession of a written permit-to-work in the prescribed form issued to him by an 'authorized'
person.

Such permits-to-work in the prescribed form shall only be issued an' authorized' person of the
Electric Traction Branch not below the rank of a Senior Linesman.

2. The permit-to-work shall first be taken from TPC by an 'authorized' person who shall earth the
electrical equipment specified and hand over a permit-to-work card to the person in-charge of the
work getting an acknowledgment on the other copy. A duplicate copy of every permit-to-work card
shall be retained in the personal possession of the 'authorized' person who issued it.

3. On completion of the work and when all men and materials have been withdrawn from the electric
equipment and its vicinity, the person in-charge of the working party shall cancel his permit-to-work
card and return it to the 'authorized' person who issued it. The 'authorized' person shall in turn issue
a message to TPC to cancel permit-to-work as detailed in para 20613.

20615 Local Cancellation of Permit-to-Work When Telephones are Interrupted

If telephone communication with TPC is interrupted when a permit to work is to be cancelled, the
authorized person to whom the permit-to-work was issued shall arrange locally for restoring the
normal (live) conditions on the equipment specified in the permit-to-work and for cancelling the
power block, if possible. Before this is done the authorized person should satisfy himself that no
other party has been given a permit-to-work for the same section.

20616 Multiple Working Parties

1. Whenever work has to be carried out by more than one working party, within a sub-sector or an
elementary -to-work shall be issued by the TPC only to one authorized person who alone shall be
responsible, section, the permit to work . Other party or parties may work for all work on the portion
of electrical equipment specified in the permit-to-work. Other party or parties on the same portion of
electrical equipment only with the permission of this authorized person. The authorized person shall
cancel the permit-to-work only when he has satisfied himself that all working parties who have been
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 133
permitted by him to work in the section covered by the permit-to-work have withdrawn their men and
materials and have removed the earths from the electrical equipment on which they had worked. In
the event of telephone communication being interrupted, the person responsible shall take action as
provided in para 20615 above for cancellation of the power block.

2. Where the two parties are working far from each other, the party who has to work for a longer
period shall take the permit-to-work and then permit the other party to start his work by a message
supported by a Private Number. The second party shall inform the party from whom he got the
permit-to-work of completion of work and removal of earths and withdrawal of men and material by a
message supported by Private Number.

20617 Entries in the Log Book

The number of each permit-to-work issued must be entered in the log book by TPC together with
the particulars and time when the equipment is made dead and re-energized after completion for the
work, as per information received on telephone from the 'authorized' person concerned.

20618 Work Inside Loco Shed or Car Shed

For work to be done Inside the loco sheds or car sheds, the application for permit-to-work must he
made to the Traction Foreman, Assistant Traction Foreman or Chargernan (RS) who shall arrange
for the issue of the permit- to-work after getting the switch of the inspection bay or the feeders
opened. No intimation to TPC is necessary. The permit-to-work must be received for cancellation
from the person in-charge of the work by the Traction Foreman, Assistant Traction Foreman or
Chargeman (RS) before the switches are closed.

20619 Local Block

Power supply for sidings which do not affect movements of trains on the main lines, for loop lines
and reception and despatch yards, is controlled by manually operated isolators. Keys for these
isolators are usually in the custody of the Stationmaster concerned. Power blocks on such sidings
can be arranged when required by an authorized official subject to the following:

(1) The Station Master, Cabin Assistant Station Master, and others responsible for the movement of
traffic, should take measures detailed in para 20621, 20622 and 20625.

(ii) TPC shall be informed. before and after the shut-down is effected.

iii) isolators may only be opened after due precautions prescribed in para 20600, 20622 and 20625.

(iv) Earthing of equipment and issue of permit-to-work is done as prescribed in these rules.

Local power blocks shall be recorded in form ETR-4 prescribed for the purpose.

20620 Protective Measures for Power Blocks

It Is essential that every Railway official concerned with the movement of trains on the electrified
section, have a thorough understanding of the precautions to be taken to ensure safety of staff
working on the OHE under power blocks. The reasons for the precautions and the nature of the
precautions
19 are therefore given at some length in the following para graphs.
The protective measures are -

(a) Longitudinal Protection: To stop movement of electric rolling-stock running on the same track on
which a section has been made dead and power block has been granted.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [134]
20622 Transverse or Cross Protection
1. Section insulators have been provided on crossovers to separate and insulate different sections
of OHE from each other, e.g., the up track from the Down track, the main line from the siding yard,
OHE inside a loco maintenance shed from the yard lines.
1
2. A section insulator, comprises of a strain insulator, with two runners connected to one of contact
wires as shown in Fig. 3.02 (Chapter 111). The runners are at the same height as the contact with
the other side, and also shaped so as to allow a smooth passage of the pantograph underneath. It
will be seen from Fig. 3.02 that the two runners overlap with the contact wire on the other side for a
short distance to ensure that there Is no Interruption of the current drawn by the locomotive as it
passes under the section insulator.

3. Electric rolling-stock with raised pantograph should, therefore, never be allowed to pass below a
section insulator if a power block has been given on one of the tracks, as the pantograph will
momentarily connect the live OIAE with the dead OHE, while bridging the runners and contact wire.
This again energizes the dead section and endangers lives of those who are working on it.

4. In view of its extreme importance the rule is again repeated: Under no circumstances should
electric rolling- stock be passed below an insulated overlap span or a section insulator which
separates a dead section on which a power block has been granted, from the line section.

20623 Procedure for Arranging Longitudinal and Transverse Protection

1. Before a power block is granted the Section Controller should advise the Station Master,o Yard
Masters and Cabin Assistant Station Masters concerned to protect the dead sections, both
longitudinally and transversely. It is only when all the Station Masters and Cabin Assistant Station
Masters concerned have confirmed that this has been done, the Section Controller can advise TPC
agreeing to the grant of power block. The Station Master, Yard Master and Cabin Assistant Station
Master concerned will continue to maintain protection till the power block is cancelled by the Section
Controller.

2. The Section Controller will in turn permit removal of protection only after the power block is
cancelled by TPC.

20624 Station Working Rules for Longitudinal and Transverse Protection 1

1. In view of the large number of possible movements which may accidentally energize a dead
section under a power block, the various protective measures to be taken by each Station Master,
Cabin Assistant Station Master and Yard Master when power block is granted for the various
sectors, sub-sectors or elementary sections should be catalogued in the Station Working Rules for
each station. It is the duty of every Station Master, Yard Master and Assistant Yard Master to be
thoroughly familiar with these instructions so as to be able to carry out efficiently and quickly the
protective measures prescribed.

2. The Station Working Rules should contain-

(a) rules to be generally observed by all stations;

(b) a chart giving exactly what precautions have to be taken for granting power. blocks on each
sector, sub-sector or elementary section; and

(c) a drawing showing the wired and unwired tracks as well as the sectionalizing arrangements
including. the position of signals and points referred to in the chart mentioned above.

This drawing is the only valid document to be referred to for the purpose of granting power block. No
modification of the installation shall be done without its first being incorporated in the above drawing.
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME 11 PART [136]
3. In case of large stations, a copy of Station Working Rules may be issued to each cabin.

4. Every Station Master/Yard Master/Asstt. Station master shall be Trained for the purpose and be
fully conversant with all the local switches/isolators/cross-overs and special Instructions applicable
to the equipment provided the station and as laid down in the Station Working Rules to enable him
to operate Isolators under instructions from TPC

20625 Protection of Dead Section

The protection of a dead section is achieved by the following means:

(a) In the normal running direction, movements of trains are generally controlled by signals.
Protection is obtained by placing a "Red Warning Collar" on the signal lever controlling the
concerned signals, painted with inscription "Beware - No Voltage".

(b) If the points and signals are locally operated, they should be locked and the keys controlling the
lever or lever frames should be kept with the Station Master on duty. When the signal cabin or lever
frames are controlled electrically by a Station Master or a Cabin Assistant Station Master, the
Station Master or Cabin Assistant on duty shall place the warning collars on the relevant slides of
electric slide Instruments or on the relevant keys of electric transmitters or Interlocked key boxes.

This action must be taken by the Cabin Assistant may be, in respect of each and every movement
completion, confirmation should be given to the power block to be issued by the TPC.

Station Master or the Station Master, as the case prescribed in the Station Working Rules and after
Section Controller to enable him to agree for the

In a large yard several warning collars may be required. Sufficient number of warning collars should
be kept in each station/cabin. The exact number provided should be indicated in the corresponding
Station Working Rules.

(C) Once a warning collar is placed on the signal lever, it shad not be removed except after
exchange of messages with private member.

20626 Shunting Movement Towards Dead Section

1. In cases where no signal exists for controlling the entry of an electric Train Into the dead section,
the Station Master should arrange a hand stop signal to be exhibited at the point upto which alone
the electric locomotive is allowed to proceed.

If It is necessary for an electric locomotive to carry on shunting movement towards the dead section,
the red warning collar placed on a lever may be removed to permit the movement, provided that a
hand stop signal as above is exhibited and the Driver Is specifically instructed not to move the loco
beyond the point.

2. An example of this operation is given In Fig. 6.02. As per para 20625 the lever controlling the
signals should have "red warning collars" placed on them to give protection to the dead section.
However, If It Is essential to carry out a shunting operation with an electric locomotive situated at
point 'A' on the loop line to move lnto the main through the turn-out, this may be permitted provided
that the shunting movement is carried out only upto limiting mast 'P', short of the overlap span,
where a hand signal is to be exhibited to prevent all movements beyond the point 'P'.
3. Train or shunting movements by other than electric locomotives, I.e., by steam or diesel locos,
may be permitted to enter the dead section, provided that the Station Master ensures by personal
inspection that the Train formation does not include an electric locomotives or OHE Inspection Car
or EMU with pantograph raised. The 11 red warning collars" may be permitted to be removed to
allow such movements.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [137]

20628 Standard Forms for Power Block Messages

Typical forms for power block messages are attached at the end of this Chapter.

Form ETR. 1 This has 3 parts and is used for exchange of message between TPC and Section
controller when a power block is to be imposed or withdrawn. When TPC and the Section controller
are located in adjacent rooms, the messages will be made out in duplicate and sent to the other
party obtaining the acknowledgment of the receiving party on a carbon copy. When they are
located far apart, the messages K4U. be exchanged on phone, the receiver recording the message
on an identical form and repeating It for confirmation.

FormETR.2 Thishas3parts and is used for exchange of messages between TPC and the 'authorized
persons' taking shut downs. These messages will usually be conveyed on telephone, the receiver
recording the message on an identical form and repeating it for confirmation.

Form ETR.3 This has 4 parts and is used when an authorized person who has taken a power block
has to issue a permit-to-work". Messages in this form will invariable be made out in duplicate and
sent to the other party obtaining acknowledgment on the carbon copy.

Form ETR. 4 This has 3 parts and is used when local blocks are to be arranged. Messages in this
form also should invariably be written out and sent to the other party obtaining acknowledgment on
the carbon copy.

An message exchange over telephone should be supported with exchange of Private Numbers.

Form ETR. 1 Part A.

........... RAILWAY

POWER BLOCK MESSAGE FOR BLOCKING OF LINES FOR ELECTRIC TRACTION

PURPOSES

Serial No.
Date .....................................
Time Hr ................ Mts ............
From, To,
Traction Power Controller Section controller
at ........ ...................... Section
....................... ..(Place)
Block the following line/s to electric trains /all traffic from Hr. Mts. ................ on .............
and advise me when this has been done.
State below which line/s and between which limits (Sector, Sub-sector, Elementary Section, etc.) the block is
required.
...................................................................
..............................................................
The block is likely to last for ... Hr. Mts ...

Private No. .....................

Sent by ...........
Received by ......................

(Name) .............. (Name)

*Score out whichever is not applicable.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 139
Form ETR. 1
Part B
................... RAILWAY

POWER BLOCK MESSAGE FOR BLOCKING OF LINES FOR ELECTRIC TRACTION PURPOSES

Serial No. Date ........ ..................

Time Hr . .................. Mts ...................
From, To,
Section Controller Power Controller
at .............................
................(Place) at................................
Your No ........ ...............Of ...
The following line/s have been blocked to ' electric trains/all traffic: -
Line/s Duration
......................................... From Hr . ....................... .......... Mts .............................
.......................................... to Hr . ................................ Mts ....................

Particulars of line/s ........................... Reasons .............

.....................................................................................
..........................................................................
..........................................................................................
..............................................................................

Private No .........................

Sent by ..............................
(Name)

Received by ...........................
(Name)

Score out whichever is not applicable

Form ETR. 1 Part-C
........... RAILWAY
POWER BLOCK MESSAGE FOR BLOCKING OF LINES FOR ELECTRIC TRACTION PURPOSES

Serial No. Date ........ ..................

Time Hr . .................. Mts ...................
From, To,
Traction Power Controller Section Controller
at ............................. ...........................Section
............................(Place)
Your No............................................. of..............................................(date)
The following line/s have been made alive and the block imposed on these line/s may be cancelled:-

Private No .........................

Sent by ..............................

(Name)
Received by ...........................
(Name)

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 I- [140]

Form ETR-2
Part-A.
................... RAILWAY
SHUT DOWN NOTICE ON TRACTION OVERHEAD OR OTHER ELECTRICAL EQUIPMENT

Serial No. Date...............

Time Hr . .................... Mts...,

From, To, .........................................

Traction Power Controller
at ..................................... at .........................................

I hereby declare that the following electrical equipment/s has/ have been isolated. The equipment
shag be earthed according to standing instructions before commencing any work or prior to issue of
Permit-to-work :-

State below exactly which section/s (Sector, Sub-sector, Elementary Section, etc.) of the electrical
equipment has/ have been isolated -

Lines isolated Limits of isolation

.............................................. ..............................................

................ ............................. ..............................................

.............................................. ..............................................

Line/s to be cleared by Time

.............................. Date ........................ Hr ................. Mts

.................................... Date ..........................Hr ..................Mts

.... .............................. Date ..........................Hr ................. Mts

Private No .....................................

Sent by ........................................
(Name)
Received by ..................................
(Name)

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [141]

Form ETR-2
Part-B.
................... RAILWAY
SHUT DOWN NOTICE ON TRACTION OVERHEAD OR OTHER ELECTRICAL EQUIPMENT

Serial No. Date...............

Time Hr . .................... Mts...,

From, To,
.................................. Traction power controller,
at....................... at................................

Your No. .............................of ....................

Local earths have been applied at the following points:-

.......................Line earthed at structured Nos. .............

.......................Line earthed at structured Nos. ............

.......................Line earthed at structured Nos. .............

The following permit to work have been issued on the authority and I am responsible for the permit
to work:-

(1)....................................(2).............................................(3)...............................
Permit to work ........................................ ..................................................
.............................
Nos.
....................................... ............................................... ...............................
Date of issue ........................................ ...............................................
..............................
Time of issue ........................................ ................................................
.............................
Dept. Issued to .................................... .............................................
..............................
Person in-charge of ..................................... ..................................................
.............................
work

Private No..............................................
Sent by .............................................
(Name)
Received by ...........................................
(Name)

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME II PART I (142)

Form ETR-2
Part-C
................... RAILWAY

SHUT DOWN NOTICE ON TRACTION OVERHEAD OR OTHER ELECTRICAL EQUIPMENT

Serial No. Date........................
Time
Hr................Mts..................
From, ............................. To,
......................................... Traction Power Controller
at ....................................... at....................................
My No. ................ ........................................ of..................................................

1 hereby declare that the work on or near electrical equipment/s which has/have been isolated has
been completed. All men and materials have been withdrawn and the men have been warned that it
is no longer safe to work on or adjacent to electrical equipments. AN Permits-to-work issued by me
have been withdrawn and cancelled. All local earths have been removed, and the electrical
equipment/s can be made,alive.

Private No .........................
Sent by .............................
(Name)
Received by .......................
(Name)
Form ETR-3
Part-A.
.................. RAILWAY

PERMIT-TO-WORK ON OR NEAR AC TRACTION ELECTRICAL EQUIPMENT

Serial No. Date..................
From, .................................... To,
................................................ .....................................................
at .......................................... at....................................................
1 hereby declare that it safe to work on or near the following electrical equipment which is dead,
isolated from all live conductors and is connected to earth.

State below exactly the electrical equipment on or near to which it is safe to work. (Sector, Sub-
sector, Elementary Section, etc.)
.......................................................
......................................................

ALL OTHER PARTS ARE DANGEROUS.

The equipment shall not be alive until this Permit-to-work is returned duly signed by the person in-
charge of the work.

The No. of the Permit-to-work, date and time Issued has been intimated by me to Traction Power
Controller at ....................................................... at ................... Hr
............ Mts . ....................
. on ................................... (date).
Signature ................
(of the authorized person)

Name ...........................
Designation ..................
Date ............ Hr ............ Mts.......
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [143]
Form ETR-3
Part-D
.................................. RAILWAY

PERMIT-TO-WORK ON OR NEAR AC TRACTION ELECTRICAL EQUIPMENT

Serial No. Date.........................

From, To,
.............................................. ............................................
at........................................... at...............................................

1 hereby declare that the 'Permit-to-work' is cancelled and all local earths have been removed. The
cancellation of this 'Permit-to-work' has been Intimated to Traction Power Controller ..................
at ...... Hr ...... Mts ......

Signature ...............................
(of the authorized person)

Name................................
Designation........................

Date...............Hr.............Mts.......
Form ETR.4
Part A
................................. RAILWAY

LOCAL BLOCK

Serial No. Date

...................................
Hr ....................... Mts ............................
From, To,
Name ............ . ....................................... *Station Master/Yard Master
Designation .................................. ..........................................
The *Isolator number *at location number
*Interruptor number at Switching station
in ..................................................... Yard .........................................................
will be kept open and overhead equipment of elementary Section/s
No/s .................................................................. will be made dead and earthed.
The lines in the above elementary Section/s will not be available for electric stock/all traffic
movement from ................... hour until further advice

The block is likely to, last for ..........................Hrs.. ................................Mts ...

Signature
..................................
Copy to:- (1) Traction Power Controller Section Controller
(c) Section Controller

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 145

Form ETR.4
Part B
...........................................RAILWAY

LOCAL BLOCK

Serial No. Date .... ...

ACKNOWLEDGEMENT

Received Massage No...................................................from........................................ ..................

At......................................Hr.......................................Mts..........................................

................................................................

Signature of the station

Master/Yard Master

Place....................................................

Form ETR-4
Part C
................................. RAILWAY
LOCAL BLOCK

Serial No. Date

.....................Hr...............Mts............
From,

Name......................................... * Station Master/Yard

Master
Designation ..............................
............................................

My No .....................................................................
of......................................................................(date)

The *Interruptor number

*Isolator number opened by me has been closed and the overhead equipment of the
................................................... elementary Section/s. No./s .................................................... have
been made alive and are now available for *electric stock /all traffic movements.
Signature .................................................

Copy to :- (1) Traction Power Controller Section Controller.

(2) Section Controller

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [146]

 CHAPTER - VII

SIGNALLING & TELECOMMUNICATION AND PERMANENT WAY INSTALLATIONS IN

ELECTRIFIED SECTIONS

Para No. Subject

20700 Introduction

I. SIGNALS AND ASSOCIATED EQUIPMENT

20701 Effect of 25 kV Traction on S&T Equipment

20702 Types of Signals

20703 Locations of Signals

20704 Insulation of Wires and Point Rods

20705 Earthing of S&T Equipment

20706 Signalling & Telecommunication cables

20707 Block Instruments and Block circuits.

20708 Track Circuits

20709 Bonding in Track Circuited Zones

20710 Signalling and Inter-locking Circuits

II . TELECOMMUNICATION FACILITIES FOR AC TRACTION

20711 Telecommunication Circuits

20712 Principle of Tapping

20713 Power Supply Arrangement

III. PERMANENT WAY INSTALLATIONS

20714 Major Track Maintenance Works

20715 New Sections to be Electrified

INDIAN RAILWAYS - AC TRACTION MANUAI - VOLUME 11 PART 1 [147]

 CHAPTER-VII

SIGNALLING & TELECOMMNICATION AND PERMANENT WAY

INSTALLATIONS IN ELECTRIFIED SECTIONS

20700 Introduction

The important points concerning the signalling, telecommunication and permanent way installations
in electrified sections can be grouped as follow:
1. Signals and associated equipments
11. Telecommunication facilities for ac traction
111. Power supply for S&T installations
IV. Permanent way installations

Various aspects for the general information of electrical staff are covered in this chapter. The rules
are covered in the Indian Railways Telecom Manual for the S&T staff and in the Indian Railway
Permanent Way Manual for the civil engineering staff.

The safety rules applicable to the staff of S&T and civil engineering departments are given in
Chapter IV, Vol. 1 of this Manual.

1. SIGNALS AND ASSOCIATED EQUIPMENT

20701 Effects of 25 kV Traction on S&T Equipment

Any circuit in the vicinity of OHE for 25 kV ac 50 Hz signal phase traction system is influenced by
electrostatic and electromagnetic induction. The electrostatic induction is practically eliminated by
transferring S&T circuits into underground cables protected with metal sheath. The electromagnetic
induction causes currents and voltages to develop in metallic items parallel to the track. The items
include the rails, traction return conductor where provided, cable sheath and S&T circuits. The
voltages that occur in the metallic items appear as potential gradients. The value of induced voltage
depends on various factors such as:
a) length of parallelism between the cable and electrified track
b) soil conductivity
c) Screening efficiency of cable sheath where existing
d) return current through the rails and return conductor where provided.
e) mutual inductance between catenary and cable conductors
f) current carried by the OHE.
Appropriate precautions to overcome the effects of the induced voltage , therfore, have to be taken
by S & T department.

Other aspects where S&T equipment is affected are:

i) OHE masts and fittings may come in the way of visibility of signals to some extent and may come
in the way of signal.
ii) Restrictions in the path of traction currents on section provided with track circuits.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [148]

20702 Types of Signals
In the double line electrified sections, the signalling system shall generally be the colour light signal (CLS)
type. But the semaphore signals may be maintained on single line sections (Main or branch) which are taken
up for Railways Electrification.

20703 Locations of Signals

1. Signals are so located as to afford maximum visibility to drivers and the signal structures have to be clear
of ,the moving dimensions. In electrified sections, however, the signals should have the required electrical
clearance
of at least 2m from the live conductor. Detailed instructions on the location of signals have been issued by the
S&T Deptt.

2. Where a signal post or its fittings have to be located within 2 m of live OHE, a screen of wore mesh of
approved design solidly connected with the structural work shall be provided between the signal post and the
OHE for protection of staff. Provision of such a screen is mandatory where non-technical staff like lamp-man
are required to climb up signal posts. The protection screen is not necessary when only the technical
personnel, such as inspectors and maintainers of the S&T Deptt. are authorised to work on the signals. When
a screen is not provided for any reasons, a caution board of approved design shall be provided on the signal
post on the side facing the ladder at a height of 3 m above the rail level to caution such staff.

3. Technical personnel shall exercise particular care to protect themselves while working on signal posts not
provided with protective screens. If there is any likelihood of any part of their tools or equipment coming within
2 m of live equipment, they shall take a power block as detailed in Chapter Vi. The same precautions are also
required in the vicinity of return conductors, which should be treated as live. '

4. To ensure maximum visibility of signals to the drivers, signal Posts should be located on the side opposite
to that of traction masts as for as possible. Where this is not possible as in double line sections and station
yards, the following steps are taken to achieve maximum visibility from the Driver's normal position in the
driving cab.

i) The distance between the signal post and the traction mast shall be as large as possible. In case the
traction mast is located in front of the signal post the distance between the traction mast and signal post
should not be less than 30m. No traction mast shall be located beyond the signal post at a distance less than
10m.

ii) The signal post should be sufficiently high so as to be seen clearly.

111) For deciding setting of mast near signals, para 20.5 of Appendix may be referred to.

iv) On curved tracks or in areas where other obstructions such as buildings, trees, etc. exist the site is
individually examined for deciding the most appropriate location of the signal.

V) In all cases a "Signal Siting Committee" which includes a representative of the Electrical Department
should be constituted to examine the visibility of the signal before finally deciding its location and height.

20704 insulation of Wires and Point Rods

Normally wires and point rods would be eliminated in the signalling system in ac electrified section. However,
where these exist, the wire transmission as well as point rods in ac electrified areas are subject to induced
voltage which could reach high values when an OHE fault occurs. This induced voltage or rail voltage is
transmitted through the wires and point rods to the lever frame. Insulators are therefore, provided on the wires
and point rods for insulating them from rail potentials and induced voltages, in accordance with detailed
instructions on the subject laid down in Chapter XXII of Indian Railway Signal Engineering Manual issued by
S&T Department.
INDIAN RAILWAYS - TRACTION MANUAL VOLUME 11 PART [149]
20705 Earthing of S&T Equipment
Earthing of the following equipment is essential on sections electrified with 25 kV ac 50 Hz single
phase system the earthing being done in accordance with prescribed instructions.
a) Signal posts provided with protective wire-mesh screens .
b) The lever frames and other metallic parts of the cabin in contact with, the lever frame, (This
includes rail stagings wherever they are used. Where the electrical conductivity of the,joints of the
rail staging is doubtful the members are to be bonded at the joints.)
c) Metallic sheaths wherever applicable and armouring of all underground cables. The earthing of
the sheath and armouring of main cables at either end is a matter of paramount importance
because unless the cables are earthed properly at both ends it will not be possible to obtain the
screening effect of the cable from induced voltages.
d)Block instruments working on earth return through the respective block filters.
e) All telecommunication equipment.
f)The surge arresters provided in block filters as well as those provided for telecommunication
equipment
in switching stations.

The telecommunication equipment may be connected to the same earth as the lever frames. Surge
arresters may be connected to the earth for the cable sheath. In all other cases separate earths
shall be provided. The resistance of an earth shall not exceed 10 ohms.

20706 Signalling & Telecommunication Cables

The main S & T cable in ac electrified sections are usually of the PVC insulated, screened and
armoured type to IRS Specification No.,S-35. These cables are laid in accordance with instructions
issued by the S & T Department. Instructions which are likely to affect traction installations are given
below
(i) The cable is laid so that it is not less than lm from the nearest edge of the traction mast
foundation provided that the depth of the cable does not exceed 0.5 m. When the cable is laid at a
depth greater than 0.5 m a minimum distance of 3 m shall be maintained between the cable and the
nearest edge of the traction mast foundation. If it is difficult to maintain these distances the cable
shall be laid in concrete pipes for distance of 3m on either side from the mast. When so laid the
distance between the cable and foundation may be reduced to 0.5m. These precautions are
necessary to avoid damage to the cable in the event of the failure of an overhead insulator.
(ii) In the vicinity of traction substations and feeding posts, the cable shall be laid at least lm away
from any metallic parts of the OHE and other equipment at the sub-station/ feeding post as well as
from the substation earthing system. In addition, the cables shall be laid in concrete pipes for a
length of 300m on either side of the feeding post . As far as possible the cable shall be laid on the
side of the track opposite to the feeding post.
(111) In the vicinity of switching stations, the cable shall be laid in the ground at least lm away from
any metallic structure of the switching station and at least 5m away from the station earthing
system. The distance of 5 m can be reduced to lm provided the cable are laid in concrete pipes.
(iv) Where an independent earth is provided for an OHE mast/ structure i.e., where the mast is
connected to a separate earth instead of being connected to the rail, the cables shall he laid 'at least
one metre away from the earth.
v) Where there are traction masts/structures along the cable route, the cable shall be laid in the
trench which should be as far as possible but not less than 5.50 m from the centre of the track.
(vi) Where cables have to cross the track, concrete or GI pipes must be used for the crossing. The
use of GI pipes or a form of metallic pipes is prohibited within a distance of 300m from the feeding
post. Similarly galvanized iron metallic pipes are prohibited in close proximity to switching station
earths or traction masts.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOI UME 11 PART [150]
20707 Block Instruments and Block Circuits

On replacement of overhead communication lines with cables, block instruments working with
overhead lines with earth return are transferred to special PVC insulated quads in the underground
cables. Special protective devices are provided at both ends of block circuits for protection of the
instruments as well as the operating staff.

20708 Track Circuits

Any of the following types of track circuits may be used on ac electrified sections :-

i)dc single rail track circuits.

ii) ac track circuits working at a frequency other than 50 Hz so as to be unaffected by the latter.

iii) Voice frequency and other forms of electronic track circuits.

The track circuits of (ii) and (iii) above may be either the double rail type or the single rail type.

20709 Bonding in Track Circuited Zones

The track bonding for the passage of traction current requires modifications in the track circuited
zones. Appendix 11 may be referred to in this regard.

20710 Signalling and Inter-locking Circuits

In view of the high level of electromagnetic and electrostatic induction in overhead lines, all
overhead lines used for signalling and inter locking circuits in ac electrified sections have been
replaced by underground cables. The replaced lines, if not dismantled before energization of the
OHE, shall be cut into sections and earthed at several places.

The length of a circuit in a cable shall be such that the induced voltage in the circuit does not
exceed 120 volts (corresponding to a parallelism of 3.5 km). If for any reason parallelism of a circuit
exceeds 3. 5 km, a relay is inserted in the circuit so that the physical continuity of the cable is
broken and the parallelism of each portion is reduced to less than 3.5 km. If the parallelism in
excess of 3.5 km is due to feeding two circuits from a common battery or power supply source,
separate batteries are provided to feed the circuit on each side so as to limit the parallelism to less
than 3.5 km.
11. TELECOMMUNICATION FACILITIES FOR ac TRACTION
20711 Telecommunication Circuits

The telecommunication facilities provided in electrified sections have been detailed in

Chapter 11 of Volume

On ac electrified sections all overhead telecommunication lines running parallel to the track have to
be replaced by underground cables. When the induced voltage in the cable is expected to exceed
60 volts; way station and subscriber's equipment, exchanges are protected from the induced voltage
by providing isolating transformers. When transformers are provided it will not be possible to
transfer dc. circuits such as CB and auto telephones, dc telegraph circuits etc. , into the cable.

The attenuation of speech in an overhead line of 56.S kg per km copper is approxirnateiyO.039 dB

per km whereas the attenuation in an underground long distance cable is approximately 0. 22 dB
per km. The telecommunication circuits are therefore subject to about five times the attenuation
when transferred to underground cables and consequently repeaters are required for these circuits
at intervals of about 50 to 6'0 km for satisfactory working. Where the cables are laid by the DOT all
repeaters and isolating transformers are provided by them.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 51
20712 Principles of Tapping

Traction Power centre, Traction loco Control and emergency telephone circuits are specifically
installed for electric traction. Control regarding utilization of these circuits rests with the Chief
Electrical Engineer. All tappings of these
circuits will, therefore, be provided with the specific approval of CEE. Adequate capacities on all
these circuits shall be provided taking into account future requirements. Usually the following
tappings are provided:

1. Traction Power Control Circuit

(1) Traction Power Control of the adjoining Remote Control Centres,
(ii) All switching stations,
(iii) All railway traction sub-stations,
(iv) All grid sub-stations,
(v) Central repair shop,
(vi) All OHE, PSI and RC maintenance depots,
(vii) ofices of all Station Masters/ ASMS,
(viii) Offices of Yard Master who control movement of trains,
(ix) Offices and residences of Traction Distribution officers,
(x) Residences of CTFO, TFO/ATFO of OHE, PSI, Substation, RC maintenance depots.

2. Traction Loco Control Circuit,

(i) All electric loco sheds,
(ii) All electric loco stabling sidings,
(iii) Offices of Station Masters of originating, and junction stations,
(iv) Offices of Yard Masters of large yards,
(v) Office of CTFR and TFR,
(vi) Offices and residences of Rolling Stock officers,
(vii) Residences of CTFO(RS), TFO(RS), CTFR and TFR provided their residences are more than
500rn from their offices and no other telephone facilities exist at their residences.

3. Emergency Control Circuit

(1). At regular intervals along side the track not exceeding l km of running track.
(ii) At all traction sub-stations, switching stations, and maintenance depots.
(iii) Near booster transformer locations and Isolator switches provided for isolation of OHE.

If the distance between two successive emergency telephone sockets determined as above is less
than 100 m, only one socket shall be provided, at such locations.

However, in large yards having more than four tracks which are likely to be occupied most of the
time, an additional emergency socket may be provided on the opposite side of the yard near an
isolator provided for isolation of traction OHE.

Where the transverse distance between two tracks involves walking of more than 300 m, separate
tapping shall 1 be provided for each individual track. If not already done, this circuit should also be
extended to the TLC to enable him to guide loco/EMU crew in the event of failures enroute

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [152]

3. Railway's local telephone
(1) Remote Control Centre,
(ii) Traction Loco Controller,
(iii) Traction Power Controller,
(1v) Offices and residences of all officers of Traction Distribution and Rolling Stock - operation and
maintenance
(v) Offices and residence of CTFO & TFO(RS) and CTFR & TFR,
(vi) Office and residence of CTFO and ATFO of OHE, PSI and RC maintenance depots,
(vii) Office and residence of ELC of sub-depot,
(viii) SEB's Grid Substation, if feasible.

5. P & T Telephones
(I) Remote Control Center,
ii) All Traction sub-stations,
iii) Offices and residences of SR.DEE & DEE(TrD), SR.DEE & DEE(RS), SR.DEE & DEE(RSO),
AEE(TrD), AEE(RS) and AEE(RSO).

20713 Power Supply Arrangement

1. To ensure reliability of ac 24OV, ac 50 Hz signle phase power supply a 25 kV/24OV auxiliary
transformer shall be connected to 25 kV OHE.

(a) At a station where a reliable local power is available, the main supply is taken from this source.
The stand-by supply is obtained by tapping the 25 kV catenary and installing a 25 kV/240 V auxiliary
transformer.

(b) At stations where no reliable local supply is available, the main and stand-by power supplies are
obtained by installing two 25kV/240 V auxiliary transformers, each connected to independent sub-
sectors of the OHE.

(C) At stations where an auxiliary transformer is installed at a traction switching post situated within
350 m of the signal cabin or the station building 240 V supply from the auxiliary transformer is
treated as the main supply and a second 2SkV/24OV transformer is installed on another sub-sector
for giving the stand-by supply.

2. Following works shall be carried out by the Electrical Department:

(i) At each way side station, 2 nos. Auxiliary Transformers, one each connected to OHE of UP & DN
lines shall be provided. A 2 x 25 MM2 . aluminium cable shall be laid from each AT to ASM's room
and shall be terminated at the CLS supply panel. Local supply, if available, shall also be terminated
at the panel as third source. A manual three-position change-over switch shall be provided on the
CLS supply panel. The CLS panel shall be provided with MCBs and neon indication lamps for the
incoming and outgoing supplies, Change-over shall be effected by ASM on duty.From the CLS
supply panel ,power supply will be extended to either cabin by S & T department through 2x25 mm2
aluminium cables.

(ii) At big yards, where a number of cabins are located, 2 to 3 cabins shall be grouped together and
a set of two ATs, one each connected to OHE of UP & DN lines shall be provided at a convenient
location to feed each such group. CLS supply panel having a three-position manual changeover
switch shall be provided at one of the cabins by the Electrical Department, from where the supply
shall be extended by S&T department to other cabins.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [153]
 (iii)Provision of 2 nos. Auxiliary Transformers, one each connected to OHE of UP & DN lines, shall
be arranged at each level crossing located more than 2 km away from the Railway station. If any
other level crossings are located within 2 km of the level crossing where a set of ATs have been
provided, then supply from the same ATs shall be extended to these level crossing through 2 x 25
MM2. Aluminium cable to be laid by S & T Deptt. The CLS supply cable alongwith manual change-
over switch shall be provided at the gate lodge. Change-over shall be effected by the Gateman on
duty.
(iv) In case of IBH, separate set of AT s shall be provided. As IBHs are unmanned, a two-position
automatic change-over switch shall be provided.
(v) In single line sections, one AT connected to the OHE will be provided for supply to CLS. The LT
supply will be extended from the AT to ASM's ,room by means of 2 x 25 MM2. aluminium cable
terminated at the CLS supply panel. Local power supply, if available, will also be connected to this
panel, which will be provided with a change-over switch. This arrangement will be adopted for the
way side stations, level crossings beyond 2 km. from the nearest Railway Station and at the IBHS.
(vi) At way-side electrified stations, where local supply is prone to prolonged interruptions, an
emergency light point shall be provided in ASM's room and in each cabin from the AT supply,
through a separate circuit protected by a fuse of proper rating. At non-electrified stations, a separate
lighting circuit shall be provided in ASM's room and in each cabin from the AT supply. From the
lighting circuit in the ASM's room, one light point each in ASM's room, on the platform outside the
station building, at the ticket window/waiting hall and in the cable hut shall be provided. On the
lighting circuit at the cabins, one light point each in the cabin, relay room, battery room and cabin
basement shall be provided.
(vii) All the power supply installations provided by the Electrical department,as detailed in paras (1)
to (vi) above, will be maintained by the Electrical department.

3. Following works shall be carried out by the S&T department

(i) A 2 x 25 mm2 aluminium cable will be laid from the ASM's room to each cabin alongwith the
signal control cables in the same trench. An integrated power cubicles including a voltage stabilizer,
inverter and battery chargers will be provided in the relay room for signal and relay supplies. A 240
V ac outlet from this power pack will be made available to Electrical Department for provision of light
points. Similar arrangements will be made at each level crossing and IBH.

(ii) An 80 Ah battery capacity, sufficient to cater for two hours failure of supply, will be provided at
each, cabin and level crossing. One extra 80 Ah battery set shall be provided temporarily at these
points until AT supply becomes available. At IBH 200 Ah battery capacity may be provided to cater
for four hours failure of supply.
(iii) At large yards, two standby diesel generating sets of 1 0 kVA rating each will be -provided for
standby power supply to the signalling installations. The supply from these generators will be
brought to the CLS supply panel in the ASM's room or in the cabin, where a change-over switch will
be provided by the S&T Deptt. to enable the ASM/Cabinman to affect the change-over supply from
the normal mode to the generator mode. A push-button control will also be provided in the ASM's
room/cabin to enable the ASM to start/stop standby diesel generator whenever required.
(iv) On sections where automatic block is planned, S&T will lay a power cable all along the section
with suitable feeding arrangements- to suit local conditions.
(V) At station where telecom repeater stations are located, a 2 x 25 MM2 aluminium cable will be
laid from the CLS supply panel in the ASM's room to the repeater station to avail AT supply to work
battery chargers and repeater equipments in the 'event of failure of local supply. Electrical
Department will provide a change-over switch at the repeater station between AT supply and local
supply. An emergency light point shall also be provided at Repeater stations by Electrical
Department from the AT supply.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 11 PART [154]

2. In the event of power block being given on both the OHE sub-sectors from which the signal
supply is derived, electric traffic would necessarily have to be suspended on the line. During such
periods, colour light signalling will not also be in operation. Such cases are likely to arise very rarely
at any station and the duration of the block is not like to exceed one hour at a time. Therefore, no
additional power supply arrangement need be made by the Electrical Department at wayside
stations. However, to cater for this condition, portable stand-by sets should be kept by the S&T
Department to be operated until 25 kV supply is restored. At large stations with considerable
shunting movements, a stand-by diesel generator set may be installed by the S&T Department to
meet emergencies, If considered essential.

111. PERMANENT WAY INSTALLATIONS

20714 Major Track Maintenance Works

1. An authorised OHE staff should invariably be present, when relaying work or any major work on
track is carried out, In order to ensure the following points:

(i) Power block is correctly taken and permit to work is issued;

(ii) The structure bonds, track bonds, cross bonds, longitudinal rail bonds etc. are not disturbed and
if disconnected for the work, they are reconnected properly when the work is completed.

(iii) The return feeder connections to the rails at the feeding posts are proper and not disturbed.

(IV) The setting distance of the structure is not affected during slewing

(V) The track level is not raised beyond the permissible limits during the work;

(Vi) Excavation or digging near a mast foundation is done in such a manner that the foundation is
not exposed;

(Vii) The clearance particularly at overline structure is maintained to the required standards;

(viii) Precautions for the safety of staff working under the OHE are taken correctly.

The Engineering officials in charge of such major work shall ensure that intimation to their
counterparts for OHE maintenance work is given with adequate notice.

20715 New Sections to be Electrified

Engineering staff working in section being electrified should be specially trained and instructed in
regard to working
in electrified sections well in time (Para 20972).

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART (155)

 CHAPTER VIII
BREAKDOWNS

1. GENERAL

20800 Knowledge of Rules

All Officers and Supervisors of the Traction Branch should be fully conversant with the "Rules for
Reporting Accidents" and other instructions in force for dealing with accidents and breakdowns. The
instructions given in the following paragraphs are to be treated as supplementary instructions
applicable specifically to traction installations; they should not be taken as nullifying or contradicting
the instructions contained in other official manuals.

Electrical accidents are dealt with in the Volume

20801 Types of Breakdowns

The types of break-downs pertaining to electric traction can be broadly divided into the following
categories:-

1 Sub-stations and switching stations

2Remote control equipment and cables

3 OHE feeder lines and transmission lines

20802 Breakdown Gangs

Accidents and breakdowns involving traction installations and electric rolling-stock should normally
be attended to by-the maintenance gangs themselves. It is, however, essential that adequate
number of experienced traction staff should be selected and housed in railway quarters close to
traction installations, so that their services can be utilized at short notice for dealing with
breakdowns and accidents whenever required.

In electrified suburban sections, however, 'breakdown gangs' of adequate strength may he located
at selected points to deal promptly with OHE failures, particularly during the hours of peak traffic.

20803 Emergency Stores and Breakdown Equipment

1. For each OHE depot/sub-depot, the actual quantity of OHE stores like masts, conductors,
insulators, fittings etc. which should be earmarked specially for use in breakdowns will be laid down
by Sr. DEE (TrD). To start with, all materials required for 3 kilometres of single line may be kept.
Based on experience, the minimum and maximum quantities may be, revised from time to time. An
inventory of such OHE stores should be maintained by the supervisor-in-charge of the depot/sub-
depot and stocks recouped periodically so as to ensure that the minimum quantity is always
available. During periodic inspections by officers, scrutiny of this inventory should be one of the
important items in order that the required stores are always made available.

2. OHE Inspection Cars, wiring trains, breakdown lorries and all break-down tools, tackles,
straining screws, clamps, ladders etc. shall be maintained in good condition and kept ready for use
at all times. Though it will be the primary responsibility of the supervisor in-charge of the OHE
depot/sub-depot to ensure that all breakdown equipment is in good working order, supervisors and
officers at all levels should specially check their condition during their periodical inspections. A
periodic review should also be made regarding the adequacy of such spares and tools.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 (158)

3. The CTFO (PSI) and CTFO (RC) should also have in their custody spares and tools pertaining
to their work as per scale to be laid down by Sr. DEE (TrD) for dealing with breakdowns and
accidents.

20804 Record of Staff Movements

TPC should, even when everything is normal, keep a continuous record of the movements of
maintenance gangs so that he can contact the gangs immediately whenever required to attend to
any emergency. All senior supervisors and officers of the Traction Distribution Branch should also
keep the TPC informed of their movements. These Instructions also apply to off-duty hours for
officers, senior supervisors and key personnel.

20805 Summoning of Emergency Staff

To enable the TPC to summon staff as required, a register showing the residential addresses of
specified staff of the Traction Distribution branch, particularly those residing in railway quarters or
close to railway stations, should be maintained station-wise by TPC. The list of office and residential
telephone numbers of officers and supervisors should also be kept up-to-date by him for ready
reference. In view of the importance of communication facilities in an emergency every telephone
should be tested at least once a month.

11. SUB-STATION AND SWITCHING STATION BREAK-DOWNS

20806 Traction Transformer Breakdowns

Breakdown of any one traction transformer or associated circuit breaker at a traction sub-station
(whether owned by the Supply Authority or the Railway) should not normally affect the working since
100% stand-by is available for the transformer at nearly all sub-stations.

20807 Central Repair Shop

Failure of traction transformers, requiring the lifting of core and winding are extremely rare.
However, repair and overhaul facilities should be provided at a central point on each railway. At
each Central Repair Shop, the following facilities are generally required (Reference may also be
made to the Appendix VI to this Volume):

1. A crane bay with the railway line leading into it, so that the traction transformer may be brought
in directly into it. The crane hook should be high enough to permit unloading of the transformer from
the wagons and placing on the floor, and also for lifting the core out of the transformer tank.

2. Two underground transformer oil storage tanks, one for old oil and one for new oil.
3 A 2500 litre/hour, electrically driven oil purification plant with pumps and interconnecting pipes and
valves to empty old oil from transformers, to fill new, purified oil into the transformers, to dry out the
oil in the transformers etc., as required.

4. An enclosure with oil testing set to test dielectric strength of oil.

5. A small workshop with a few essential machines to carry out urgent repair work.

6. A test-room and laboratory fully equipped with testing equipment for carrying out repair,
calibration and testing of all types of relays and instruments used on the traction system.

20808 Mobile Power Van

A mobile power van should also be provided on each railway which has to maintain traction
transformers. On this the following equipment should be provided:

1. -*An engine-generator set rated to deliver 100 kVA at 415 ac 50 Hz, 3-phase 4-wiree along With
necessary
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 159
oil storage tanks.
2. A 2500 litres/hour electrically driven oil purification Plant.
3. A small mobile, workshop to attend to urgent on-the-spot repair work, comprising a motor driven
drilling machine, grinding machine, a power driven hacksaw, a welding machine and oxyacetylene
flame cutting equipment.
4. Portable floodlights with trailing cables to light up accident sites to facilitate repair work.

The mobile van can be used for purifying transformer oil of traction transformers in situ when
required, eliminating the need for bringing the transformers to the Central Repair Shop. At stations
where no 3-phage, 4 1 5 V supply is available from a nearby source, the engine set is operated to
meet the heater load of the oil purification plant and also to drive the motors. The mobile van would
also be useful to flood-light an area such as when there is an extensive OHE breakdown.

20809 Breakdown of Circuit Breakers, Interruptors

If a circuit breaker or interrupter requires major repairs, it should be brought to the PSl maintenance
depot after replacing it by a spare one.

20810 Rail and Road Access

Every traction sub-station should have all-weather road access in addition to rail access for
transporting heavy equipment to and from the installations. For switching stations too, road access
should be provided wherever possible. Suitable fittings and tackle should be available to move an
Interrupter or circuit breaker from the PSI maintenance depot on a motor trolley or OHE Inspection
Car and unload it by the side of any switching station and take it in. A suitable platform and a firm
pathway leading to the gate should be available and maintained well.

111. BREAKDOWNS OF REMOTE, CONTROL EQUIPMENT

20811 Procedure for Manning Sub-Stations And Switching Stations

1. Whenever Remote Control working is not possible due to any fault on the P & T cable or in the
remote control equipment concerned or failure of the battery etc. CTFO (RC) or TPC shall suspend
remote control operation of the particular section or switching station concerned until the defect is
rectified. During this period it is necessary to arrange for manning the switching stations by posting
suitably qualified staff, who are authorized to carry out emergency switching operations manually as
instructed by TPC. Such staff will be referred to as 'Operator' in the following paragraphs. To meet
such emergencies, TPC shall maintain a register of authorized operators, who have been trained,
examined and declared by AEE (TRD) as competent.

2. Whenever an operator is placed on duty at a switching post when the remote control equipment
is not functioning due to any reason, the following instructions shall be adhered to:-
(a) Before taking over his duty, the Operator shall make himself conversant with the equipment he
is required to operate and the rules that are laid down by the Administration for operation of the
equipment.
(b) He shall carry out orders issued to him by TPC over the telephones observing the rules laid
down for exchange of telephone messages.
(C) He shall maintain a log book showing the details of operations carried out by him in the order
in which they were done, interruption to power supply, abnormal occurrences, defects in plant
requiring attention, and other information if any. The log will be signed by both the relieving and
relieved Operators at every change of shift as a token of having taken over and handed over all
equipment correctly.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME ii PART [160]

 (d) The Operator shall be responsible for all the plant and equipment, spare parts, stores and
furniture (at the sub-station or switching station) during his shift,

(e)Whenever a switching station is manned, the Operators shall work in accordance with the duty
rosters exhibited. The regulation of the shifts shall be effected by TPC.

(f)The operator on shift duty is forbidden to leave the post station unless he is relieved by an
authorised person .No interchange of duties or variation of duty hours is permitted without the prior
permission of TPC and staff who are unable from any cause to take their shift shall at once notify

(g) Whenever an Operator is posted at a switching station or sub-station he shall always be

accompanied by another person e.g., a Khalasi, who can use the telephone intelligently.

20812 Restoration of Remote Control

CTFO (RC) shall arrange for expeditious rectification of the defect and restoration of remote control.
It is undesirable to continue any controlled post on local control for prolonged periods.

20813 Breakdown of Tele-Communication Between TPC and Sub-Stations, Switching

Stations etc.

If the TPC circuit becomes defective for any reason, several alternative channels of
telecommunication are available. Should the P & T cable it self breakdown all circuits through it may
be in operative in such cases , essential messages may be passed through P & T telephones,
Railway local telephones network , Railway wireless network or microwave network.Urgent
messages from TPC to traction sub stations could also be passed through the operators of grid sub
stations.
Close co-ordination should be maintained between the officials of the Traction Distribution Branch,
S&T branch and DOT authorities to ensure quick restoration of normal communication facilities.

IV. OHE BREAKDOWNS

20814 Importance of Expeditious Repairs

Every breakdown of OHE , even if minor in nature , should be attended to urgently as it is generally
interferes with traffic. Since electrified lines carry a high density of traffic , the effect on traffic will be
quite severe if restoration is not arranged expeditiously.

20815 Types of OHE Breakdowns

The common types of OHE breakdowns are as under-

1. Uprooting of or damage to OHE masts on account of cyclone, derailments etc.,
2. Entanglement of pantographs with the OHE,
3. Snapping of OHE- conductors,
4. Flash-over or other damage to insulators,
5. Faults on account of stray wires etc.,
6. Theft of OHE conductors.

20816 Look-out for OHE Defects

The engine crew of all trains should keep a sharp look-out and report to the TPC from the nearest
station any defects noticed by them in the OHE.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [161]
All break-downs or defects in OHE which are likely to affect the train services, noticed by any
Railway servant, shall be reported immediately to TPC. If TPC cannot be contacted, the nearest
Station Master or Cabin Assistant Station Master shall be advised' The SM/CASM to whom such
breakdowns or defects are reported shall convey the information immediately to TPC through the
control or other available telephone. The person reporting a breakdown to TPC should give as
detailed Information as possible on the nature of the breakdown, its location, if masts have been
uprooted or both lines in a double track section have been affected etc.

The person conveying the information to TPC should not leave the vicinity of the telephone without
TPC's permission, as the latter may want to contact him again to elicit further information.

20817 Action to be taken by TPC

If required, TPC shall direct the nearest available Electrical Department official to proceed to site to
obtain full details. Simultaneously the TPC should switch off power supply to the affected lines and
inform the Section Controller.

Though initially power may have to be switched off over a whole sub-sector, the faulty elementary
section should be identified and isolated as quickly as possible so that power supply may be
restored to the healthy sections and. normal train operation resumed.

Further, it should be possible in many cases to block the lines for electric locos and EMUs only,
permitting movement of steam and diesel trains. It may also be possible to move electric locos and
EMUs at restricted speed or to coast through the affected section with pantographs lowered if the
damage is only slight. It is for TPC to decide after careful study of information available from the site
and In consultation with traffic officials the extent of restriction to be imposed on, traffic.

20818 Protective Steps

1. On receipt of information about OHE break-down, the SM/Section Controller shall also take such
steps as deemed necessary to regulate traffic on the affected lines and issue caution order where
required. Single line working may be introduced, if feasible.

2. It is the duty of every railway servant who notices hanging OHE conductors to take immediate
preventive steps to ensure that no person comes into contact with them treating such conductors as
live until an authorized person from OHE section arrives at site and makes the OHE dead and earth
it.
20819 Breakdown Staff
1. On receipt of the first report about the breakdown, TPC shall direct the nearest OHE
maintenance gang to proceed to site immediately with available breakdown vehicles for dispatch of
staff without waiting for full details of the breakdown.

2. A quick assessment should be made on the basis of information available and where necessary
one or more gangs from both sides of the site may be asked to proceed to the site. If the accident
spot cannot be reached by railway vehicles on account of the line being blocked by other trains,
road vehicles equipped with emergency stores, tools and staff may be directed to the site. In sub-
urban sections with large number of roads running along side the track, this method may help in
tackling the repairs much more quickly.

3. If the OHE Inspection Car or wiring train is required to attend to the break-down, the Section
Controller, on request from TPC shall arrange for quick passage of the OHE Inspection Car or
wiring train to the site of the accident.

20820 Officers and supervisors to Proceed to Site

On receipt of information about an OHE breakdown the ATFO(OHE),
CTFO(OHE),DEE/AEE(TrD) shall
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [162]
Proceed by quickest available means to the scene of accident. The Sr. DEE(TRD) should also
proceed to the site if the circumstances of the case require his personal supervision and direction. In
the event of a major break-down likely to result in interruption of traffic for more than 12 h, CEDE
should also proceed to the site for supervising restoration.
20821 Assistance to be sought
1. It should be remembered that restoration of traffic in the event of accident or breakdown is the
responsibility of the Division as a whole. The Electrical Department Officer in-charge of the
restoration work should, wherever required, ask for assistance from the Engineering, Traffic or other
Officers as necessary. He should also keep the DRM fully posted with arrangements made and the
expected time of restoration.

2. When circumstances warrant, the assistance of OHE gangs of another contiguous Division may
be sought for by contacting AEE(TRD) or Sr.DEE/DEE(TRD) of the Division concerned. The
Officers who receive such requests from neighboring divisions should treat the matter as of utmost
importance and render all possible assistance.

20822 Continuous Communication with TPC

The Officer or Supervisor in-charge of supervising repair work should maintain continuous
communication with the TFIC from the site of breakdown. For this purpose an intelligent person
should be posted to man the nearest emergency telephone socket continuously to transmit and
receive messages as required. It is very important that the field staff remains on call all the time until
normal service is restored, since no provision exists in the emergency telephone circuit for the TPC
to ring up the emergency telephone stations at the site.

20823 Detailed Assessment by the First Supervisor/Officer Reaching Site

The first Supervisor or Officer of the Traction Branch reaching the site of the breakdown should
make a quick assessment of the extent of damage and the time required for restoration. He will
ascertain from TPC the details of break-down gangs and equipment directed to the site and if the
circumstances warrant, ask for additional gangs and breakdown equipment to be sent to the site.
On receipt of these details, TPC should arrange for additional gangs and equipment to be sent to
the site expeditiously. In the meanwhile, isolation and repair works should be started at site.

Further details on the extent of damage and estimated time as obtained from the Supervisor/Officer
at the site from time to time will be passed on from TPC to the Section Controller to enable him to
review the arrangement for regulating the traffic initially made.

In the event of major breakdowns affecting main line traffic, Sr. DOM/DOM of the Division should
personally take over regulation of traffic arrangements.

20824 Preservation of Evidence

When a pantograph gets entangled with the OHE, it is often very difficult to establish whether the
damage originated from a faulty pantograph or a defect on the OHE.

The first Officer or Supervisor of the Electrical Department arriving at site of a breakdown
particularly those involving entanglement of pantographs with the OHE, should make a very careful
note of all relevant details pertaining to the breakdown and also prepare a sketch indicating the
particulars. He will also arranges for preservation of such evidence as may be useful subsequently
for investigating the cause of the breakdown.

Items to be checked on the pantograph and OHE are indicated in the Annexure 8.01 and 8.02.
20825 Safety Rules to be Observed
While speed is the essence of emergency working, rules prescribed for safe working shall never be
infringed.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME 11 PART [163]

Repair work may commence only after an emergency power block has been obtained and all other
precautions necessary for protection of the staff taken. On completion of the repair work, the power
block may be cancelled according to the prescribed procedure.
20826 Temporary Repairs for Restoration of Traffic
In the first instance, repairs to the OHE should be kept to the barest minimum necessary for
restoration of traffic with least possible delay. Work must proceed simultaneously at many points.
After effecting temporary repairs, the Officer or Supervisor in-charge of the work should personally
check the whole area and satisfy himself that the Installations are in order and safe. He may impose
such speed restriction as necessary for movement of electric and other than electric trains till
permanent repairs are carried out. Permanent repairs should be arranged and speed restrictions
removed and normal operation restored at the earliest opportunity. -

20827 Clearance of Line for Steam/Diesel Traction

If the breakdown is extensive and restoration of electric traction is unlikely in a short time even with
temporary repairs, the line should be cleared for diesel/steam traction as soon as possible, so that
traffic may be kept moving until repairs to the OHE are completed. After steam/diesel traction is
introduced full precautions should be taken for protection of staff working at site.

20828 Wring Train

If the OHE has suffered extensive damage, the OHE wring train should be requisitioned to speed up
the work.

The wiring train generally consists of a stores-cum-tool van, a workshop van, a staff and kitchen
van, a reel wagon loaded with one drum of catenary wire and one drum of contact wire, wagon
loaded with materials for temporary diversions, a BFR loaded with structures, a hand-operated
crane to facilitate erection of masts, a power car with two diesel generator sets for supplying power
to the workshop van and for lighting, two brake vans, an adequate quantity of OHE material and
flood-lights with trailing cables. The vans have platforms with side-railings to facilitate working on the
roof.

20829 Interference with OHE During Restoration

In clearing the line for traffic, breakdown staff are forbidden to disturb the OHE masts or to cut the
OHE conductors except under the specific orders of Sr. DEE(TrD)/DEE(TrD). If it becomes
necessary to slew the OHE conductors to facilitate crane working, this should be arranged to be
done by the Electrical Department staff. It should be borne in mind that indiscriminate cutting of
OHE conductors will necessitate Introduction of splices which are not conducive to good current
collection. Also introduction of such splices is liable to delay restoration of normal electric services.

20830 Temporary Diversions

Sometimes with derailments and accidents occurring in electrified sections, temporary diversions
have to be laid to clear the traffic with other than electric traction. A quick means of wiring such
diversions so as to resume electric traction without waiting for the main line to be commissioned is
described below.

The constructional details of the arrangement for such diversions on BG may be seen in Fig.8.01.

The portal type structures are made out of 8Ornm diameter GI pipes using two right angled 'T' joints.
Guys are used in both perpendicular and parallel directions to the track so as to give extra safety
against heavy wind load. The contact wire is suspended with the help of special fittings made of MS
flats form the catenary wire stretched between the two uprights of the structure and insulated by two
9-tonne insulators as shown in the figure.

The 80 mm diameter GI pipes are placed in 15Omm diameter MS pipes welded on to a 1Omm thick
45Omm X 45Omm MS base plate which in turn is bolted by 1Omm diameter through bolts to a
488Omm long crossing sleeper
INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 11 PART 1 [164]
The contact wire is anchored at both ends at a height of 6 m on existing masts and 'fly guys' are
provided from the anchor mast to the base of the next mast so that no separate foundation is
necessary for anchoring and also the guy can be removed easily at the time of dismantling.

-The advantages of the above type of construction are as under

1. It is cheap.

2. The structures weigh less than 150 kg and 4 men can easily erect or dismantle them,

3. Since no foundations are required, time is not lost in excavation for foundation and consequently
the structures can be erected quickly.

4. The equipment can be dismantled and erected at new sites quickly.

5. The traffic can move at the speed restriction imposed for the permanent way and no extra speed
restriction on account of OHE is necessary.

6. The materials used for the work are easily obtainable the new fabrications required can easily
be manufactured in workshops and stocked at depots for quick use in emergencies.

20831 Funds Required for Dealing with Breakdowns

Funds required for dealing with breakdowns may be obtained from station earnings in accordance
with para 7 14 of the Indian Railways Permanent Way Manual reproduced below: -

(1) The Divisional/District Engineer or the Assistant Engineer on his behalf may drew upon the
station earnings according to such instructions as prescribed by the Administration under note to
para 1405G, for the following purposes:-

(a) Payment to daily labour employed at the site of breach or accident.

(b) Purchase of tools or materials required in connection with accidents which cannot be supplied in
time by the Stores Department.

(C) To provide food to engineering labour at the site of breach or accident with the assistance of
Station Masters or Inspectors of the Commercial Department.

The supply of food free of charge is permitted in special circumstances at the discretion of the
Administration to facilitate expeditious restoration of traffic.

When food is supplied free at the site of an accident to engineering and other labour the expenditure
per head per day shall not exceed the prescribed limit.

2. The Accounts Officer should be advised immediately by telegram of each sum taken from station
earnings.

In all cases, Engineers obtaining advances from station earnings should, do so under a clear
receipt. On the receipt, the object for which the money has been procured should be clearly stated.

A complete account should be submitted at the earliest possible date to the accounts department
supported by pay sheets and vouchers.

3. All pay1ments to labour should be witnessed .by the Assistant Engineer at site.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 166

20832 Log of Events and Reporting of Breakdowns

1. In all major break-downs TPC, senior officials and Officers concerned shall maintain a detailed
log of events in their diaries noting the time and brief details which may help in fixing the
responsibility for any avoidable delay in restoration.

2. The DRM should submit to CEE and COM a detailed report covering every major breakdown of
OHE or other traction installations giving all essential information including-

1. nature of break-downs and lines affected with detailed sketch;

2. chronological account of action taken to effect repairs and restore traffic;

3. repercussions on traffic and rough estimated cost for repairing the damage;

4. cause of breakdown and staff responsible, if any;

5. any other special features including an objective analysis of the time taken for repairs and
restoration of traffic with a view to see if these could have been done more expeditiously and if so
measures proposed to improve the performance in future.

20833 Protection of Staff

In addition to ensuring that work on OHE is commenced only after obtaining a power block as stated
in para 20825 above, the supervisor in-charge shall take all measures for protection of staff and for
exhibition of hand-signals as per GR and SR, particularly when the line under repair and the
adjacent lines are not blocked for other traffic.

20834 Use of Cranes

Special care is necessary when steam or hand cranes are used at the site of break-downs. The
movements of the cranes shall be carefully controlled by the person in-charge so as not to come
within 2 m of live OHE, in addition to the usual precautions necessary to prevent infringement of
adjacent tracks which have not been blocked for other traffic.

V. ROAD VEHICLES
20835 Use of Road Vehicles during Emergencies

Road vehicles like motor trucks and jeeps available with maintenance officials should be maintained
in proper condition at all times, as they are liable to be called for use in attending to breakdowns or
emergencies. The essential rules for operation of road vehicles are given in the following paras.

20836 Driver's Duties

1. No person shall drive a vehicle belonging to the railway unless he has a proper license and is
duly authorized. No vehicle shall be driven on a public road unless the necessary tax has been paid
to the Licensing Authority for the area as prescribed by the Motor Vehicles Act.

2. Every Driver of a vehicle shall familiarize himself and comply with the traffic laws prevailing in
the area, where. he operates. He shall be liable to disciplinary action for any willful violation thereof.

3. Before operating any vehicle the Driver shall make sure that it is in a proper operating condition
as follows
(a) Test brakes, steering gear, clutch, horn and lights.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [167]
(b) See that the tyres are in good condition and properly inflated.
(c) Check emergency equipment e.g., first aid kit jack and tools.
(d) Ensure that requisite quantities of petrol, lubricating oil and water are available in the vehicle.

Drivers shall test the head and the tail lights before undertaking night driving. They shall not
undertake driving until these are in order.

4. If any major defect is noticed during a journey, it shall be reported to the Electrical Foreman
concerned immediately, and the vehicle shall not be operated until the defect has been set right.

5. Before filling the petrol tank the engine shall be shut off. The hose nozzle shall be kept in
contact with the tank o avoid static sparks.
While filling petrol tanks of the vehicles, smoking and use of open flames shall not he permitted near
the vehicle.

6. 'Left-hand-drive' vehicles shall have these words written and displayed conspicuously at the back.

7. All loaded trucks, carrying loads projecting beyond the rear end of the body shall carry red flags
of approved type and size when driving during day-time and red lights placed at extreme ends of the
loads or trailers at night.

8. Drivers shall not drive vehicles while in a drunken state.

20837 Opeiration of Road Vehicles

1. When loading or unloading vehicles, the emergency parking brakes shall be applied and the
wheels blocked.
2. Equipment, materials and tools carried on vehicles shall be properly secured and arranged so
as not to obstruct the view of the Driver or to interfere with his giving traffic signals.
3. The vehicle shall be operated within prescribed speed limits. The speed shall be reasonably
reduced, where necessary, due to bad weather, poor visibility, heavy traffic and the conditions of the
road and the Driver.
4. Drivers shall keep at a safe distance from vehicles in front. They shall not attempt to overtake
any vehicle unless they can see far enough to be sure of passing safely and until the horn signal
given for this purpose has been accepted by the Driver of the vehicle in front.
5. Drivers shall not attempt to pass other vehicles on curves, grades, street intersections or such
other places where the view is not clear.
6. No motor vehicle shall be driven past school buses that are taking in or putting down children.
7. Drivers shall, at night, dim lights when meeting other vehicles. When blinded by glaring
headlights they shall slow down and, if necessary, stop until the vehicle has crossed.
8 'When fire department vehicles, ambulances or police patrols are heard or observed approaching
from any direction, vehicles shall be stopped at a safe place until these vehicles have passed.

9 . When proceeding down a grade the clutch shall not be disengaged. The engine shall be
throttled.
10. When approaching railway crossings and road intersections, Drivers shall slow down speed and
be prepared to stop.

11. On slippery roads, Drivers, shall operate at a much lower speed and keep a safe distance from
vehicles in front to enable them to make a stop within safe limits, leaving the vehicle in gear and
applying the brakes until speed has been retarded sufficiently to engage the clutch without danger
of skidding.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 168

12. Drivers shall anticipate the intentions of other Drivers and pedestrians and shall themselves give
clear signals of their intentions regarding stopping or turning. They shall make allowance for lack of
skill or improper attitude on the part of other Drivers, pedestrians, children and animals. They shall
not frighten or annoy them by hooting too frequently.

13. When moving a vehicle in reverse direction make sure that the rear is clear and free. Under poor
visibility or an hilly or congested roads, driver shall employ a signal-man.

14. Horns shall be used only when necessary. Use of horn just near the object is dangerous and
shall be avoided.

15. Doors, tall gates, or parts of load of a vehicle shall not be kept dangling when the vehicle is in
motion.

16. The number of persons riding with the Driver shall not exceed the number of seats actually
provided.

20838 Precautions when Transporting Heavy Materials

1. Drivers of trucks carrying heavy structures or long ladders equipped with booms shall not drive
with such equipment in an elevated or partially elevated position.
2. Proper precautions shall be taken at all times to prevent contact with overhead lines, trees or
structures.

3. In transporting material, particular care shall be exercised to see that material mall not shift or
fall from the vehicle.
4. Where poles or the long sections of material projecting beyond the vehicle are to be transported
along public roads, a red. flag in day-time or a red light at night shall be fastened to the end of the
projection.

20839 Transportation of Personnel

1. The number of employees carried in vehicles shall not exceed the prescribed limit and they shall
be provided with proper sitting arrangements.
2. Persons who are not employed in the railway shall not be allowed to use the vehicles unless
specifically permitted.
3. A person shall not put any part of his body outside the vehicles and shall not sit or stand on the
rung-board or other outside projections of the vehicle when in motion to avoid injury from other
vehicles.
4. Employees shall not enter or leave the vehicle when it is in motion.
5. Employees shall not ride on a load of poles or, other material carried on vehicles in a dangerous
way.
6. Vehicles fully loaded with personnel shall not be started or stopped suddenly with a jerk, except
under emergency conditions.

20840 Parking
1. Vehicles should be parked on the correct side close to kerb of the road so as not to interfere
with traffic. Vehicles shall not be parked on bridges, road curves, culverts and Intersections:

2. When parking on a grade, the vehicle shall be in gear, hand-brakes, applied wheels turned
towards the kerb. Bricks or stones shall be placed in the wheel path on the down grade side so that
the vehicle cannot accidentally roll down.

3. When parking along a highway at night, parking lights shall be left on, but dirnrned. If any repair
work is to
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUM.E 11 PART 1 169
be done, flares shall be set at opposite ends so as to be visible from a distance of at least 150m to
warn other Drivers in advance.

4. When parking on the highway near another vehicle on the opposite side of the road, sufficient
clearance shall be kept between the two vehicles.

5. Before leaving a parked vehicle, Drivers shall take with them the ignition key to prevent theft or
unauthorized starting of the vehicle. 1

6. Before changing tyres or making any other repairs along a highway, the Drivers shall pull off the
vehicle to the side of the road at a safe distance from the running traffic.

7. When leaving or entering a parked vehicle, kerb side doors alone shall be used. If the doors
open on roadside, look back and make sure that no vehicle is approaching from the rear.

8 . Before starting a parked vehicle, the Driver shall observe the front and the rear to ensure that
there are no persons or objects in the way.

20841 Maintenance of Road Vehicles

1. Road vehicles are costly and should be driven carefully and maintained efficiently. The
Foreman-in-charge shall inspect every vehicle under his control at least once a fortnight, and
arrange to have the defects noticed rectified promptly.

2. Every emergency vehicle shall also be inspected by an AEE once a month and by the DEE once
in six months and the observations made recorded in a register.

3. Each vehicle shall be equipped with an approved set of tools and first aid kit and the Driver shall
be trained in their use.

4. A first aid blanket shall be carried on every truck and the Driver shall be trained to use it as an
improvised stretcher.

5. When vehicles are jacked up for working underneath, sufficient number of wooden blocks shall
be put below to protect men underneath, should the jack fail. Goggles shall be worn to prevent dust
getting into eyes.
20842 Procedure in Traffic Accidents

1. Accidents which may appear trivial often result in claims for personal injury or damage to
property. A Driver shall, therefore, always be courteous and helpful.

2. Drivers shall not get involved in an argument as to who was responsible for the accident but
endeavor to get all the facts in the case.

3. The following instructions shall be observed by Drivers should an accident occur: -

(a) Stop the vehicle and pull over to the kerb if no other vehicle is involved. The vehicle should not
be disturbed should there be a fatal accident, as police may make note of the evidence. Protect the
rear and front so as to divert the traffic.

(b) If any one is injured, render first aid; send for the Doctor and ambulance, if necessary. Render
every assistance.

(c) Do not leave the scene of accident without stopping to identify yourself.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 170
5) Check the pantograph frame for signs of bending or cracks. Check the springs for any cracks

(6) if possible, take the measurement of the pan as per the Fig. 8.02.

(7) Check the broken or cracked fittings of the pantograph and see whether the cracks are old or
fresh.

II. Annexure 8.02

PROFORMA FOR RECORDING MEASUREMENT/OBSERVATION IN RESPECT OF OHE IN

CASE OF PANTO ENTANGLEMENT.

1.Location

2.Height of contact wire of main line above R.L.

3. Height of contact wire of turn-out/cross-over above R.L..

4.Stagger of contact wire of main line,

5.Stagger of contact wire of turn-out/cross-over.

6. Length of steady arm holding main line contact wire.

7. Length of steady arm holding turn-out/crossover contact wire.

8.Position of Registration tube and register arm dropper clip.

9.Track separation at obligatory point.

10. Position at which horn of pantograph jumped above contact wire.
11. Vertical height of steady arm clamp from register arm.
12. Hitting marks on the steady/Registration arm tube, P.G. clamps droppers, contact wire, dropper
clip, splices, jumpers, if any.

13. Condition of cracked or broken OHE fittings such as clamps, splices and clips etc. Check
whether the cracks are fresh or old.

14. Check free vertical movement of the steady arm.

Above observations will be made on every mast within at least 500 m in the rear of the location of
entanglement.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 172

CHAPTER IX
PREPARATION FOR CONMSSIONING

20900 Introduction

Prior to commissioning new Railway Electrification, schemes, detailed preparation work is a

necessary pre- requisite. While instructions are issued separately in technical manuals of various
equipments, salient points in respect of the following major heads are outlined in this chapter.

I Traction sub-stations

II Transmission lines and 25 kV feeders

III Protective equipment

IV Switching Stations

V Remote Control 4quipment

VI Overhead equipment

VII General

This chapter is devoted to the technical aspects of work which call for attention during inspections,
tests and trials before energization.. Chapter X deals with procedures in connection with
energization and commissioning and putting the assets into beneficial use.

20901 Reference to Rules and Statutory Rules

The safety of travelling public, railway staff and property shall be ensured by strict compliance with
the rules laid down in.

i) Indian Electricity Act 1910 (latest revision),

ii)Indian Electricity Rules (latest edition),

iii)Indian Railway Act (as amended from time to time),

iv)General Rules for Indian Railways and associated Subsidiary Rules prescribed by Zonal
Railways,

v)Indian Railways' Schedule of Dimensions,

vi)The Rules for Opening of a Railway or Section of a Railway for Public Carriage of Passengers,
1935 (as amended from time to time),

vii)Bonding and Earthing Code, Code for Earthing for Traction Installations and Regulations for
Power line Crossings,

viii) Relevant IS or IRS specifications and code of practices for various equipment.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [175]

During the preparations for commissioning, the provisions of all these rules shall be kept in view.

Wherever extracts and Appendix etc., of the rules have been included from these rules in the
ACTM, the figures and contents would automatically get amended with dates of amendments.

Methods/procedures indicated in the manual are only for guidance and may be modified as per
latest methods/standards prescribed by RDSO/approved by CEE.

20902 Pre-Commissioning Inspections

1 Pre-commissioning inspections and tests cover two distinct parts, viz.

a) Detailed inspection at the level of the ACE and Senior Subordinates, and

b) General inspection at the level of the Divisional Officers.

These two inspections are primary Inspections covering all the Installations and are independent of
any inspections which may be carried out by Administrative officers.

2, Officers and staff of various sections (Departments) in the Division should associate themselves
with the field work during construction, acquaint themselves with the Installations, satisfy
themselves about high standards and quality of work and get the defects noticed rectified then and
there, while work is in progress.

3. The departmental agencies executing the work in the construction organization shall also keep
constant liaison with their counterparts on the open line, who will be responsible for the
maintenance of assets created by the construction unit.

20903 Defect and Deficiency Lists

When the work is declared as having been completed and ready for Inspection, the field officers and
Senior subordinates of the open line, along with their counterparts of the construction unit and
representative of contractors, if any, will carry out joint checks. The checks should be thorough and
cover every part of the Installation. In making these checks the latest drawings should only be used
(superseded versions can be misleading and should be positively avoided).

All defects noticed during such joint checks should be rectified before the sections are taken over by
the open line maintenance organization. The defects will be categorized in three types and jointly
signed lists be prepared accordingly:

Category A - Defects concerning vital safety items and serious shortcomings, which must be
rectified before even test charge.

Category B - Defects , not affecting safety though their rectification before cornrnissioning is
essential for trouble free working of electric train service.

Category C Minor defects, which need not hold up commissioning and can be rectified after
commissioning in a reasonable time.

During the preparatory period, these lists should be constantly reviewed jointly and progress of
rectification to be done by construction organization be watched.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [176]

1. TRACTION SUB-STATIONS
20904 Planning of Power Supply
1. Sub-stations play a vital role in electric traction and, therefore, the need for considerable care
during erection and commissioning cannot be over-emphasized. A high standard of workmanship Is
essential and the pre- commissioning tests should be systematically carried out by competent staff,
using dependable and calibrated instruments.
2. When a long stretch of section of the railway is sanctioned for electrification, detailed planning of
section by section energizing be undertaken and commissioning for commercial operation of electric
traction over appropriate sections with partial change of traction be decided. Keeping in view the
fact that 100% traffic cannot be switched over till a viable section of the Railway is completed, the
order in which the sub-stations should be brought on line should be decided by CEE in consultation
with RE and operating branch. This decision should take into account the reliability of supply for the.
energized section, the tariff structure and the commitments in regard to contract demand and
minimum guarantee to supply authorities.

3. The supply authorities may then be advised the dates by which power supply will be needed at
the various sub-stations. Agreements may be entered into at appropriate time to make sure that the
supply authorities do not delay the work on their part and have adequate time to complete the
construction of their works for connecting the substation to the grid.

4. The phasing diagram, deciding which phases of SEB's transmission lines will be connected at
different sub- stations should be finalized in consultation with supply authorities for the entire section
of the Zonal Railway planned for electrification, keeping in view power supply on adjacent railway
systems. The connection of the substations to the transmission lines should be in cyclic order so
that the load due to electric traction on the grid system is well balanced and remain within the
permissible limits of unbalance.

5. The power supply to traction substation is connected through transmission line, which often
cross the track. The application for the 'Track Crossing' should therefore be processed well in
advance through Sr. DEE (G), to avoid delays in the supply connection.

20905 Commissioning of Traction Transformers

During the preparation for commissioning of transformers at traction sub-stations In addition to
manufacturer's instructions, the following steps shall be taken:

i) Drying out of transformer shall be undertaken as per the procedure laid down. (Refer para 20208)

ii) Tap-changing mechanism shall be checked for being in perfect operating condition, both
electrically and mechanically. Ratio test should also be done in this procedure. (Refer para 20206)

iii) Transformer bushings should be paid special attention to ensure that the manufacturer seal is
intact and the bushings are in excellent condition. The Insulation Resistance of the bushing should
be around 10,000 Meg Ohm.

iv) All gaskets should be properly compressed and tight fitted. No leakage of oil should be visible
from valves, pipe joints, gauge glass, radiators or any other parts of transformer. The welded joints
should also be checked for for seepage if any.

V) For a sub-station with more than one transformer, they should preferably be identical. The
polarity on both should be checked.

Vi) The oil filled in transformer should be fully de-aerated to avoid false operation of Buchholz relay.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [177]

vii) The Buchholz relay should be erected as per instructions of the makers and tested for correct
operation.
vii) All accessories like silica gel breather vent pipe, explosion vent diaphragm, circulating oil pump
and special cooling equipment, if any should be checked.
ix) In addition to Buchholz relay, (Refer para 20214) other protective devices provided for the
protection of transformer (Refer para 20212, 20213) should be examined and checked carefully and
tested after erection at site.
Y.) Earthing of transformers and its neutral terminal shall be done in accordance with the "Code of
Practice for Earthing of Power Supply Installations" (Appendix 111).

20906 Precautions During Commissioning of Traction Transformer

While working on traction transformers, the following special precautions should be taken by all the
staff:

1. It is very important that any one working on a transformer with any of its covers open should
remove all loose articles from his clothing such as pens, pencils, watches, money, smoking articles,
tools particularly if they are oily, as they are liable to slip and fall into the transformer in the course of
work. The number of men working on top should be restricted to the minimum. If tools have to be
used they should be fastened by lengths of strings to the workers' wrists or to the tank rim.

2. Moisture lowers the dielectric strength of oil, and hence every possible precaution should be
taken to prevent its entry. Sweat on hands and face should be wiped off frequently by a dry cloth
and tools should be kept clean and dry, especially when coming in contact with oil. Another source
of entry of moisture into the tank is by condensation. If at transformer is at a lower temperature than
its surroundings, condense will form on the exposed surfaces. Transformer should, therefore, be at
or above the ambient temperature before being opened for work at any time.

If any cleaning or wiping is necessary, this should be done with clean, dry oil using soft, non-fluffy
cloth, and never by using cotton waste.

20907 Tests on Transformer Windings

(i) Insulation resistance readings should be recorded with a 2500 V or 5000 V megger. The
following are the minimum permitted values at an ambient temperature of 30 degree centigrade.
Temperature has a material influence on insulation resistance, and therefore the test should not be
conducted when oil is hot.
2000 Mega Ohm between EHV winding and earth.
400 Mega Ohm between 25 kV winding and earth.
2500 Meg Ohm between EHV and 25 kV windings.

ii) Test on insulation: The test consists of applying dc high voltage (2500 V or 5000 M, with the help
of a megger, continuously between winding and earth, and noting the insulation resistance at the
end of 10 sec, 60 see and 600 sec. To maintain constant voltage, a motor-driven megger is
preferable. The polarization ratios R60/RIO and R600/R60 should not he less than 1.4 and 1.2
respectively. (RIO, R60, R600 are the Insulation Resistance values after 10 sec, 60 see and 600
sec respectively).
iii) Phasing out test : This is comparatively easy, as single phase transformers alone are provided at
traction sub station : if both the transformers install at a sub station are of identical manufacture the
terminal connections will be identical. Nevertheless , the correctness of polarity should be checked
applying 400 V across the primaries in an identical manner and measuring the relative voltage
between the two secondaries of transformers after connecting one terminal of one secondary with
the corresponding terminal of the other.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 178
iv) oil test : The tests on transformer oil should be done In accordance with IS-1866 for oil in use
(See Annexure 2.03 Chapter 11).

20908 Circuit Breakers and Interruptors

The installation of circuit breakers and interruptors should be carefully done as per Instruction
Manual of makers. The following special checks may be made.

Cheek, first of all, if the circuit breaker mounting is quite vertical and the base firmly secured.
Examine the operating mechanism in the weatherproof housing for cleanliness, free movement of
rollers, bearings and sliding surfaces, which should be very lightly oiled. Open and close the breaker
several times to cheek that everything is working smoothly. Make sure that all pins, locking plates
and split-pins are in place.

On the electrical side, examine the condition of the wiring, its insulation resistance and tightness of
the terminal screws. Check if the opening and closing solenoid or motor when electrically operated
does operate satisfactorily with battery voltage 20 per cent less and 1 0 per cent more than the
rated voltage. Check also the manual operation and record the operating time for closing and
opening. Examine whether the heater in the equipment cabinet is in working order. Observe if the
auxiliary contacts are clean and good and the terminal block well secured.

Select a few circuit breakers at random to inspect the Interior of the arc-extinction chamber to make
sure that the main circuit breaker contacts are in excellent condition and their alignment good, but
taking care not to contaminate the parts. The parts handled should be washed thoroughly well with
good transformer oil and put back and oil level restored.

Check and record the dielectric strength of oil in every circuit breaker, taking out the oil through the
sampling cock. If the break-down voltage (BDM is less than 40 kV, oil will have to be dried out. This
is easily done by a small portable oil purifier having, a capacity of 200 liters per hour. After drying-
out, repeat the BDV test, taking the precautions described in Chapter 11.

Examine particularly if there is any strain on the circuit breaker porcelain housing because of
misalignment or rigidity of the connection from its terminals to the busbars. Usually this is made
through flexible connectors; nevertheless, it is wise to check the position of the connecting leads
when the bolts are loosened. Make sure also that the metal-to-metal contact is perfect at the
terminal connections. Any imperfection here will result in overheating of the terminal which may
even lead to eventual fracture of the housing itself. It is best to measure the contact resistance by
"Ductor" or similar low-resistance-reading instrument.

Finally, cheek the general condition of the equipment, finish and weather-proof-ness of the cabinet
and whether it is Insect-proof, whether fuses are intact, and if the operation counter, where
provided, works properly and if the metal supports and frame are well earthed.

20909 Isolators
Examine the insulators carefully for any surface cracks and make sure if the surface is clean. Check
operation of isolator manually to see if the movement is free and smooth, and if the switch blades
are fully open or fully closed when the handle is locked at the top or bottom position. Examine the
contacts and cheek if the spring pressure is adequate and blades make full contact. Cheek terminal
connections, preferably the a "Ductor", Examine whether the interlocking between the circuit
breaker and its associated Isolator functions properly and the isolator frame is solidly connected to
earth by two independent connections. For interlocking scheme for EHV and 25 kV CBs & isolators,
reference may be made to RDSO Drawing(ETI/PSI/5212).

20910 Current and Potential Transformers

Check and record the insulation resistance of primary and secondary to earth and between primary
and secondary.Check oil level in PT if it is not of the sealed type as also its dielectric strength. Top
up the oil drawn for test. Make

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [179]

sure that the terminal connections are well made preferably recording the contact resistance of CT
connections by a "Ductor". The frames of the PT and CT should be well earthed by two independent
connections to earth.
20911 Lightning Arrestors
Make a thorough visual examination of the outer porcelain housing for hair-line cracks and chipped
sheds. Clean the outer surface of all dust. The connecting leads to the arrestor should be solid and
direct. The earth terminal of the lightning arrester should be connected to the general earthing main
at the substation, to the transformer tank body and finally to an independent earth electrode
provided very close to the arrestor.

20912 Shielding and Earthing

Cheek whether the whole of the sub-station area is well protected against atmospheric surges by
screening conductors strung between substation structures and solidly connected to the earth
system in accordance with the approved drawing.

Check visually whether the metallic casing of every sub-station equipment and the neutral terminals
of the power transformers are solidly connected to the sub-station earthing grid,and confirm that
the "Code for Earthing Power
Supply Installations" Appendix 111 is complied with in all respects.

20913 Busbars and Insulators

A careful inspection should be, made of every insulator supporting a busbar to detect any minute
cracks on the surface; paint marks or dust should be removed and the surface gloss restored.

Time spent in checking the current carrying joints on busbars and terminal connections will pay
ample dividends. The contact surface should be clean, smooth and without any irregularities and
burrs, so that when they are tightened the area of contact is large. The pressure should also be
adequate. Particular care should be taken when joints are made between two dissimilar metals like
aluminium and copper. Special bimetallic fittings should be used in such cases to prevent
electrolytic corrosion. Connections should be such as to produce no strain on the equipment.

20914 Clearances

The minimum clearances in mm in air for live equipment shall be as under

25 KV 66kV 100kV 132kV 22OkV

1. Between phases - 630 900 1300 2400

2. Between one phase and

earth for rigid connection. 500 630 900 1300 2100

3. Between any points where man may be

required to stand to the nearest
(a) unsecured conductor in air (mm) 3000 3500 3500 4000 5000
(b) secured condition in air (mm) 2000 - - - -
4. Min. height of busbar 3800 4600 4600 4600
5500

20915 Auxilaiary Power Supply for Traction Substations & Control Room

Whenever possible, a 3 phase, 415 / 240 V, 50 Hz supply upto 100 kVA is obtained to meet the
power demands for erection and commissioning of the substation. The LT control board should also
have matching capacity. An

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 180

auxiliary transformer of 100 kVA, 1 -phase 25 kV / 240 V is provided to cater to the substation and
control load. The station transformer should also he subjected to detailed inspection and check as
for the main transformer.
The control room building shall be neat, well ventilated and provided with a strong door. The control
panel should have sufficient space all round to provide working space to carry out the necessary
tests.

20916 Batteries & Battery Charger

The Battery room should be particularly well ventilated, protected, dust-free and dry. The battery
room floor and walls upto a height of 2 m should be painted with anti-sulphuric acid paint. The
batteries themselves should be well supported on teakwood stands, painted with anti-sulphuric acid
paint and resting on porcelain insulators to prevent leakage. Examine the log book for the period
during which the battery was given its first charge and make sure that the manufacturer's
instructions have been adhered to as regards the rate of charge and the number of charge and
discharge cycles. Make sure there is no possibility of the battery gases reaching the equipment
room. Observe the condition of the battery plates 'take specific gravity of all the cells and voltage
across each cell on load. Check if all the inter-cell connectors are tight and well vaseline. Check
finally if the battery fuses are of the correct capacity and there is no possibility of battery supply
failure. Make sure that the alarm bell goes off if the supply is interrupted for any reason to the
control panels.

The battery charger should be inspected to make sure that its capacity,for normal and boost charge
as well as trickle charge is sufficient and that it complies with the technical specifications, that the
meters provided are indicating properly and it is complete with necessary fuses and indicating
lamps. The metal easing should have two independent earths.

20917 General
Inspect the substation area to make sure that it has good drainage, that it has good all-weather road
as well as rail access, that the whole area is well fenced-in with lockable gates wide enough to
permit entry of a motor truck. Ensure that baffle wall in between traction power transformer and
suitable oil drainage arrangement with an oil soak pit has been made in accordance with IE Rule 64
(2). The numbering of transformers, isolators, circuit breakers, Incoming transmission lines and
outgoing 25 kV feeder lines should be checked to see if it has been correctly done, and does
correspond with the numbering scheme on the control panels at the sub-station control room , and
also on the mimic diagram board at the RCC. Fire extinguishers and fire-buckets filled with sand
shall be kept ready at hand. Station name-board, Danger and Caution boards, Protected Area board
etc. shall be well
displayed.
20918 General Inspection of Substations and Commissioning
After defects observed during detailed inspection have all been rectified, the Sr. DEE (TrD) of the
open line and the Dy. CEE(PSI) of RE organization shall carry out a general inspection of every part
of the sub-station along With the Contractors' representative. Considering that these are high
voltage installations, the inspection should be thorough. As many spot checks as possible should be
conducted to ascertain the condition of the equipment and the care taken during erection. Particular
attention should be paid to the safety aspects like clearances, operation of protective relays and
functioning of the trip circuits and earthing. The statutory regulations such as the Indian Electricity
Act and Rules should be strictly complied with and the inspecting officers shall each personally
satisfy himself by tests and measurements that the installations are fit in every way to be energized
and then issue a joint certificate to that effect.

An application should thereafter be submitted to the CEE and the Electrical Inspector to the Railway
seeking his permission, for the commissioning of the sub-station, provided power supply will be
made available by the supply authority and testing of protective relays has been completed. After
his sanction is received and the precautions and procedures detailed in Chapter X are complied with
the substation may be commissioned.
For the first three days after commissioning, the substation equipment shall be kept under careful
observation by a senior and experienced supervisory official. Thereafter daily inspection should be
continued for the first fortnight.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 (181)
Immediately after energization the correct operation of every protective relay shall be checked. The
substation should be taken over on RC.

11. EHV TRANSMISSION LINES AND 25 kV FEEDERS LINES

20919 Detailed Inspection of Transmission Lines

As soon as a section of transmission line between two substations is declared by the Contractor as
ready for inspection, detailed inspection shall be carried out by the ACE (TrD) and his staff together
with their counterparts on the construction organization and contractors' representatives and a joint
note prepared of the observation made and tests conducted. An defects, whether major or minor,
shall be arranged to be rectified immediately so that there may be no delay in energizing the
transmission lines.

20920 Compliance with Rules and Approved

The work shall strictly comply with Indian Electricity Act and Indian Electricity Rules, the Contract
Specifications and approved including sag-tension charts, particularly in respect to clearances
between ground (and other structures) to live conductors.

20921 Visual Inspection

This will cover every mast location and crossing across railway tracks, roads etc., special attention
being paid to workmanship, completeness of installations and cleanliness of insulators. The
tightness of bolts and nuts in structural steel work and fittings shall be checked. If galvanizing of
steelwork has been damaged anywhere, the part affected shall be properly protected by painting
with cold galvanizing paint to the satisfaction of the railway. Muffing for each of the tower footings
should be checked to make sure that it extends from well below the ground level to at least 380 mm
above the ground in irrigated fields, 230 mm above ground level in dry location and 150 mm above
the maximum water level in water-logged areas.

Joints in transmission line conductors shall be not less than 15 m from the tower. There shall be no
joints in tension lengths of less than 3 spans, nor any in spans over rivers, railway tracks or roads. A
few jumper connections between line conductors shall be opened at random to check whether the
contact surfaces are good and joint compound has been applied. At the same time, the tightness of
all PG clamps should be checked.

20922 Clearances and Sag

The minimum clearances shall be in accordance with 1. E. Rules and Indian Standards. In case of
132 kV lines under maximum temperature condition, in still air, the minimum clearances are
indicated below.

1.Open route 6.1m

2. At all roads and accessible places 6.1m

3. Between nearest live conductor and any part of 4.6m

any fences, wall, building or other structure on
which a man may stand, or against which a
ladder may be placed.

4. Between the nearest live conductor and the Earth. 6.1m

5. Between the nearest live conductor 6.1m

and any tree or hedge in the vicinity.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 182

6. Minimum spacing between conductors

Vertical 3.9 m
Horizontal 6.8 m

The minimum clearance between live parts and earthed tower or cross arm members for 132 KV
shall be

1. Single Suspension strings 1370mm

in still air and when deflected by
wind by 30 degree from the vertical.

2. Single Suspension strings 1070mm

in still air and when deflected by wind by
60 degree from the vertical.

3. Strain strings at strain towers 1530mm

4. Jumper connections at strain towers when 1530mm

deflected by wind upto 10 degree from
the vertical.

The height of the lowest part of conductor shall be checked and recorded -

1.At mid-spans at typical locations on the open route.

2. Above railway tracks, roads building and public places

Minimum clearance of live parts shall be checked for each of tower at typical locations and
recorded. Sag of the earth wires and conductors shall also be checked at selected spans and
recorded.

20923 Earthing
Every tower is individually earthed by connecting one of its legs to one or more earth electrodes
near by, through a galvanized steel flat 40 mm x 6 mm so that the earth resistance is not more than
10 Ohm before the overhead earth conductor is bonded to the structure. Examine whether the steel
flat is properly bolted to the stub-angle iron and well protected below the ground up to the earth
electrode.

20924 Insulators and Insulation Resistance

Suspension and strain insulators shall be in inspected as closely as possible for any chippings or
cracks, for cleanliness, and preface of arcing horns at the line end of each suspension string above
the conductor, at both ends of each tension string, and at both ends of each insulator string up to a
distance of 1.6 km from the sub- station.

The number of 255 mrn dia porcelain discs shall normally be 9 for suspension strings and 10 for
tension strings for 132 kV supply. To provide graded insulation, the number of discs will be reduced
by one, namely 8 for suspension string and 9 for tension strings upto a distance of 1.6 km from the
sub-station.

Duplicate suspension/tension strings shall be provided for all road crossings. For railway crossings,
anchor type towers shall be provided on the two sides with duplicate tension insulators, the whole
crossing, being in conformity with the Regulations for Power Line Crossing of Railway Tracks (
Appendix iv)

Insulation resistance for each power conductor shall be measured and recorded from sub-station to
sub-station, using a 2500 V or 5000 V megger. It shall be not less than 100 Meg Ohm.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [183]
20925 Continuity Test
Continuity of each conductor shall be measured from, substation. To substation using a megger
continuity tester and the results recorded.-

20926 Accessories
During detailed inspection, it should be verified whether every tower is fitted with an: anticlimbing
device and
enamelled number plates. In addition circular enamelled discs coloured red ,'yellow and blue are to
be provided. on terminal towers to indicate the phases. Danger boards should also exist on the
transmission line towers where they are near roads or other public places.
'
20927 General lnspection and Energization

After defects noticed during detailed inspection are rectified, Sr. DEE/DEE(TrD) of the open line
together with his counterpart on the construction organization and Contractors' representative shall
carry out general Inspection to make sure that the lnstallation,is in good order. During this
inspection, the inspection party will carry out as many spot checks as possible to confirm that the
detailed inspection has been properly carried out earlier. On the basis of their personal
observations, a joint certificate will be issued by the inspecting officers and contractors'
representative, confirming that the installation is fit in every respect for energization

Wide publicity should be given to warn the public that the lines will be energized and of the
accompanying danger to any trespassers. After getting sanctioned of the CEE and Electrical
Inspector to the Railway, and clearance certificate from all concerned in a manner similar to the
procedure for energizing OHE described in chapter X, the transmission line may be energized
provided the sub-station and the connected protective gear have already been tested and
commissioned

20928 25 kV Feeders
Detailed and general inspection of 25 kV feeder lines should be carried out on the same lines as
described for the transmission lines and the OHE. Here too, each tower is individually earthed by a
separate electrode, in addition to being connected together through the overhead earthing
conductor. The, clearances to, road and rail crossings should be checked with respect to approved
plans, duplicate insulators being provided in each case. No earthed structure, other than the earthed
supporting structure of the 25 kV feeder lines shall be nearest than 2 m from the live OHE.
Tower footing resistance, insulation resistance of both phase and return conductors and through
continuity should all be checked and recorded. If the substation is already energized, the 25 kV
feeder; lines can also be energized on lines similar to procedure described for the transmission lines
and the OHE after taking all precautions for safety of equipment and staff working on contiguous
sections.

111. PROTECTIVE EQUIPMIENT

20929 Testing of Protective Relays

Before any traction installation is commissioned, the proper operating of every protective- relay
should be ensured so that it can be fully dependent upon in all circumstances. This is done in three
stages
-Checking the relay in the laboratory prior to installation.
-Checking after installation and before the substation is commissioned.
-Confirmatory test after energization and before introduction of commercial services.

In carrying out the tests, the Manufacturers' instruction manuals should be studied. The
commissioning engineer should be well acquainted with the principles of operation, constructional
features and the traction load conditions,
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 184
so that the relays may be correctly set.

20930 inspection of Setting of Relays and Calibration of Meters

Protective relays are usually received well packed in separate cases. -After opening the case, the
relay should be- carefully removed, examined for any external damage and taken into the Relay
Testing Laboratory. Before removing the cover, remove all traces of dust from the case and the
cover. Check the name-plate particulars to see if they are correct. Check carefully the delicate relay
movement and make sure if it is quite free mechanically, and all parts are clean and connections
tight, taking care not to disturb the settings. See whether the flag operating and reset mechanism is
functioning well. Examine the cleanliness and wipe of contacts.

The performance of the relay for different settings should then be checked using standard relay
testing equipment, making such adjustments as may be found necessary. A detailed record of the
test set up and the calibration curves should be entered in a register as a permanent record. The
plug
1 settings are then correctly made to cater for the expected load conditions.
Where relays have both current and potential coils, as in directional and MHO relays particular
check should be made to see whether the internal connections of the two sets of coils are correct. If
the polarity of one with respect to the other is not right, the relay will fail to operate on a fault, which
should, of course, never be permitted to occur.

If everything is alright, the relay cover may he put back, after checking the interior once again and
wiping all dust on the cover. It is recommended that the date of calibration should be painted on the
case for ready reference. A test certificate should be issued to the field officer for record.

Simultaneously, maximum demand and energy meters should also he got calibrated and sealed in
consultation with the Supply Authority.

20931 Protective Devices at Sub-stations

The following protective and indicating devices are provided for each traction transformer :

1.Differential protection
2.Restricted earth fault protection on EHV and 25 kV sides.
3.Buchholz relay with alarm and trip contacts.
4. Winding temperature protection with alarm and trip contacts.
5.Oil temperature protection with alarm and trip contacts.
6. Protection against low oil level.

In addition, a low oil level indicator is provided on the conservator tank. Local Indicators are
provided on the transformer tank for excessive oil and winding temperatures, whereas a common
indication only is provided on the control panel at the RCC for excessive winding and oil
temperatures as well as Buchholz relay.

The following further protective relays are provided for each feeder circuit breakers :
1. Over-current relay for faults close to the substation
2. MHO relay for distance protection.
3. MHO relay for wrong coupling between two substations.

Proper functioning of each of these relays and the contact mechanism of each should be checked
individually.At the same time, the correct operation of the following annunciations and the
associated cancelling buttons and flag indications should also be checked :

1.EHV transformer circuit breaker auto-trip.

2. Buchholz alarm

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 185

3. Buchholz trip
4. Winding temperature alarm
5. Winding temperature trip
6 Oil temperature alarm
7 Oil temperature trip
8 Low oil trip
9 25 KV transformer circuit breaker trip.
10., 25 kV feeder circuit breaker trip
11 Transformer circuit breaker inter-trip
12. 230 V ac failure
13 110 V dc low voltage
14 24 V dc low voltage
d
Check should be made of all indicating instruments on the control panel to see if the movements are
free and the readings are correct. Test plugs where provided for checking relay operation should be
examined if they fit properly. Indicating lamps should be functioning properly, but a switch should be
provided to cut them out when the station is unattended.
Check should also be made for proper functioning of device provided for tripping CBs in the event of
110 V dc supply failure.

20932 Control Circuits and Wiring

After installation of all equipment and completion of control cable connections, a detailed check of
the wiring should be conducted. verifying the colour, code and identification tags and markings on
the terminal strips on the equipment and the control panels with respect to the approved wiring
diagram. Insulation and continuity tests should also be taken and values recorded.

A word of caution is necessary here. The detailed diagrams of control circuit and wiring, of control
panel supplied by the Manufacturers should not merely be taken on trust, but subjected to careful
scrutiny as to their correctness. Errors do occur in drawings and if they are not detected at the very
early stage Itself, they may cause a great deal of confusion and trouble later. The best method of
detecting errors in detailed wiring diagram is to prepare a simplified schematic or functional diagram
so that the circuit arrangements becomes quite clear and obvious. It will then be known what exactly
to do for any test, what links to close or open and what connections to make or break. To restore the
connections back to normal after the tests have been successfully completed, a detailed diary
should be kept of every change or alteration made for purpose of test. If any modifications are
required to correct the errors discovered, the Manufacturer should be advised immediately and his
confirmation obtained. When the work is completed, overall operation may be checked by manually
closing the relay contacts and finding out whether the appropriate device has operated or not..
20933 Fuses
Control circuit fuses shall be-of correct rating. If the-trip battery circuit fuse is under-rated, it is liable
to deteriorate due to excessive heating and fail ultimately, which could indeed be dangerous. To
guard against this possibility, alarms are sometimes provided to draw the attention of the operator in
the event of fuse failure. In ac traction, failure of battery fuse is automatically relayed to the RCC but
the TPC cannot replace the fuse by RC, someone has to go and replace it which may take
considerable time. In view of this, fuses in the control circuit may err by being slightly over-sized. but
should never be under-sized. For the same reason all connections in the trip circuit should be well
made and the fixing screws kept tight, but not over-tight which may cause excessive pinching of the
connecting lead and may eventually cause a breakage.

20934 Insulation and Lead Burden Measurement

Insulation resistance to earth should be measured. Any connection to earth and wiring made
deliberately such as

earthing links on current and voltage transformers and on dc supply should be removed before the
test; care being
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 186
A' should be a moving coil centre zero type low range ammeter . A 6 V storage battery may be used to
energized the primary winding through a single pole push-button switch. On closing the push button, the dc
ammeter should show a positive flick, and on opening a negative flick.

20936 Primary Injection Test

This check is carried out with a primary injection set , which is usually arrange for connection to the 240 V
supply means and furnishes heavy current at a low voltage. Provision usually exists to connect the secondary
windings of the test set either in series or in parallel to get the necessary output. A 10 KVA test set usually
permits currents up to 1000 A to be obtained with four secondary windings in parallel and upto 250 A at a
higher voltage with the windings in series. When dealing with very large currents, it is essential that the
connecting leads and area of contact and contact pressure should be adequate enough: otherwise, higher
values of current will not flow.

The merit of primary injection test is that it gives an overall check on the correctness of the entire circuitry.

20937 Voltage Transformer Ratio and Polarity Check

Polarity of the potential transformer could also be checked using the same method described for current
transformer testing. In this case, however, care should be taken to connect the battery supply to the primary
winding with the moving coil ammeter connected to the secondary winding.

The ratio check can be may when the 25 KV busbars are first made alive. The PT secondary voltage is then
compared with that of another PT known to have the correct ratio, after connecting it to the primary bars.

20938 Electrical Operation of Indicators and Associated Devices

All shunt connected indicator, annunciators, internal auxiliary elements, DC auxiliary and master trip relays,
should be checked for operation at the minimum voltage stipulated by the Manufacturer. Series-operated
indicators or auxiliary relays should be checked at their pick-up values. Confirm that auxiliary relays reset
when voltage and current supply is removed after operation.

20939 Secondary Injection Test

These tests are done with a secondary injection test set. Normally, operating times and minimum closing
values are checked for induction relays. For instantaneous attracted armature type relays, the minimum
closing and resetting values are checked. For directional relays, directional characteristics are checked.

20940 Alarm and Trip Check

Ensure that all fuses, links, trip latches etc. are in normal position. By operating each relays manually, verified
if the appropriate circuit breaker trips. Inter-tripping of primary and secondary circuit breakers should also be
checked. There should be no normal-operation of any other circuit. In every case of tripping, the appropriate
flag indication should take place on annunciator, accompanied by operation of the alarm.

20941 Load Test

After the section is commissioned, a final check should be made of the proper operation of all voltmeters
ammeteres and relays when normal load currents are flowing through the circuits. For differential circuits, spill
currents should be measured to prove that protection will be stable under external faults, by shorting the
secondary terminal on one, current,transformer : operation under an internal fault should also be checked The
directional features of directional relays should also, be checked This ensures that the,relative polarity of CT
and PT is correct.

20942 Confirmatory test of OHE Protective Relays

A short time after OHE has been successfully charged at 25 kV, it is de-energized to conduct final
confirmatory test on the operation of OHE protective relays. Although relays would necessarily have been
tested on the test
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 188
bench at the laboratory and subsequently in the field after erection, a final confirmatory field test is essential
before declaring the section as fit for commercial operation to ensure that in the event of a fault the relays do
trip.

2. The over current and MHO relays should all be set for instantaneous operation as mentioned earlier. In
all, the following three tests are necessary and in each case all the feeder circuit breakers and their
associated relays should be tested one after another :
a) A direct fault on the busbars of the feeding post to test operation of the over-current relays.
b) A fault at the farthest end of a single line section under emergency feed conditions to check the operation
of the MHO relay and also the under-voltage relay at the sectioning post.
C) Closing the bridging interruptor at sectioning post to check the operation of wrong phase coupling relay.

3. Test (a) can be conducted as soon as the substation and feeding posts are commissioned, without
waiting for the energization of the OHE. In carrying out Tests (b) and (c) one must provide and be prepared for
the very remote contingency of the MHO relay failing to trip the circuit breaker when It is closed on the fault,
due to polarity of the potential coil of the MHO relay not being correct in relation to that of the current coil.
Before starting the test, trip circuit operation should be checked by manual closing of the relay contacts. A
responsible official should remove the MHO relay cover and be ready to close the relay contacts manually and
trip the circuit breaker, should it fall to do so automatically when the circuit breaker Is closed on the fault.
Should this happen, the connecting leads either of the potential coil or the current coil on the MHO relay
should be reversed and the test repeated.

4. For carrying out the short circuit tests, care should be taken to earth the line by a solid flexible, jumper
connection (105 mm to an earthed structure. A thin wire such as 14 SWG should never be used for
connection to earth, under the mistaken impression that the fuse would blow out and not jeopardize system
stability, should the 25 kV circuit breaker fail to trip. It should be remembered that the circuit breaker is
designed to clear the fault whereas the improvised fuse is not. When it blows on account of heavy short circuit
current, the flash over caused by it can damage the galvanizing of the mast and perhaps shatter any insulator
nearby.

5. A point to be- ensured in particular is that none of the relays at the grid substation trips during any of
these short circuit tests. This can be ensured earlier by proper co-ordination of relay settings at the traction
sub-station. Normally, the traction circuit breaker trips out within about 250 milli-seconds from the occurrence
of short circuit. The Supply Authorities should be requested to set their relays allowing a time lag of 0.5
seconds to ensure that the substation circuit breaker dots not trip for faults on the railway traction system.

6. It is quite possible that in these short circuit tests, more than one relay associated with the feeder circuit
breaker may operate; for example, the MHO relay In addition to the over-current relay, even for a fault close to
the sub- station. This is quite in order, since this automatically gives back up protection. A note should be
made as to which flag indications have operated to ascertain which of the protective relays have operated
during each test.

7. When testing the wrong phase coupling relay, it may sometimes happen that the relay at one substation
alone may operate and not at both ends, as may be expected. This is possible if the operating times of the
two relays differ even slightly. This, however, does not matter at all. Nevertheless if it is required to check the
other relay, the relay which has operated may be blocked and the performance of the other relay tested by a
second test.

8. The operation of the under-voltage relay at the sectioning post for a fault at the farthest end under
emergency feed conditions can be checked by posting someone at the sectioning post. The test could
however be postponed by a few days and conducted after introduction of commercial services.

9. Since these confirmatory tests are to be conducted after successful energization of the OHE and before
introduction of commercial operation, It is essential to complete the tests in the shortest possible time.
However, being the most severe tests these should not be repeated too often. This can be ensured by
organizing the work properly by posting testing parties at the right places and controlling all operations
through the TPC and by RC.

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IV. SWITCHING STATIONS AND BOOSTER TRANSFORMER STATIONS
20943 Power Supply
Power supply for all switching stations is arranged through the 10 KVA,25 Kv/240V auxiliary
transformers connected to UP and DN line in double line section. If an ac 240 V supply near by is
available from the supply authority, a service connection should be taken from the source as well.
A 24 hour record of voltage should be taken and the tap switch of the auxiliary transformers
correctly set.

20944 Installation of Equipment

The installation of every item of equipment like interruptors, isolators, busbars, lightning arresters
and wiring from equipment to the control panel in the switching stations cubicle, 72/110 V and 24 V
batteries and ,battery chargers etc. .should be,checked, keeping the points referred to in paras
20915 to 20918 in mind, except for the following minor variations.

1. Intterruptors are installed for controlling supplies to the sub-sectors. The remarks made
under para 20908 are equally applicable, except that no relays are associated with them.

2. Potential transformers for catenary supply indication are mounted on the switching station
gantry.

3. 25 kV lightning arrestors are also installed on the gantry.

20945 Clearances

Check whether the following minimum clearances for 25 kV do exist:

1. Height of any live conductors from ground level 3m

2. Distance between any live part(25kV) and 500m

earthed part or part likely to be earthed

(In special circumstances and with the approval of the design office this can be 450mm.)

3. Between any live part (3kV) and earthed part 150mm

such as return conductor or return feeder

No live part may project beyond the fenced enclosure except at a height of 6.1m or more. This
should be particularly checked to guard against the possibility of danger to any member of the public
who may walk by the side of the switching station with an umbrella or a long pole.

Check and ensure that the distance from the centre of the nearest track to the face of the switching
station gantry is not less than 3.5 m.

20946 Auxiliary Transformers & Booster Transformers

These should be inspected and tested in accordance with the procedure earlier stipulated under
substation part I above.

The mounting of these transformers should be checked to ensure proper fitment and conformity with
schedule of dimensions and electrical clearances.

The booster installations, in particular should be checked for correct jumper connections.
INDIAN RAILWAYS - AC TRACTIOP4 MANUAL - VOLUME 11 PART [190]
20947 General

Verify whether the erection of fencing is neat and all parts are given a good finish with paint, the
gate is provided with a good lock and anti-climbing devices are satisfactory. The area inside the
switching station should be leveled at least 10 cm above the surrounding area. Good drainage must
be provided so that there may be no possibility of water logging at any time.

To facilitate unloading and loading of heavy materials transported by trolley or OHE inspection car,
a suitable loading platform should be provided from which a path-way should be available upto, the
gate. Wherever possible a jeepable road approach should also be provided from the nearest public
road.

When the switching station is at the foot of or at the top of a steep embankment, suitable foot steps
should be provided leading upto the gate.

20948 Interlocking

Verify whether the double-pole isolator associated with every interruptor is equipped with an
interlock and it is functioning properly. It should not be possible to open or close the isolator unless
the interruptor is locked in the open position. It should also not be possible to operate the interruptor
either manually or by RC, unless the isolator is locked in the open or closed position. To ensure this,
the interlocking device should consist of a lock combined with an electrical contactor on the
operating mechanism of the interruptor to make or break the RC circuit and a lock for the isolator
operating mechanism, with a common captive interlock key for the two locks.

20949 Feeding Posts

At locations where the traction substation is close to the tracks, the feeding post may be a part of
the substation; if, however, it is far away, the feeding post close to the tracks will receive 25 kV
supply from the traction substation, with 25 kV feeder circuit breakers located at the substation end.

In either case, the neutral conductor (also called the negative or return conductor) of the feeder line
should be solidly connected to the track rails, In addition to being earthed at the traction transformer
end. This connection to the rails is vitally important for the proper and safe working of the traction
system and it should under no circumstances be broken. To ensure this, the neutral conductor is
connected to the rails by eight independent galvanized steel stranded (7/16) cables for a double
track section with two conductors for each rail. The ends of stranded cables are brazed or welded
on to suitable shoes which are riveted to the rail webs.

Examine all the connections and make sure that the cables are well bonded to the rails with
sufficient length left free for flexibility. The down-lead from the terminal tower should be well
protected mechanically to prevent its being cut and stolen.

20950 Number Plates and Boards

Check the numbering of the interruptors, isolators, PTs and then jumper connections to the OHE to
see if they do correspond to the numbering scheme on the control panel in the switching station
equipment room, the mimic diagram board at the RCC and the sub-sector numbers.

Check also if the following boards and fittings are provided at each switching station :

1 Switching station name board,

2."Danger boards" to caution public,
3. "Protected place" board prohibiting unauthorized entry,

4. Fire-buckets and fire extinguisher inside the equipment room.

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 5. First aid box and Rules for Resuscitation from Electric Shock board inside the equipment
room.
Essential caution boards and number plates should be painted with fluorescent paint so as to be
brightly visible in light at night.

20951 Earthing and Bonding

The structural steel work as well as the neutral conductor of auxiliary transformer, and the metal
case of every electrical equipment shall be connected by two independent connection to earth in
accordance with the Code for Earthing Traction Power Supply Installation vide Appendix III.
According to this code, HT and LT earths should be provided separately, but interconnected
together by a link. It is equally important to check that the structure supporting the busbars are
solidly connected by two independent connections to the none- track circuited rail with single rail
track circuit or to the mid point of the impedance bonds where both rails are used for track circuiting.

During detailed inspection, the resistance of each electrode should be measured and recorded by a
megger earth tester so that the combined resistance of the HT earthing system is 2 Ohm, or less
and of the LT earth 10 Ohm or less, when not connected to the rails.

V. REMOTE CONTROL EQUIPMENT

20952 Importance of Remote Control
Remote Control Center is the nerve center of the traction system, from where full control over every
switching operation on the entire electrified route is exercised, its efficient operation is, therefore, of
prime importance for successful working of the system. It is desirable to complete all tests and trials
on the RC equipment at the RCC and at the switching stations and to make them fully functional
before energization of OHE. To achieve this, tests and trials should start about a month earlier, by
which time the following item of work should be ready.

1. Derivative cables from the main telecommunication trunk cable should be led and terminated
inside the equipment room in RCC, substations and each of the switching stations. Care should be
taken to ensure that the metal sheathing of the derivative cable is terminated short of the cable
terminating box and kept insulated from earth inside the equipment room and surge arrestors are
provided for each terminal.
2. Repeater stations should be fully functioning.
3. All control phones in RCC and TPC telephones in sub-stations and switching stations be
installed and commissioned.
4. The air conditioning of the RCC should be complete before the erection of the RC equipment
starts.
5. RC equipment should be ready and wired up at RCC control led posts.
6. Batteries and battery charger along with power supply and charging arrangements should be
ready.
20953 Manning of Substations and switching posts
When RC equipment is first brought into operation, it will take about 6 months before teething
troubles are overcome and equipment stabilizes for trouble free service. During this time, it is
necessary to man the substations and switching stations to operate the interruptors manually and
give reports to TPC when required. This situation also arises for longer period if the RCC is not
ready before energization.
The switching station attendants should be given adequate training in their duties and should
normally be available from about a month before the date of commissioning. It is usually possible to
introduce commercial service on limited scale, before commissioning of RC equipment.

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20954 Level Measurements
Signal levels should be measured and recorded both at the sending and receiving ends at the
control center as well as at every substation and switching station. These measurements are of two
kinds:

1. Individual levels of every frequency on the 'send' channel. These are measured by a vacuum-
tube voltmeter (VTVM) /Transistorized voltmeter (TVM with its selector switch in "high" Impedance
position at the oscillator output terminals. These should be about - 16 dB.
2. On the receive side, the levels are taken with VTVM in the "high" - impedance position, at the
detector Input terminals: this should be between-17 and - 25 dBm. 1
3. Composite levels taken between the terminals of the tele-command and tele-signal cable pairs
with a VT VM with selector,switch in the "high" impedance position. Readings may also be taken at
the input and output terminals of the repeater station and plotted. on a graph sheet.
4. Measurements should be taken of the levels of every channel on send and receive pairs at the
control centre using the Selective Level Meter. The levels for the send-channels should not be lower
than - 22 dBm. and for the receive channels - 22 to - 30 dBm.
5. After final adjustment of the levels, a note should be made of the values of the attenuation pads
included in all the circuits and kept as a permanent record for purposes of comparison and
reference.

It may be noted that the line impedance of the send and receive circuits is 1120 Ohm whereas that
of the amplifier output only 150 Ohm. A matching transformer is therefore provided between the two.
When measurements are taken, care is required to keep the selector switch of the VTVM in the
"high" position, as long as the circuits are through, but if the output level is to be me asured with the
line or equipment disconnected the switch shall be kept at the 150 Ohm or 1120 Ohm position as
necessary to achieve matching.

Another point to be kept in mind is that although the individual level of a single channel is say -22
dBm, the level indicated on the line is much higher if measured with VTVM because of the presence
of a large number of frequencies each of which has a level of - 22 dBm. Thus the correct reading of
- 22 dBm is indicated when a Selective Level Meter is used with frequency range switch in the
"frequency" position; but the same meter would indicate perhaps + 5 dBm if there are say 12
channels and the frequency range switch is kept In the "flat" position. Distinction should therefore be
made between the individual channel levels and composite level, where all
frequencies are present.

20955 Detailed Inspection of RC Equipment

Detailed program of erection of equipment, sequence of preliminary tests to be carried out at the
RCC and controlled stations, shall be furnished by the contractor to enable the Railway staff to carry
out stage Inspections and testing of individual panels, equipment cabinets and control units at the
master station and Remote Terminal units.

When contractor reports completion of erection, commissioning and all adjustments and testing
work and notifies that the installations are ready, detailed inspection shall be carried out by AEE
(TRD) and open line staff along with their counterparts on construction organization and
representative of the contractor. The defects noticed shall be rectified immediately.
Contractor shall also furnish a detailed test program for the final testing of the RC equipment for the
approval of the Railway Engineers. These tests will he done jointly by open line officers, RE officers
and the contractors' representative. The test program shall cover the proving tests for all the
parameters and facilities provided for the operation of RC equipment In the specification. The tests
at site after Installation and commissioning shall constitute the acceptance tests, which will be
carried out after the detailed Inspection and rectification of defects is completed. Thorough checking
of all switching operations, correct operation of all alarm, Indications and annunciation facilities, tele-
signallng and tele-metering arrangements, mimic diagram displays, VDU displays,

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [193]

 data logging and data storage, diagnostic facilities etc. shall be done from both control stands of
the master station as well as from the remote terminal units. Operating time for various operation
shall also be checked and recorded.

All these tests carried out jointly shall be recorded so as to establish, authentic initial record of the
performance of the equipment to ensure that the RC equipment is complete and trouble free.

20956 Interlocking of the Bridging Interruptor

Interlocks in the RC equipment for the bridging interruptor at the sectioning post provide for the
following:

1. When catenary supply is available on both sides of the interruptor, the interruptor should not
close.
2. When supply is available only on one side, the interruptor can be closed.
3. When supply is not available on both sides of the interruptor the interruptor can be closed
but should trip immediately

This is achieved by utilizing 100 or 110 V ac supply from potential transformers provided for this
purpose at the sectioning post.
Provision is also made for the bridging interruptor to trip if the catenary voltage drops too low. This
sectioning is adjustable between 15kV and 19kV and should be set at 19kV.
The above interlocks should be throughly checked when commissioning RC equipment at
sectioning posts.

20957 General Inspection by Divisional Officers

After defects noticed during the detailed inspection as above have been rectified, the
Sr.DEE/DEE(TrD) of the open line together with the counterpart on the construction organization
and Contractors representatives shall carry out general inspection of the entire installation to make
sure that it is in good working condition. During the inspection verification of as many tele-command
and tele-signals operations as possible shall be carried out from the control centre. Inspection of the
installation at every sub-station as many posts as possible shall also be carried out. Level and
frequency measurements should be taken at random at a few points to compare the result obtain
with those recorded during the detailed inspection.

The divisional officers will issue a joint certificate if they are fully satisfied with their observations and
tests, that the RC installations are fully fit for commissioning. Thereaftaer, the RC may be put into
regular services and its operation closely watched by manning the switching stations and sub-
stations as mentioned earlier. Detailed record of every failure shall be maintained by TPC and the
maintenance official. Each of these failure should be gone into fully to ascertain the cause of failure,
which incidentally would give the staff excellent opportunity to get familiar with the circuitry and fault-
find in a procedure.

VI. OVERHEAD EQUIPMENT

20958 Detailed Joint Inspection of OHE
The importance of OHE arises from the fact that it is extensive, with a very large number of
insulators, fittings and component parts, failure of any one of which may result in dislocation of
traction services for appreciable periods untill the defect is rectified. The adjustment work is
particularly important at cross-over and over-lap spans since any wide departures from the
standards laid down could cause entanglement of the pantograph with the OHE, with serious
repercussions. The need for a very thorough detailed inspection of every part of the installation, post
by post, can not, therefore, be over-stragged.

When the OHE contractor reports completion of all adjustment work, detailed inspection will be
carried out by the AEE(TrD) and staff of the open line with their counterparts on the construction
organization and
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [194]
representatives of the Contractor, using on OHE inspection car, flat-topped wagon of wiring train, or
ladders as may be convenient.

20959 Compliance with Latest

The OHE shall be strictly in compliance with the latest approved General Supply Diagram,
Sectioning Diagram, Layout Plan and Structure Erection, particularly in regard to

1. run of conductors; stagger and height;

2. disposition of brackets and clearances;

3. correctness of jumper connections, especially at switching and booster transformer stations;

4. numbering of interruptors, circuit breakers and isolators in relation to the elementary sections,
sub- sectors or sectors controlled.

20960 Infringements

None of the wayside or over-line structures shall cause infringement of the Schedule of Dimensions.
Every such infringement shall be individually recorded and action taken immediately either to have
them removed or, where this Is not possible, to obtain sanction from the Commissioner of Railway
Safety.

20961 Important Point to he Checked

The following points shall be checked during the detailed inspection:

1. Cantilever Assemblies: Every cantilever assembly shall be adjusted strictly in accordance with
the approved structure erection , especially in regard to the positioning of stay arm, bracket tube
and register arm. The projection of bracket tube and register arm and the allowance in the stay arm
shall be sufficient for slewing of tracks. Normally this allowance is 15 cm to 20 cm from the centre
line of catenary suspension bracket to end of bracket tube and 20 cm (min.) for register arms. All
nuts should be tightened and locking plates provided with split pins or check nuts. Make sure that all
temporary earths provided by Contractor's men during construction work have been removed.

2. Anchoring Points: The movement of counter-weights shall be free and not obstructed in any
way. Flexible steel ropes shall move freely and centrally with respect to the pulley sheaves and not
rub against any member. The distance between the pulley centres and the height of counterweight
above the muff level, shall be as per the chart in relation to the prevailing ambient temperature. Anti-
creeps shall be properly tensioned and positioned.

3. Overlap Spans.. Adjustments at insulated and uninsulated overlap spans, turn-outs, crossovers
and section insulator assembly shall be correct not only in respect of the run of conductors and
jumper connections, but also the height of contact wire. The separation between different OHE and
displacement of cantilevers at insulated overlaps should be adequate.

4. Insulators : Insulators shall be perfectly clean. Should the surface be polluted by dust, it should
be cleaned and gloss restored. All. insulators on out-of-run wires should be so located that they do
not foul but are well away from the zone swept by the pantographs: The runners of section
insulators should be so located as to be beyond the zone of sweep of pantographs running on
adjacent tracks. There should be no undue sag due to the section insulators, the runners should be
level and not be tilted to one side so that the pantograph may pass smoothly.

5. Height of Contact Wire: This shall be checked at every structure and at mid-span for regulated
OHE. A pre- determined sag in the contact wire of 50 mm or 100 mm at mid-span on a 72 m span
for 50 or 100 mm presag compensated OHE respectively should exist on the open routes. Height of
contact wire at level crossings shall not be less than 5.50 m.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 195

6. Stagger : Stagger in tangent track shall be to the left and to the right of the alternatively, not
exceeding 200 mm on either side of the centre line of the track, except where otherwise specified in Structure
Erection Drawings. Stagger for in-running OHE shall not be more than 300 mm at the mast/structure on the
outside of curves except in case of overlap spans and also at the turn-outs. Stagger of contact wire at mid-
span in transition portion of the curves shall be within 200 mm.

7. Gradient of Contact Wire : On both side of overline structures, tunnels and level crossings, the
gradient of contact wire shall be in accordance with the approved profile.

8. Clearances: The live metallic caps of insulators on out of run wires shall be at atleast 2 m away from
adjacent earthed mast/structure (other than the OHE structure). The distance of these insulators shall be 3 m
from the bracket supporting the OHE in case of insulated overlaps. Clearance of 2 m shall normally exist from
nearest point of two adjacent elementary sections except at the section insulators. Where clearance of 2 m is
not available. It shall be not less than the minimum long duration electric clearance of 320 mm. Whenever
the OHEs of two elementary sections cross one another, necessary cut in insulators shall be provided.

9. Bonding : Every mast/structure supporting OHE as well as platform structures, foot over bridges etc.
shall be properly bonded to the rails and earthed in accordance with the Bonding and Earthing code (
Appendix II)

10. Return Conductors of Booster Transformer Installations: The return conductor connection both at the
OHE and the rail should be checked from the point of view of good electrical contact and security from
mechanical damage.

11. Telephone or Power Crossings : Keep a close watch for any overhead telephone crossings over the
OHE, which may not have been removed by oversight. Immediate steps should be taken to have these
removed. High voltage transmission line crossings across the tracks shall be checked against the approved
plan authorizing the crossing, particularly the clearance between the OHE and the guard wires, duly recording
the results individually. If the crossing is not in accordance with the approved plan, the Supply Authority
should be contacted immediately and the infringements should either be removed or necessary relaxation be
obtained from CEE and Electrical Inspector to the Railway.

20962 Notices to be Displayed Caution Boards and Number Plates

During the detailed inspection, special attention shall be paid to verify whether the following notices have
actually been displayed at the various locations indicated below: -

1. Treatment for electric shock boards, giving instructions for treatment of electric shock in English and the
regional language, at all railway stations (ASMs or SMs Offices) signalling cabins, PWIs Sub-PWIs and IOWs
offices and depots, Signal Inspectors Officers and depots. OHE Maintenance depots, OHE inspection car
sheds, substations, switching station cubicles, loco sheds etc.

It should be noted that standard printed charts for Treatment for electric shock are meant for voltages upto
1100 Volts. A person in contact with higher voltages should be isolated only after switching off power.
2 General Caution Notices regarding danger of high voltage traction wires for public at various entrances to
railway station and for staff at prominent places at each station, particularly on stanchions or pillars supporting
platform roof.

3. 25 Kv Cautions Boards shall affixed on to the screens erected on foot over and road over bridges.

4. Danger boards on level crossing height gauges.

5. Engine Stop boards, at termination of OHE in the sections to be energized.
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME II PART I 196
6"Caution-Unwired Turn out" boards ahead of all unwired turn-outs or crossovers taking off from
wired tracks.
7."Warning" boards for neutral sections.
8.Boards for "Switching on" and "Switching off" of power at neutral sections. Four boards are
required for each track as detailed in Chapter 11, Vol. 1.
9."Danger" boards to be installed on OHE near watering stations, if any.
10."25 kV Caution" boards at sub-stations and switching stations.
11."Caution" notices on all diesel, electric and steam locos which work on the energized section,
including those owned by private parties.

12."Caution" boards at such signal posts where protective screening cannot be provided for signal
and telecommunication staff.

20963 Recording of Defects and Rectifications

During the detailed inspection, defects and deficiency lists as indicated in para 20903 shall be jointly
prepared.

As soon as the defects are rectified, the open line officers should be advised and suitable remarks
made against
each Item of the list. The open line officer and his staff, if deemed necessary, re-cheek the
Installation, to ensure rectification of defects. -

20964 General Inspection of the OHE by Divisional Officers

After all major defects observed during detailed inspection have been rectified 'Sr' DEE/DEE (TrD)
of the open line and Dy. CEE(OHE) of the construction organization shall carry out a 11 General
Inspection" of the entire section proposed for energization, along with the Contractor's
representative. For this purpose, an OHE inspection car fitted with pantograph shall be used and
run at a speed not exceeding 8 km/h observing all safety precautions laid down, such as earthing
the OHE. The pantograph may be used to measure height and stagger of contact wire, which
should be test checked at least at two locations per track km.

The object of this "General Inspection" Is to make sure that the OHE and connected installations are
in good order and are fit for energization. During this inspection, the whole installation shall be
inspected visually observing, in particular, the following details and looking for any thing unusual or
abnormal in the installation :

1. Cantilever assemblies, positioning of fittings, stagger of contact wire, lift of the steady arm in
curves where the radial pull of contact wire tends to move the steady arm upwards, kinks or twists in
contact wire, infringement of section insulators and conductors in overlap spans or any deformity
suffered anywhere. Any loose wires hanging anywhere or other obstructions shall be observed, and
any abnormality removed or rectified immediately.
2. Clearances to live metal parts of insulators on out-of-run wires should be atleast 2 m from the
adjacent structures (other than OHE).
During this inspection, spot checks shall be conducted at as many places as possible to verify
whether the detailed inspection by the senior subordinates has been thorough, to confirm that the
defects noticed earlier have been rectified and to make sure that the installations are in excellent
order and suitable, for energization subject to final pre-comrnissioning tests.

20965 Lapping and Polishing of OHE

After the OHE is ready in all respect, lapping and polishing of contact wire be undertaken to remove
all dirt collected

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 197

on the contact face with the pentograph. For this purposes an electric loco pentograph raised and hauled by
a diesel loco may be use at a speed of 15 to 20kmp/h during the first run and not more than 40kmp/h in
subsequent runs. Alternatively, an OHE inspection car may be used. It is an advantage if before lapping by
pantograph under side of contact wire is manually cleaned by rubbing and wiping with a wet cloth and
detergent and finally wipe with clean cloth. Normally 3 to 4 runs for lapping and polishing may be done.
When lapping and polishing is in progress suitable safety precautions to block the section and earthing of the
line as per rules, should be taken and work is supervised at a level not less than CTFO.

20966 Procedure for Final Test of OHE

After the OHE is declared as fit for energization and all construction staff have been withdrawn from the field,
insulation and continuity test shall be conducted jointly by officers of the construction organization and the
open line with assistance of senior subordinates. This should be done at least a day in advance of
energization. This tests should be conducted for every elementary section. The following preliminary action
shall be taken to prepare the circuit for the test.

To carry out the test in a systematic manner, a detailed programme of work should be prepare. A senior,
experienced official should be nominated for controlling the movements of all working parties each of whom
will be given a copy of the programme with specific instructions as to the sequence of switching operations to
be carried out. This preliminary action should be taken atleast a week in advance of the date fixed for the test.

On the day of test, interruptors and circuit breakers at all switching stations shall be taken on local control
and RC put out of operation. All interruptors and double-pole switches are then opened and locked in the
open positionDanger-Men Working boards should be attached to the operating handle of each 25 kV isolator
at feeding post. All potential and auxiliary transformers at switching stations should be temporarily
disconnected from the busbars. All other isolating switches in the various yards and other locations provided
for isolation of elementary section also be plays in the off position. When all these operation are completed
a confirmatory message shall be sent to the TPC.

The test shall be controlled by one senior official who shall continuously remain at the RCC and direct al
operations as required. Basically, these tests comprise-

1. Measurement of insulation resistance of every elementary section with respect to earth.

2. Checking electrical independence and insulation resistance between adjacent elementary section and
also adjacent sub-sectors.
3. Checking electrical continuity of every sub-sectors.

The test shall be carried out by one party with the assistance of two or more field parties as required. The
control party alone will carry with it all test instruments and take measurements. The field parties will merely
carry out instructions given. They should have with them necessary jumper connection and earthing poles for
earthing the equipment when directed to do so .The field parties are forbidden to carry out any operations on
their own. As the different working parties will be working at different locations, independent from one
another, they should carry with them portable telephones through which they will remain in continuous contact
with TPC through emergency telephones circuit. In case the emergency telephone circuit is not
available,alternative arrangements shall be made by S&T Department for telephone communication.

Along with the control party carrying out the tests, the Contractors shall attach a work party who will
accompany the control party from location to location and rectify any defects which may come to light during
the tests.
20967 Insulation Tests
Starting from the feeding post, the control party will measure and record the insulation resistance of every
INDIAN RAILWAYS- AC TRACTION MANUAL VOLUME II PART I 198
elementary section to earth by a 2500 V megger, after arranging with the out-field parties to (i)
isolate the elementary section concerned and (I!) earth adjacent elementary sections. This test will
show -

1. the insulation level of every elementary section; and

2. the electrical independence of the elementary section, from adjacent elementary sections.

If the tests for all elementary sections at that location are satisfactory, the control party may proceed
to the next elementary section and carry out similar tests. when all elementary sections at a
particular station have been tested, the control party will move to the next station, directing the field
parties to do likewise and carry out the tests on each elementary section at that station as before
until every elementary section in the sector has been tested.

During the course of construction work, erection staff usually provide temporary earths, using a
short piece of binding wire on the OHE at certain locations to safeguard themselves, but after the
work is completed these temporary earths may not have been removed by oversight. Such
temporary earths on the OHE will give misleading readings during the final insulation test and cause
annoyance. To prevent this, Contractors should be particularly instructed earlier to remove all such
temporary earths.

Guide Lines for Minimum Permissible Insualtion Resistance

It Is very difficult to lay down any specific rules in regard to the minimum permissible values, as they
depend upon a number of factors, which should he taken into account when fixing the value In any
given case. Some of these factors are mentioned below.

1.. Voltage rating has an important bearing on the minimum value necessary, before switching on
supply. Obviously, the higher the voltage rating, the greater should be the insulation resistance.

2. Condition of Equipment : The insulation resistance for new equipment should necessarily be
much more than for the same equipment after a few years of service. Similarly, the value required
(after an equipment has been overhauled, cleaned, dried out) before being turned out of the repair
shop should be appropriately higher than when the same equipment was in service before being
brought into the shops. A unit which is lying idle for some time may show a comparatively low
megger reading merely because of absorption of moisture and yet its insulation may be good and it
would work satisfactorily when put into service; the absorbed moisture would soon be driven out
when it is loaded up and the insulation resistance would automatically improve.

3. Type of equipment : It is a fundamental fact that the larger the number of leakage paths, the lower
would the insulation value tend to be. Assuming that the voltage rating and the type of insulation
provided for two armatures are Identical it is obvious that the one with a commutator will have a
lower value of insulation resistance, than one with mere slip rings.

For the same reason, the insulation resistance of 25 kV OHE tends to be quite low, Assuming that
each support Insulator has a value of 500 megohm, an elementary section may have 50 of them in
parallel, bringing down the overall value to 10 meg ohms. Smoke pollution will greatly diminish this
too. A single badly polluted section insulator may easily bring down the value to half a meg ohm or
less. While one would not dream of switching on supply to a 3.3 kV transformer showing so low a
reading- 25 kV supply is commonly switched on to the OHE even in such cases since the
accumulated dust and smoke particles, which are responsible for the low value of resistance, soon
get burnt out, and the insulation resistance usually improves greatly after energization. .

Size of plant :Some of the formulae commonly used are

Large AC motors : V
------------------------- at 75"C
1000 + (kW/100)

INDIAN RAILWAYS,- AC.TRACTION MANUAL - VOLUME 11 PART 1 199

Large DC motors V
------------------------at 75 0 C
1000- + kW

Having referred to the various factors which should be taken into account in fixing the minimum
value of insulation resistance, a few thumb rules are given below for guidance: -

Insulation resistance in megohoms to earth at room temperature (40 0 C)

1. Intenal wiring 50/number of outlets

2 .Power equipment in general 2Meg/kV desirable

1Meg/kVminimum

3. Transformer windings 400V-2Meg,11kV-50Meg

25kV-200Meg.,132kV-2000Meg.

4. Circuit -Breakers -do- -do-

5. OHE-Elementary Section New installation

-25Meg. desirable

On sections having steam traction

And several section insulators.
-1Meg.
(These, however, would need to be
cleaned
to improve IR)

6.Traction Motors 1 Meg. for motors upto 750 V

and
3Meg for motors of higher voltage (at 75 0 C)
20968 Continuity Tests

When insulation tests are completed for all the elementary sections, the control party may proceed
in the reverse direction towards the feeding posts carrying out continuity tests as described below -

In this test, the various control switches which might have been opened out earlier should be put
back to their final positions as indicated in the Station Working Rules, as in normal operation. Any
temporary earths provided for earthing adjacent sections shall be removed. When this is done, the
various elementary sections are automatically joined up electrically and each sub-sector is made
through' The continuity test is then conducted by a low reading ohm-meter by measuring the
resistance of each sub-sector from the feeding post and with each sub-sector earthed at the farthest
point towards the neutral section. The through continuity of every sub-sector shall be checked
individually. It is important to note that a megger insulation tester is unsuitable for measuring
continuity as It may read zero even when the resistance is as high as 1000 ohms.

If the tests show up any defects on the line, -they should be rectified at once. Sometimes, it may be
found that although the insulation resistance is all right, there is no through continuity on some sub-
sectors. The most probable cause for this is a disconnected jumper connection at an overlap span.
This should also be immediately traced and rectified.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [200]

20969 Divisional Officers' Joint Certificate

The test results shall be recorded and signed by Sr. DEE Open line and Construction and forwarded
to CEE, along- with other papers for sanctioning energization in his capacity as Electrical Inspector.

VII. GENERAL ARRANGEMENTS

20970 Preparation for Operating Electrified Services

While the engineers are busy carrying out tests and trials of electric equipment to get everything
ready by the target date fixed for commissioning, several steps have to be taken by the Operating
Department to be ready to operate the electrified services when the section is commissioned. The
DOM of the open line and the DOM of the construction organization shall both be jointly responsible
for the following :

1. The Rules and Regulations concerning operation, namely General and Subsidiary Rules,
Revised Station Working Rules to come into operation after introduction of electric traction, relevant
Chapters of this Manual shall be handed over to every Station Master on the section to be
electrified. In addition It is essential that the Implications of these rules and procedures should not
only be explained to the concerned staff, but they should be examined verbally to make sure that
they do understand them and further, their assurance In writing to that effect should be obtained.

The training of Station Masters, Section Controllers, Cabin staff and other categories in the special
rules and procedures applicable to 25 kV traction is best arranged at a short orientation course for
the purpose in the Zonal Training School.

2. (a) At every station on the electrified section, a large scale Sectioning Diagram, should be
exhibited, with the different elementary sections painted in distinguishing colours to help better
understanding, also showing location of isolating switches, wired and unwired lines etc. The
meaning of these should be explained to the concerned staff.

(b) A complete sectioning diagram of the OHE for the relevant section should also be exhibited in
the office of the Section Controller in a similar manner. These diagram shall be kept up dated by
OHE supervisors, marking the changes made from time to time.

3. Sufficient number of 'Yellow Warning Collars' should be supplied to each of the signal cabins;
the cabin staff should be instructed regarding their purpose. They should also be told that no electric
train or EMU should ever be permitted to enter an unwired line or a section for which power block
has been taken. That they understand the new procedures should be confirmed by them in writing.

4. Station Masters and Section Controllers should also be fully conversant with the system of
power blocks and the need for longitudinal and cross protection on electrified lines, and the
precautions to be taken by them in regard to train movements especially oversize consignments.

5. Station Masters/ Assistant station master should be issued with competency certificates, after
giving practical training, to enable them to operate specific isolators under instructions of TPC.
6, First Aid boxes and charts showing resuscitation of persons who have suffered electric shock
should be kept at every station. As many persons as possible should be trained in the correct
method of rendering artificial respiration, preferably by a doctor.

7. The extreme danger of any one coming near line OHE should be fully explained and widely
publicized amongst all staff and members of the public. No one should be permitted to ride on roofs
of coaches and locomotives.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [201]

8. The rules for watering of carriages should be distributed to all TXR and station staff concerned
and the procedure fully explained and assurance obtained from them in writing.

9. On all steam and diesel engines which may enter the electrified section, 'Caution' legends shall
be painted on the side panels. Steam engine Drivers and the Firemen should be particularly warned
that they should under no circumstances climb up the coal stack on the tender or wield the long
steel rake so as to come any where near the OHE and never direct jets of water on the coal in the
tenders or towards the traction wires. Experience has shown that In spite of such warnings, many
an unfortunate loco Driver or Fireman have suffered electrocution: by force of habit they climb up
the coal heap for loco for some work, forgetting the presence of OHE in a newly electrified section.
Drivers and Firemen should be repeatedly warned of the danger of death due to such carelessness.

10. Traffic staff should be advised of the provision of emergency telephone sockets and their
locations, and instructed in the correct way of plugging in these telephones into the sockets.

After the two DOMs have toured the area and assured themselves that all the above preparatory
steps have been implemented, they shall render a certificate to the effect that the section can be
opened for public carriage of passengers under electric traction without endangering the safety of
the travelling public or of the employees of the railway.

20971 Preparation by the Engineering Department

The Divisional Engineer of the open line and his counterpart on the construction organization shall
also warn engineering staff In regard to the precautions to be taken by them while working on
electrified sections. The PWIs and the maintenance gangs should be particularly advised that the
alignment of the track with respect to the OHE structures should be strictly preserved and
maintained. Their attention should be drawn to the instructions contained in Chapter 11 Part 'J' of IR
Permanent Way Manual for taking the necessary steps to educate the Permanent Way staff and to
equip them with the accessories.

20972 Preparation by the S&T Department

Introduction of ac 25 kV traction involves a considerable amount of work to be done by the S&T

Department, to modify the existing circuits, shifting of signals, introduction of colour light signals and
laying of appreciable lengths of signal cables apart from providing telecommunication facilities
required for electric traction. The precautions to be taken in testing and commissioning the S&T
equipment, which should precede electrification, are the responsibility of the S&T Department and
is, therefore, not dealt with here.
INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 11 PART 202
 CHAPTER X

COMMISSIONING OF ELECTRIC TRACTION

PARA No. SUBJECT

21000 General
21001 Preparation by Open Line
21002 Organisation for Inspection and Taking over
21003 Duties of Sr. DEE/TRD
21004 Duties of Sr. DEE/RS
21005 Responsibility of Construction Organisation
21006 Commissioning of Traction Sub-Stations
21007 Sanction of CEE and Electrical Inspector to the Railways
21008 Notification Regarding Energisation of OHE
21009 Application to CRS
21010 Procedure of Energisation
21011 Precaution to be Taken for Progressive Energisation of OHE
21012 Final Inspection by CRS for the Introduction of Commercial Services
21013 Sanction of CRS
21014 Anti Theft Energisation
21015 Responsibility for Maintenance and Provisional Acceptance Certificate
21016 Contractor Responsibility during the Guarantee Period
21017 Failure of Equipment After Commissioning and during the Guarantee Period
21018 History Sheet
21019 Final Acceptance Certificate
21020 Standard Forms.

[203]
 CHAPTER X
COMMISSIONING OF ELECTRIC TRACTION
21000 General

When electric traction is to be introduced for the first time or extended to new section on a Railway,
considerable additional responsibility devolves, particularly on the electrical deptt. To discharge
these responsibilities, it is essential to have a clear programme of action to be taken in the final
stages of complition to ensure that:

1. the works carried out departmentally and by contractors are of high standards.

2. the organization for running the services will be ready by the time the sections are
commissioned;

3. as and when installations are energized on 25 kV, they are taken over promptly and operated
efficiently.

21001 Preparation by Open Line

The intention of having electrification works carried out by a separate organisation within the
Railway is to relieve the CEE of the Open Line of the burden of detailed design, supervision and
execution of works, departmentally or through Contractor, It is, however, essential for CEE of the
Open Line to keep himself in touch with the developments and progress of works, so that he may
take timely action for taking over the installation on commissioning. He will have to arrange every
other things.

1. creation of an organization, with sufficient number of trained personnel, to take over the operation
and maintenance of the electrified section from the date of commissioning

2.recruitment and training of operating and maintenance staff;

3. close association of Open Line Officers and staff during the final stages of erection and
adjustment work to enable them to study the details of installations;

4. carrying out of detailed inspection of the works by Assistant Officers and senior subordinates
followed by general inspection by Senior Officers for getting all defects rectified.

5. final tests and trials with rolling-stock;

6. Administrative Officers' inspection and sanction to the energization of substations, switching

stations and OHE by Electrical inspector.

7- final Inspection of OHE and installations by CRS, commissioning and putting into commercial
service-,. and

8, post-commissioning work, operation and maintenance.

21002 Organization for Inspection and Taking Over

The CEE of the open line railway shall set up the organization on the following line:

(1) Create all the posts of officers'and staff in accordance with the norms and fill up at least 6
months in advance two post of JAG Officers viz. Sr. DEE/TrD and Sr. DEE/RS along with requisite
site staff and supervisors.
(2) when electrification is introduced for the first time on the zonal railway, a nucleus set up at the
headquarters
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [2041
office should also be created.

(3) organize a Training School at least one year in advance/ for the training of maintenance,
operation and running staff to man the services.

(4) Recruit maintenance and operating staff and train them to man the services, arrange for
selection of running staff from steam and diesel cadre and start their conversion training courses at
least a year prior to the date of energization, so as to position adequate number of drivers, assistant
drivers and supervisors in time to take over the services.

(5) Position the Inspectorial cadre to ensure compliance with the requirements laid down in para
20970 station by station and to train along with Sr. DSO all the Operating Deptt. staff.

(6) Augment the organizational set up 3 months in advance of the date of commissioning posting
additional officer and staff to ensure detailed joint checks and. rectification of defects in time.

(7) Expedite the completion of facilities for setting up OHE and PSI depots and workshop' facilities
built by the construction unit and arrange to equip the emergency vans, OHE Inspection Cars and
other maintenance vehicles to undertake the maintenance and operation. -

(8) If a loco-shed is part of the RE project, some officers and staff should be posted at least 6
months before the locos are received so that they can set up the shed facilities jointly with the
construction unit, arrange for jigs, fixtures, and other special tools, take over the major plant and
machinery such as cranes for light and heavy lifting bays etc. and get themselves organized for the
maintenance and operation of the rolling stock .

Having nucleus setup of key officers is an important step which enables establishing a good rapport
with, and making full use of the resources of, the construction organisation in creating full facilities
for the open line maintenance. Opportunity to select right type of men with skill for different jobs
from a number of sources viz. direct recruitment, other open line units and sheds, contractor's
skilled labour etc. can be taken by the officers If they are In position in good time. This enables the
change of traction from the very first day of energization on trial basis and increase it to a very
significant level immediately after CRS's inspection and sanction for carriage of passenger traffic.

21003 Duties of Senior Divisional Electrical Engineer (TrD)

1. Assisted by his DEE/AEE(TrD) he WILL follow up with the Construction Organization to ensure
that the following works are ready well in advance of the-date of commissioning:-

(a) Accommodation for the new Sr.DEE(TrD)'s Office together with necessary furniture ,office
equipment etc.
(b) Central Repair Shops, PSI and maintenance Depots, and Sub-depots with necessary road and
rail facilities.
(c) Full stock of spare parts, tools and plant, testing equipment, lifting tackle, emergency vans,
motor trolleys, push trolleys, jeeps, motor trucks etc. required for operation and maintenance.
(d) Installation of emergency power plant at the RCC.

2. He will make a detailed study of tariff for power supply and get acquainted with officers of the
power supply authorities.

3. He will arrange for creation and timely filling up of all posts required for operation and
maintenance.

4. He will ,arrange for screening and conversion training of staff expected to be rendered surplus
due to electrification and recruitment and initial training of the balance requirement of staff.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [205]
21004 Duties for Senior Divisional Electrical Engineer (RS)

1. Assisted by his DEE/AEE(RS) he will follow up with the Construction Organization to ensure that
the following works are ready well in advance of the date of commissioning: -

(a) Additional accommodation for the new Sr.DEE(RS)'s Office together with necessary furniture,
office equipment etc.

(b) Electric loco/EMU shed and out-station maintenance depots with all facilities like travelling crane,
pits for inspection, power supply, plug sockets, lighting, storage racks etc.

(c) Installation of the full complement of machinery, tools and plant and testing equipment at all
repair and maintenance depots.

(d) Full stock of spare parts and arrangements for stocking, them for recurring consumption.

2. He will also arrange for sanction for necessary posts for operation and maintenance of rolling-
stock.

3. He will arrange for screening and conversion training of Steam/Diesel Drivers through all phases
including their basic theoretical and practical training in electric rolling-stock, their learning the road
and rules for operation of electric stock.

4. He will arrange for preparation of loco link diagrams and Drivers' rosters as well as Trouble-
shooting Directory for different types of rolling stock.

5. He will arrange for screening and conversion training of maintenance staff rendered surplus due
to electrification and also recruitment and initial training of balance requirements of staff.

21005 Responsibility of Construction Organisation

The Construction Organization is responsible for the execution and completion of works and testing,
commissioning and handing over all. installations in proper working condition to CEE of the Open
Line and in particular to ensure that-

1. the design of all installation is in accordance with approved standards and where any departure
from accepted norms becomes necessary approval of Railway Board/ RDSO/ CRS/ Flectrical
Inspector is obtained;
2. progressing of works is done to comply with the target dates fixed by the Railway Board and all
works executed are to a high standard;
3. procurement of all special stores, transport vehicles including OHE- inspection cars for
maintenance, tools . and plant, machinery and testing instruments and their handing over to the
Open Line in two stages the minimum
required before tests and trials followed by the balance immediately after installation and
commissioning in done (refer Appendix VI);
4. the CEE informed of all developments and in consultation With him the programme and date for
commissioning of installations is fixed;
5. copies of all approved , specifications, contract documents and Important letters are furnished to
the CEE. Sufficient number of copies of all , specifications and manufacturer's instruction booklets
should be to the Divisional Officers concerned so that they may be distributed to the maintenance
Staff. "As made drawings" or tracings incorporating all modifications during construction,
countersigned by the Engineers of the Contractor and construction organization are handed over to
CEE of the Open Line for safe and permanent custody;
6. exercising necessary co-ordination with the Supply Authorities to ensure that power supply "I be
made

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART] [206]

available and with the P & T Department to ensure that all their works will be completed and the
necessary clearance given for energization of the lines well in advance; and

7 complying with all the formalities connected with the energization of all sections in accordance
with the rules laid down.

21006 Commissioning of Traction Substations

1. Energization of traction substations is the first step towards commissioning of electric traction on
a new section of a Railway. This can be done subject to-

(a) Power Supply Authorities being ready to give power supply;

(b) detailed inspection of the substations, protective equipment and connected RC equipment
having been completed and test being quite satisfactory;

(c) full communication facilities being available;

(d) permission for energization of the substation having been received from CEE and Electrical
Inspector to the Railway.

2. Norwilly all sub-stations should be commissioned well before the date fixed for energization of
OHE for commercial traffic use. With the sanction of CRS limited trial runs could be undertaken after
the sub-station is commissioned.

3. On the appointed day,necessary clearance certificates should be obtained from the Contractors,
Dy.CEE(PSI), Officers of the Supply Authority and.others who were working at the substation during
the construction period,' that their staff have been withdrawn and the substation may be energized.
The 25kV feeder Isolators at the sub- station and feeding post ends should be opened and locked
and the 25 kV feeder conductors solidly earthed by duplicate earths. Readings of the tariff metering
equipment should be recorded and the meters jointly sealed by the Open Line Sr.DEE/DEE and the
Officers of the Supply Authority. After final meggering of the whole installation, all circuit breakers
and isolators are kept in the open position and the 'remote/local' switch put in the 'local' position.

Power supply may then be switched on step by step to the transformers and busbars and the
indications on the control panel checked. Subject to everything being in order, operation of the
various control-gear can be checked, followed by tripping of circuit breakers by manually closing the
contacts of the protective relays. Finally, overall confirmatory test may be conducted of the correct
tripping of circuit breakers when close against dead-short circuits on the 25 kV busbar. This test will
also confirm If the settings of the grid sub-station relays are properly co-ordinated with the settings
of the traction substation relays so that the grid substation CB's do not trip for a fault on the 25 kV
installations.

4. The two transformers may then be kept energized continuously. An experienced supervisory
official should be deputed to keep a close watch on the equipment for the first three days, followed
by a detailed inspection after a week and then after fortnight.

Should a circuit breaker trip during the period, the cause should be carefully investigated. The
annunciator panel should be checked to ascertain which of the relays have operated. Occasionally
the Buchholz relay may operate. A probable cause for this when a transformer is energized for the
first time is that air bubbles which may have been entrapped between the windings when oil is filled
into the transformer tank, may get released when the transformer gets warmed up and may operate
the Buchholz. However, a careful check is still necessary to ascertain the cause of every tripping.

5. 25 kV power supply may he extended up to the feeding posts if all work on 25 kV feeders and the
feeding posts has been completed in all respects, after taking the usual safety precautions.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [207]

21007 Sanction of CEE and Electrical Inspector to the Railway

1. Application shall be submitted at least a fortnight before energization to CEE and Electrical
Inspector to the Railway for the following:-

(a) Formal approval, if not already received to the design and layout of all high voltage equipment
including traction sub-stations, transmission lines, 25 kV feeders, switching stations, booster
stations etc.

(b) Approval for energization of HT installations mentioned above including OHE,

2. The following documents shall accompany the application for El's sanction.

(a) Copies for Press cuttings of the Public notification as mentioned in para 21008.

(b) Certificate regarding OHE (proforma 10-03).

(c) Certificate regarding bonding and earthing (proforma 10-04).

(d) Certificate regarding safety instructions and precautionary measures (proforrna.10-05).

(e) Certificate by DRM regarding safety precautions (proforma 10-06).

(f) Copies of insulation resistance test results of OHE.

(g) Insulation test results values for auxiliary and booster transformers.

(h) Test results for equipment in switching stations and sub-stations and their safety certificates,if
earlier sanction for the energizing this is not o6tained separately.

(I) Clearance certificates form Deptt. of Telecommunication.

0) Any other data, test results and certificates required by the Electrical inspector.

The sanction of the Electrical inspector may be issued in the proforma 10-07.

21008 Notification Regarding Energization of OHE

1. A notification indicating the intention to energize completed section/s of OHE, a month in advance
of the approximate date on which the line is expected to be energized, will have to be issued to the
following:-

(a) The Press.

b) The CRS and CEE and Electrical Inspector.

c) General Manager, Chief Operating Manager, Chief Engineer/Construction, Chief

Commercial Manager, Chief Mechanical Engineer, Chief Signal and Telecommunication
Engineer, Chief Security Officer and Divisional Railway Managers concerned.
d) Power Supply Authorities.

e) Posts & Telegraphs Department. .

f) Field Officers of Railway Electrification.

g) OHE Contractors
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [208]
(h) Goverment Railway Police.

The notification shall be issued in the proforma 10-01 appended.

2. Notification regarding level crossing gauges:

At least a month in advance of the energization of a section, a notification in the proforma 10-02
appended shall be issued by the concerned Railway for the safety of public and vehicles using level
crossings. This notification shall be published in local papers and also in the Gazettes of Railways
and State Govt.

3. Notification for particular section to be energized:

At least a fortnight in advance of the probable date of energization, a notification in the proformna
10-01 shall be issued by the field unit of RE construction, notifying all concerned of the energization
of the relevant portion of the section.

21009 Application to CRS

1. Sanction is required from the CRS in respect of

(a) Introduction of electric traction on any railway or section of a railway;

(b) bringing into use any type of electric locomotive or EMU or to operate any in service at speeds
higher than those already sanctioned;

(c) For new yard lines/loop lines/sidings being laid down and electrified: Electrification of existing
lines on already electrified sections/loops/sidings/yards lines of length not more than 2 km
permission to introduce electric traction shall be granted by Electrical Inspector.

2. Prior to the energization of any section, the following certificates and documents shall be
submitted to the CRS:-

(a) General Safety Certificate of Works, signed by CEE and CSTE of the Construction Organization.

(b) Safety Certificate for electrical works signed by CEE of Open Line and CPM/CEE/Dy. CEE of the
RE Organisation.

(c) Safety Certificate in respect of electric rolling-stock signed by CEE, CME, COM and CE of the
Open Line Railway.

(d) Certificate of Open Line Officers about the knowledge of their staff regarding safety rules for
electrified sections.

(e) Certificate issued by DRM of Open Line regarding introduction of safety measures, issue of
Special Station Working Rules and obtaining assurance of the staff concerned regarding their
knowledge of rules applicable to ac traction.

f) Copies of Station Working Rules which have been distributed to the various Station Masters.

2 1 0 1 0 Procedure for Energization

1. The inspection of the entire section will be carried out by means of an OHE Inspection car by
CRS alongwith CEE or his HODS, Chief Project Manager (CPM)/RE alongwith their concerned
officers and the concerned Divisional Officers. During this inspection particular attention is paid to
the safety and operational aspects of the

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [209]

train movements and that staff are in possession of statutory rule books, Instructions Book,
Registers, forms etc. and that transportation, Electrical, P-Way and S&T staff are fully acquainted
with their duties after ac traction is introduced. CRS may issue sanction to energize the OHE and
authorise trial runs with light electric locomotive as well as a few goods trains.

2. Wide publicity through the Press and posters given earlier would keep the public fully informed
about the proposal to electrify the lines and warned to danger of live OHE. The Station Masters
should, nevertheless, advise and warn all passengers of the danger of 25 kV OHE and not allow
them to ride on the roofs of coaches. All Diesel and Steam engine Drivers should also be advised
that they should, under no circumstances, climb over engines or tenders when they are under the
OHE, as they will endanger their lives by coming close to the live OHE. Train watering staff should
also be cautioned so that they may not Inadvertently climb on the carriages, by old habit.

Energization of OHE..

3. On the appointed day and hour, all concerned will assemble either at a feeding post or at the
RCC assuming it has already been commissioned. The entire energization operation shall be
carried out under one Senior Electrical Officer who will be nominated for the purpose. He AI first
collect the following Clearance Certificates: -

(a) Certificate from Contractors working on OHE, switching stations, booster transformer stations,
RC and also from other agencies whose staff were engaged on construction works, to the effect that
their men have been withdrawn from work, that they have been warned that installations would be
energized and that no work be done thereafter without obtaining a permit-to-work.

(b) Joint Certificate by the RE and Open Line Sr.DEEs stating that they have withdrawn their staff
and warned them as above and that the installation has been jointly inspected and is fit for
energization and also that due precautions have been taken to protect contiguous sections where
men may be working.

(c) Certificate issued by S&T Officers that their work has been completed and the OHE can be
charged at 25 kV ac.
(d) Certificate of the CEE and Electrical Inspector of the Railway permitting energization.
(e) Sanction of the CRS permitting operation of ac rolling-stock and energization of the OHE.
(f) Certificate of clearance from DOT for energisation of OHE; provided further that no such
clearance shall be necessary in cases of additions and. alterations to traction Installations on
existing electrified routes where CEE and EIG is satisfied that the amount and nature of traction
energy transmitted in the system as a whole, will remain unaltered.

Standard forms for issue of typical certificates and notification mentioned in this chapter are
appended at the end of this Chapter.

4. The Senior Electrical Officer in-charge of the energization programme will supervise the detailed
sequence of operations to switch on 25 kV supply progressively, step by step, starting with 25 kV
feeders from the sub-station to the feeding post, busbars of the feeding post, followed by one sub-
sector after another until the whole section is energized. It is best to start by keeping all circuit
breakers and interruptors in the open position so that one after the other they may be switched on
according to a prearranged programme. The merit of this procedure is that a faulty sub-sector, if
any, is immediately identified. Alternatively, the whole section covered by a sub-station may be
energized at one go. Should the feeder circuit breaker trip, it will be necessary to identify the faulty
sub-sector and arrange for its rectification. Before commencing energization, certain essential staff
should be kept ready at strategic locations enroute to rectify any faults which may be detected,

5. A short time after the energization of OHE confirmatory tests for proper operation of the protective
relays as per para 20931 shall be carried out.

INDIAN RAILWAYS - Ad TRACTION MANUAL - VOLUME 11 PART [210]

21013 Sanction of CRS
Subject to the trial run being satisfactory, an "all concerned message" may be issued by the CRS
communicating his sanction for the introduction of commercial services.

After the receipt of CRS's sanction, commercial services may be commenced either immediately or
subsequently. It is, however, desirable wherever possible to cheek the performance of the electric
locomotives and OHE for sparkless current collection at different speeds during night time, when
hauling a fully loaded train. These tests may be conducted jointly be Dy.CEE(OHE)(RE), Sr.
DEE(TRD) and Sr. DEE (PS) along with representatives of the OHE Contractor. Defective working
noticed shall be rectified as soon as possible and on successful completion of the tests, a joint
certificate shall be given confirming that full commercial working may be introduced.

21014 Anti-theft Energization

To over come the problem of copper wire thefts, it may sometimes be necessary to charge the
conductors at 2.2 kV. Guidelines for such charging of OHE are given in the Appendix Vii to this
Volume.

21015 Responsibility for Maintenance and Provisional Acceptance Certificate

1. When a long sections is under Electrification, shorter sub-sections are often energized as an anti-
theft measure. Till such time commercial services are not Introduced after CRS's inspection and
sanction, the OHE and other power supply and switching installations shall be maintained by the
construction organisation.

2. With the energization of the OHE and CRS's sanction and introduction of commercial services, all
electrical equipment including sub-stations and all other connected equipment are deemed as
having been taken over the Open Line of the Railway and thereafter the responsibility for operation
and maintenance shall devolve on the Divisional Officers concerned.

However, in order to ensure that all works are completed by the construction organisation, a specific
"Handing Over" procedure may be evolved by openline CEE, CSTE & CE to bring out left over work
if any; to be completed even after introduction of commercial services. The construction
organisation shall have such work completed in a reasonable period.

3. A letter of "provisional acceptance" shall then be issued by the head of the Construction
Organization to the 'various Contractors in respect of the equipment erected and handed over by
them. Should the test results for any particular equipment or Installation be unsatisfactory, an
extension may be given to the Contractor to have the defects set right and to hand over the
installation in good condition. When this has been done, a separate letter of acceptance shall be
issued in respect of such equipment. The provisional acceptance certificate shall be jointly signed
by the concerned Dy. CEE of the Railway Electrification Organization and Sr. DEE (TrD) and
Contractor's authorized representative. ,

21016 Contractor's Responsibility During Guarantee Period

1. This is defined by the terms of the contract. Norwilly, the Contractor of a "supply and erection"
contract guarantees the satisfactory operation of all equipment and Installations for a period of
twelve months from the date of issue of "provisional acceptance certificate". The contractor provides
the services of an experienced Engineer to maintain liaison with Officers of the Open Line and the
Construction Organization and help in rectification of defects observed and investigation of serious
breakdowns of equipment, and advise on the maintenance procedures. The contractor is expected
to bear the cost of all modifications, additions and substitutions which may be considered necessary
due to faulty materials, design or workmanship of the installations for which he is responsible.

2. Most of the heavy equipment for sub-stations, switching stations, booster stations etc. are
usually obtained from different manufacturers against a "Supply Contract". In such cases, the usual
guarantee clause provides for suppliers responsibility for a period of 12 months from the date of
commissioning or 18 months from the date
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 212
of supply-whichever is earlier. A clear record should, therefore, be maintained of the dates of receipt
of the equipment and the dates of energization of each equipment so that the period of responsibility
of the Contractor is clearly defined.

3. It is essential for the Electrical Officers and Supervisors concerned to make a careful study of the
contract documents so that appropriate action may be taken as circumstances dictate. In regard to
the defects noticed during the guarantee period the procedure to be followed for reporting and
investigation are described in the next para.

21017 Failure of Equipment After Commissioning and During the Guarantee Period

Although during this period the equipment is operated and maintained by the Open Line Railway
Engineers, the procedure described below should invariably be followed to ensure that defects
noticed during the guarantee period are rectified by Manufacturers under the Guarantee Clause.

1. Instructions issued by the manufacturers for operation and maintenance should be strictly
followed by the Railway. If any modification is required, approval of the Manufacturers should first
be obtained. The standard Guarantee Clause provides that the equipment shall be free from defects
in material and workmanship during manufacture. The liability of the supplier in this respect is
norwilly limited to the supply and installation of replacement parts, free of charge, and repair of
defective parts noticed during normal usage of the equipment as also those, attributed to faulty
design of the equipment. If the equipment becomes irreparable the supplier will have to replay the
same in its entirety.

2. It is essential that any defect noticed is brought to the attention of the supplier without delay. A
clear record of defects and deficiencies noticed shall he entered in a register by the Open Line
Officer and the date of intimation to supplier recorded against each item.

3. When an equipment fails, the Sr.DEE shall first make an inspection of the equipment on the spot
with the least possible delay along-with the representative of the Contractor. The presence of the
Manufacturer's or Contractor's representative is essential and should be ensured during the joint
inspection to avoid disputes later on. The defective equipment shall not be dismantled or disturbed
except with the approval of, or in the presence of, the representative of the supplier, to avoid
obliteration of any important evidence which could help in investigation of the defect. After the
inspection, a joint report shall be prepared recording the relevant data such as-

(a) Full particulars of the equipment - date received and date commissioned.
(b) Full circumstances in which failure occurred.
(c) Observations and tests made
(d) Probable cause that could lead to the failure.
(e) Recommendations, long term and short term, for preventing such failures in future.

4. -Should there be repeated failures of the same type, the cause of failure should be investigated
intensively, taking all connected factors Into account such as switching operations carried out,
maintenance work done etc. These factors should be statistically analyzed. A report on the failure of
the equipment should be sent promptly to the supplier of the equipment endorsing a copy to the
COS, Inspection Agency, CEE and RDSO.

In the case of works contracts, too, the same procedure should be followed.

6. According to the provision of the contract, in the event of design defects, the contractor's liability
is not only limited to repair/replacement of the components/equipments affected; but also to all other
components in similar situation/ condition. even though they may not have failed in service, have to
be replaced or modified by the supplier. This aspect needs careful study by the Sr.DEEs.

INDIAN RAILWAYS AC TRACTION MANUAL - VOLUME 11 PART 213

21018 History Sheet

Maintenance of a History sheet for each major equipment is very important as this will give a
connected account of all failures of the equipment and particulars of repairs carried out and will be
of great help in investigating recurring failures.

21019 Final Accentance Certificates

Immediately after the comletion of the guarantee period, a final acceptance certrificate shall be
jointly signed by the Sr. DEE of the concerned Railway and Contractor s representative and
countersigned by the head of the cCnstruction Organisation and issued to the Contractor, provided
that the terms of the Guarantee Clause have been fulfilled. With the issue of the final acceptance
Certificates, the responsibility of the Contractor or Supplier ceases, but their advice may still be
sought where it may be consiered necessary.

21020 Standard Forms

Typical forms for issue of notifications and certificates mentioned below are appended at the end of
this chapter.

SN. Particulars Proforma

-------------------------------------------------------------------------------------------------------------------------------------
----------
1. Public Notification regarding energisation 10-01
2. Public Notification regarding level crossing 10-02
3. Joint Certificate regarding OHE by Sr. DEE(TrD) 10-03
& Dy. CEE(OHE)/RE
4. Certificate regarding bonding and earthing 10-04
5. Joint Certificate by Divisional Officers regarding safety instructions 10-05
6. Certificate by DRM regarding safety measures 10-06
7. Sanction of CEE and Electrical Inspector for energisation 10-07
8. Certificate by S&T Department 10-08
9. Clearance certificate by DOT 10-09
10. Clearance Certificate for 25 KV feeder line 10-10
11. Clearance Certificate for OHE 10-11

12. Clerance Certificate for Switching Station 10-12

13. Clerance Certificate for Booster Transformer Station 10-13
14. Clerance Certificate for DOT and works 10-14
15. Clerance Celrtificate by OHE Contractor 10-15
16. Clerance Certificate by Switching Station Contractor 10-16
17. Clerance Certificate by Remote Control Equipment Contractor 10-17
18. Clerance Certificate by Contractor for Booster Transformer Installation 10-18

INDIAN RAILWAY AC TRACTION MANUAL VOLUME II PART I 214

 Proforma 10-1

INDIAN RAILWAYS

PUBLIC NOTIFICATION"

Notice is hereby given to all users of Railway lines and premises situated on the completed section
of the under- noted section of the ............ Railway that the 25000 Volt, 50 Hz., ac overhead traction
wires will be energized on or after the date specified against the section. On and from the same
date the overhead traction line shall be treated as live at all times and no unauthorized person shall
approach or work in the proximity of the said overhead line.

Section Date

1
2.
3.
4.

Chief Project Manager

Railway Electrification

(To be published in all the leading Newspapers and local Railway Gazette in English, Hindi and
local language for one day at least a week before the date of commissioning. Also notices to be
pasted at all Railway Stations and Offices to give wide publicity).

Copy forwarded for information to:-

1. The Secretary (Railway Electrification), Railway Board, New Delhi.

2. The Commissioner of Railway Safety.

3 The Chief Electrical Engineer and Electrical Inspector.

4 All other Heads of Departments.

5 The Divisional Railway Managers of the Railway and contiguous Divisions.

6 The General Manager (DOT) Railway Electrification Project,

7 The Postmaster General,

8 The Chief Engineer, State Electricity Board.

9 The Superintendent, Government Railway Police.

10 All officers of Construction Organisation.

1 1. Contractors engaged in the project.

PlACE: Chief Project Manager

Date Railway Electrification

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 215

 Proforma 10-02
INDIAN RAILWAY
INTRODUCTION OF ac 25 kV TRACTION

"WARNING TO ROAD USERS"

It is notified for information of the Public that in connection with introduction of 25 kV ac electric
traction over the section .............. of the ........... Railway, height gauges have been erected at all the
level crossings with clear height of 4.67m above road level with a view to prevent loads of excessive
height from coming into contact or dangerous proximity to live traction wire.

Public are hereby notified to observe the height specified above for the purpose of loading vehicles
and to see that the loads carried in road vehicles do not infringe the height gauges under any
circumstances.

The dangers of a load of excessive height are as follows: -

i) Danger to the height gauge and consequent obstruction to the road as well as the railway line.

ii) Danger to the materials or equipment carried or the vehicle itself.

iii) Danger of fire and risk of life due to contact with or dangerous proximity to the conductors.

No.

Date Chief Project Manager

Railway Electrification

(To be given wide publicity through the press and posters well in advance of erection of height
gauges).

Proforma 10-03

CERTIFICATE REGARDING OHE

Certified that the OHE in the above mentioned section has been erected as per approved and
standard specifications and there are no infringements to the Schedule of Dimensions (including the
Rules applicable for 25 kV ac traction) except when approval of Railway Board/competent authority
has been obtained. The OHE has been inspected and found to comply with the above requirements.

Sr. DEE (TRD) Dy. CEE(OHE),

RE

PlACE:

Date
Proforma 10-04

CERTIFICATE REGARDING BONDING AND EARTHING

Certified that bonding and earthing of the section have been carried out as per the "Bonding Code"
and as per approved drawings.

Dy.CSTE(Signalling) Sr. DEE (TrD) Dy.CEE(OHE), RE

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 216

 Proforma 10-05
CERTIFICATE REGARDING SAFETY INSTRUCTIONS AND PRECAUTIONARY MEASURES

Certified that requisite instructions in connection with working on tracks and areas equipped with
25kV ac traction have been issued to all categories of staff of various departments working on and
required to work on the section.

Further, it is certified that all staff have been made fully conversant with the safety and
precautionary measures to be taken when working in the electrified areas.

SR.DOM DSO SR.DEN SR.DME

SR.DSTE Sr. DEE (G) Sr. DEE (TrD)

Countersigned

Divisional Railway Manager

........................................Division

Proforma 10-06

CERTIFICATE BY DRM REGARDING SAFETY PRECAUTIONS

1 do hereby certify that:-

(i) Stations on the electrified sections between ... have been supplied math a copy of General and
Subsidiary Rules for 25 kV ac electric traction.

(ii) Special working rules for 25 kV ac electric traction have been issued and supplied to all stations
and cabins on the electrified sections.

(111) The staff have been advised of the necessary safety procedures and precautions as laid down
in General and Subsidiary Rules and Manual for ac Traction Maintenance.

(iv) All the sectional running and maintenance staff have also been duly instructed in safety
procedure and precautions for 25 kV ac electric traction.

(V) The assurance of the station, running and maintenance staff regarding their knowledge of safety
procedures and special working rules has been obtained.

Divisional Railway Manager

....................................Division

....................................Railway

INDIAN RAILWAYS - AC TRACTION MANUAL;- VOLUME 11 PART [217]

 Proforma 10-07
.....................Railway

To,

Chief Project Manager

Railway Electrification

Sub: Sanction for energization of overhead equipment, switching stations. booster transformer
stations etc. on the Section.
...................
Sanction is hereby accorded to energize progressively the completed works for 25 kV feeder lines
from traction Sub-stations to feeding posts, switching stations, booster transformer stations and
auxiliary transformer stations, as and when each section is completed arid jointly inspected,
measured IR value and certified by Sr.DEE(TrD)/ ..................... and DY.CEE (Construction).

Chief Electrical Engineer

and Electrical Inspector,
....................... Railway.

Proforma 10-8
Chief Project Manager
Railway Electrification
.....................................
......................................
Reg: Energization of the OHE in the section ...........................................................-Signalling Works.

1. All modifications to mechanical and electrical signalling have been carried out to make the
installations suitable for introduction of 25 kV ac traction.
2. Colour light signalling has been installed at ............. stations and the mechanical semaphore
signals have been re-sited and/or their heights increased to afford necessary visibility to the engine
crews.
3. The existing block and token instruments have been modified to suit the introduction of 25 kV ac
traction.
4. All overhead signalling circuits have been transferred to underground cables. Communication
installations have been modified to make them suitable for 25 kV ac traction. Traction Loco
Control, Traction Power Control and Emergency Control circuits have been introduced with
emergency sockets alongside the track as per approved plans.
5. The new signals have been erected and the existing signals re-sited without infringement to the
Schedule of Dimensions" except where approval of Railway Board/competent authority has been
obtained.
6. Necessary rule books in connection with working in the section energized with 25 kV ac have
been issued to the staff concerned. Specified insulated tools have been issued to the S&T staff for
working
in the above section.
7. The modifications and the new works mentioned above have been done according to the "Manual
of Instruction for Installation of S&T Equipment on 25 kV, 50 Hz ac Electrified Sections".
8. The undersigned has no objection to the energization of the section mentioned above with 25 kV
ac with effect from .............
Dy.Chief Signal and Telecommunication
Engineer (Railway Electrification)
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 218
 Proforma 10-9
CLEARANCE CERTIFICATE

Chief Project Manager

Railway Electrification
.......................................
.......................................

Sub: Energization of OHE in the Section ...................................................

The DOT has completed all its woks in connection with electrification of the above section at 25 kV
ac and has no objection to; the Railway energizing the OHE with 25 kV ac in the above section.

for General Manager

(Electrification Circle)

Proforma 10-10
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV

1. 25 kV Feeder Lines

1. Detailed description of installation to be energized:

25 kV double circuit feeder line from... substation to............................ feeding station near the
tracks.

It is hereby certified that:

a) The above installation has been jointly checked tested for completeness, electrical clearances,
insulation resistance, earthing etc. and found in order. Test results are separately submitted.

b) The works have been completed in accordance with approved and complies in all respects with
the requirements of the "Manual of ac Traction Maintenance and Operation", Indian Electricity Rules
and special instructions on the subject.

c) All our staff have been withdrawn and warned that the line will be charged at 2.5 kV ac
immediately. Clearance Certificate to the same effect have been obtained from all the Contractors
working on the above section. No work on the above section will be taken up hereafter without
obtaining a power block from an official authorized by Sr. DEE (TrD).

d) All other safety precautions necessary have been taker,

3. The 25 kV feeders referred to above are now clear and fit for energization and may be energized
at 25 kV ac.

4. Forwarded to CEE(RE).
...............................
........................................... DY.CEE (OHE)RE
Sr. DEE (TrD)

PLACE.
Date.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 219

 Proforma 10-11
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV
2. Overhead Equipment

1. Detailed description of overhead equipment to be energized:

2. It is hereby certified that:

a) The above overhead equipment has been jointly checked for completeness, electrical clearances
and tested for insulation and continuity, electrical independence of different elementary sections as
also bonding and earthing etc. and found to be in order.

b) The work has been completed in accordance with the latest approved generally supply diagram
and sectioning diagrams etc. and complies In all respects with the requirements of "Manual of ac
Traction Maintenance and Operation" and Indian Electricity Rules.

C) All our staff have been withdrawn and warned that the line &411 be charged at 25 kV ac
immediately. Clearance Certificates to the same effect have been obtained from all the Contractors
working on the above section. No work on the above section will be taken up hereafter without
obtaining a power block from an official authorized by SR.DEE (TrD).

d) All safety precautions necessary have been taken. In accordance with "Manual for ac Traction
Maintenance and Operation" Sections viz ..................... have also been adjusted, checked and
made ready for energization. Solid earths have also been provided on contiguous sections viz. at
structures Nos ...................... Isolating switches Nos .............. and interruptors Nos .......... have
been opened and kept locked in the open position.

3. The overhead equipment referred to above is now clear and fit for energization and may be
energized at 25 kV ac.

4. Forwarded to CEE(RE).
...............................
Sr. DEE (TrD)
PLACE ........................
Date .........................
...............................
Dy.CEE(OHE),RE

Proforma 10-12
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV
3. Switching Stations

Detailed description of switching stations to be energized:

a) The above switching stations have been jointly checked and tested for completeness, correct
electrical connections including cross-feeder connections, electrical clearances, insulation
resistance, earthing and bonding etc. and found to be in order. Test reports are separately
submitted.

b) The works have been completed in accordance with approved drawings and complies in all
respects with the requirements of the "Manual for ac Traction Maintenance and Operation", Indian
Electricity Rules and special instructions on the subject.

INDIAN RAILWAYS AC TRACTION MANUAL -VOLUME 11 PART] [220]

C) All our staff have been withdrawn and warned that the line will be charged at 25 kV ac
immediately. Clearance Certificate to the same effect have been obtained from all the Contractors
working on the above section. No work on the above section will be taken up hereafter without
obtaining a power block from an official authorized by Sr. DEE (TrD).

d) All other safety precautions necessary have been taken.

3. The switching stations referred to above are now clear and fit for energization on 25 kV ac.

4. Forwarded to CEE(RE).
................................

Sr. DEE (TrD)

............................
Dy.CEE(PSI),RE
PLACE. ...............
Date...............

Proforma 10-13
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV
4. Booster Transformer Stations

1. Detailed description of Booster Transformer Stations to be energized:

2. It is hereby certified that: -

a) The above Booster Transformer Stations have been jointly checked and tested for completeness,
correct electrical connections including cross-feeder connections, electrical clearance, insulation
resistance, earthing, bonding, midpoint rail connections and found to be in order. Test reports are
separately submitted.

b) The works have been completed in accordance with approved and complies in all respects with
the requirements of the "Manual for ac Traction Maintenance and Operation", Indian Electricity
Rules and special instructions on the subject.

c) All our staff have been withdrawn and warned that the line will be charged at 25 kV ac
immediately. Clearance Certificates to the same effect have been obtained from all the Contractors
working on the above section. No work on the above section will be taken up hereafter without
obtaining a power block from an official authorized by SR.DEE (TrD).
d) All other safety precautions necessary have been taken.

Forwarded to CEE (RE).

..................................
Sr. DEE (TrD)
............................
Dv.CEE(PSI),RE

PLACE. .................
Date. ....................

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 11 PART 1 [221]

 Proforma 10-14
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV

5. DOT and S&T WORKS

1. Description of section for which clearance is given:

2. It is hereby certified that:-

a) Clearance has been obtained from the DOT, Electrification Circle that the overhead equipment,
switching and booster transformer stations on the above section may be energized at 25 kV. ac.
b) All S & T works have been completed in accordance with approved and instructions, and
complies in all respects with requirements of "Manual for ac Traction Maintenance and Operation"
and special instructions.
c) All our staff have been warned that the above section would be charged on 25 kV ac
immediately. No work on or within 2 m of the line OHE would be parried out hereafter without
obtaining a power block from an official authorized by SR.DEE (TrD).
d) All safety precautions necessary have been taken, in accordance with "Manual for ac Traction
Maintenance and Operation".

3.The sections referred to above may now be energized on 25 kV ac.

...........................
Dy.CSTE(Sig.
......................
DY.CSTE (Tele)
PLACE.........
Date............

Proforma 10-15

The DY.CEE (OHE) .

.................... Electrification Project
. ...................................................

Sub: Clearance Certificate by Contractor for energization on 25 kV ac in Section..

Dear Sir,

1. It is hereby certified that all our work on the above section has been completed.

2. It is hereby certified that all our staff have been withdrawn and warned that the above section
would be energized on ................ and that no one may henceforth carry out any work on the above
section without obtaining a permit-to-work from an official authorized by SR.DEE (TrD).

3. Adequate precautions will also be taken by our staff when working in areas contiguous to the
section electrified on ac 25 kV system or on parallel lines.

4. The dead overhead sections contiguous and adjacent to the electrified sections have been and
will be kept solidly earthed. The installations on the above section are now ready and safe for
energization. They may now be charged at 25 kV ac, 50 Hz, supply.

Yours faithfully,

for M/s ..................

Contractor for OHE.

INDIAN RAILWAYS --- AC TRACTION MANUAL - VOLUME 11 PART 1 [222]

 Proforma 10-16
To
Dy.CEE(PSI),

...................................Electrification Project,
................................ .................................

Dear Sir,

Sub: Clearance Certificate for energization of Switching Stations in Section ................................

It is certified that all physical works have been completed on the following FPs, SPs, & SSPs and
that these switching stations are fit to be charged with 25 kV ac single-phase, 50 Hz., electrical
energy on and from ................

All men, materials and earths have been removed from the switching stations and the OHE.

FP at .................

SP at .....................

SSP at ................

Yours faithfully,

for M/s ......................................... Contractor for Switching Stations

Proforma 10-17

To

DY.CEE (PSI),

...................... Electrification Project,

......................................................

Dear Sir,

Sub: Clearance Certificate for the commissioning of Remote Control Equipment in the Section..

It is certified that all works in regard to the Remote Control Equipment installed by us for the section
.............. have been completed and that they are fit for commissioning.

All men and materials have been removed from the site of the equipment and from the vicinity of the
switching stations.

Yours faithfully,

Date

for M/s ................................. Contractor for Remote Control Equipment.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [223]

 Proforma 10-18

To

DY.CEE (PSI),
.................. Electrification Project,
................................................

Dear Sir,
Sub: Clearance Certificate for the commissioning of Booster Transformers installed In the Section
..........

Certified that all works in regard to Booster Transformer Stations installed in the Section ....... have
been completed and the installations are fit for energization at 25 kV ac single-phase, 50 Hz., on
and from ...........

All men, materials and earths have been removed from the Booster Transformer Stations and from
the vicinity of the OHE.
Yours faithfully,
for M/s ....................................
Contractor for Booster
Transforrner installations

PLACE:

Date :

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [224 ]

 CHAPTER XI

RECENT DEVELOPMENTS

Para Nos. Subjects.

21100 2 x 25 KV Auto Transformer Feed System

21101 OHE Recrording cum Test Car
21102 Rail cum Road Vehicle
21103 Transportable Self Propelled Trolley
21104 Dry type Booster Transformer and Auxiliary Transformer
21105 Static Distance Protection Relay for Protection of OHE
21106 Composite Insulators.

INDIAN RAILWAY AC TRACTIAON VOLUME II PART I 225

 CHAPTER XI
RECENT DEVELOPMENTS
21100 2x25 kV Auto-Transformer Feed System

1. Incoming Power Supply

The incoming power supply scheme is similar to 25 kV simple feed system. Power supply for ac
traction is obtained from the nearest grid sub-station of the Power Supply Authority. For this purpose
duplicate feeders, generally at 132 kV or 22OkV, comprising only two phases are provided from the
grid sub-station to traction substation.

The loads, however, are 2-3 times higher compared to.25 kV system and therefore Wood-bridge/V-
connected transformers are provided in the traction substations to bring down the unbalance within
acceptable limits. It is possible to absorb such unbalances without exceeding the permissible limits if
the grid system capacity is adequate.

2. Power Receiving Arrangement: Traction Sub-station

The incoming extra high voltage power is stepped do" to 2x25 kV by the main traction power
transformer. The 2x25 kV supply is then fed to an auto-transformer. One terminal of the auto-
transformer is connected to the overhead catenary wires and the other terminal to a feeder wire
which runs parallel to overhead contact/catenary wire all along the section and is usually supported
from super masts fixed on the OHE structures. The mid point of the auto-transformer is connected
to the rail, thus providing a 25 kV supply, with reference to the rail potential, for traction.

The capacity of the auto-transformers and their spacing is decided based on the traffic pattern in the
section.

The general arrangement of the scheme for 2x25 kV auto-transformer feeding system is indicated at
Fig. 1. 0 1 This is for a Scott connected transformer substation.

3. Distribution of Traction Power Supply

Feeding Post (,FP)

The arrangement at the feeding post is generally similar to that at the 25 kV conventional system
feeding post.

Sectioning and Paralleling Post (SP)

A short neutral section is provided in the OHE opposite the feeding post as well as mid-way
between two adjacent traction substations. The feeder wire is also provided with a neutral section by
means of two cut-in insulators coincidental in space with the ends of the neutral section.

Sub-sectioning and Paralleling Post (SSP)

The arrangement at the SSP is generally similar to that at the 2SkV conventional SSP system.

Auto-Transformer Post

These are provided adjacent to the track through-out the length of the section. The spacing and
capacity of the auto-transformers is decided as a part of system design based on specific
requirements and traffic pattern. Typically the spacing is 15 km and capacity 2 MVA. Distribution of
current in AT system is shown in Fig. 11.02.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [226]
dynamic conditions. The proposed car will be of trailer type, suitable for running at speeds of 160
km/h with potential to run up to 200 km/h. The car shall be hauled by locomotive or attached to a
train. The car will be provided with on-board computer based data acquisition and processing
system. The facility for video recording of arcs generated due to interruption in current drawn by
locomotive as a result of loss of contact between pantograph and the OHE is also proposed to be
provided.

4. The various parameters proposed to be monitored are:

Measurements on pantograph:
a) acrodynamic upward force of the pantograph;
b) contact force between pantograph and contact wire;
c) vertical and horizontal movement of pantograph;
d) quality of current collection- loss of contact;

Measurements on OHE:
a) height of contact wire ;
b) stagger of the contact wire;
c) gradient of the contact wire;
d) detection of hard spots;
e) checking of crossovers and turn-outs;
f) body vertical acceleration;
g) body lateral acceleration;
h) quality of current collection - loss of contact.

21102 Rail-cum-Road Vehicle

Such a vehicle is suitable for propulsion both on the road as well as on the track. Two sets of
wheels are provided for this purpose. This vehicle is provided with an extendible swivelling platform.
The vehicle can be driven on road to the level crossing nearest to the work site and taken there on
the track.

21103 Transportable Self Propelled Trolley

This is a self propelled trolley which can be transported by a truck to a point accessible through
road, close to the work site, for carrying out work on OHE. The trolley is provided with extendible
swivelling platform.

21104 Dry Type Booster Transformer and Auxiliary Transformers

Conventional oil filled transformers require lot of care and attention for maintaining the characteristic
of oil within the permissible limits to avoid failure of Insulation.

Dry type cast resin transformer is a relatively new technology. The chief advantage of this type of
transformer over the oil filled ones is that they are practically maintenance free. The copper in the
windings cannot be retrieved from the cast resin and so the risk of theft is eliminated. There being
no oil risk of fire and explosion are also absent. Dry cast resin transformers are currently under
evaluation for their service performance.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [229]
21105 Static Distance Protection Relay for Protection of OHE

1. For the distance protection of the overhead equipment, the relay which is in use is the
electromechanical type. This relay has a Mho characteristic as illustrated in Fig, 1 1.03. The relay is
prone to trip on normal over loads because of its inadequate discrimination between load current
and the fault current when the fault is at the farther end causing undesirable tripping of the feeder
circuit breaker. This problem will be more acute in the future due to the further increase in traffic
anticipated and the increase in the traction power transformer capacity at TSS.

2.To over-come the above problem RDS0 has developed a static type distance protection relay.
This relay is a three zone relay,the first two zones having MhO characteristic and the third zone
having a lenticular characteristic with adjustable aspect ratio. The relay characteristic is illustrated in
Fig.11.04. While the first zone operation is instantaneous, the second and third zones have
adjustable time settings (zero to Is). The first zone can be set to cover about 80% of the OHE from
TSS to SP, the second zone to cover a distance which is slightly shorter than the distance to the
adjacent TSS and the third zone may cover the adjacent TSS. By providing a time delay of about 0.
4s to 0. 5s in the second zone/third zone of the relay, adequate discrimination between faults from
TSS to SP and SP to the adjacent TSS can be achieved - the under voltage relay at the SP acting
as primary protection and the second/third zones of the distance relay at TSS acting as back up
protection for faults beyond SP in case of feed extension. The settings of the various zones of the
relay should be based on the RDSO's guidelines in this regard.

3. As an alternative to the static distance relay described above, the static relay with parallelogram
characteristic as illustrated in Fig. 11.05 can also be used. At present these relays have to be
imported. However, efforts to develop these relays indigenously are on. The advantages of this
relay as compared with the electromechanical relay with Mho characteristic are similar to those of
the static relay described above. The relay settings for this relay also should be based on the
RDSO's guidelines in this regard.

21106 Composite Insulators

The conventional porcelain insulators have poor impact withstand capability. The sheds of such
insulators are easily broken during handling and also due to acts of vandalism. The glazed surface
of porcelain also does not have good hydrophobic property. These limitations can be overcome to a
great extent with the use of composite insulators. The composite insulator comprises a porcelain
(alumino) or a resin bonded glass fibre core and moulded sheds of elastomeric/plastic material e.g.,
silcone elastomer or poly-tetra-fluoro-ethylene (PTFE). The interface between the core and the
sheds is sealed with special compound to prevent ingress of moisture and direct tracking along the
length of the core. The end fittings are usually crimped to the core. Such insulators have exhibited
excellent performance in simulated pollution tests. They also have excellent impact withstand
capability. Efforts are on in RDSO to introduce such insulators.

INDIAN RAILWAYS -'AC TRACTION MANUAL VOLUME 11 PART 1 [231]

 CHAPTER XII

TRAINING AND COMPETENCY CERTIFICATES

I TRAINING

Para Nos. Subject

21200 Introduction
21201 Planning of Training in Advance
21202 Categories to be Trained
21203 Initial Training
21204 Promotical Courses
21205 Refresher Courses
21206 Facilities for Training
21207 Training in Genreal and Subsdiary Rules
21208 Responsibility of Officers and Supervisors
21209 Examination at the End of Training
21210 Specilised Training
21211 Syllabi

II COMPETENCY CERTIFICATES

21212 Authorised Person

21213 Competency Certificate
21214 Qualified Person to be Incharge of Motor Trolley
21215 Period of Training
21216 OHE Inspection Cars
21217 Knowledge of Rules
21218 Register of Certificates
21219 Service Records
21220 Inspections.

INDIAN RAILWAY AC TRACTION MANUAL VOLUME II PART I 233

 CHAPTER XII

TRAINING AND COMPETENCY CERTIFICATES

1. TRAINING

21200 Introduction

Electric traction is a specialized field. Efficient operation and maintenance of the traction
installations and equipment is only possible if the staff concerned have acquired an intimate
knowledge of the details of construction, adjustments and operation of the equipment. A thorough
knowledge of the special rules and procedures on the part of the staff is also essential to ensure
safety of equipment and personnel. These requirements call for specialized training for all
categories of staff before they can be entrusted with the responsibility for maintenance or operation.

21201 Planning of Training in Advance

Before electric traction is commissioned on any section, adequate strength of weft-trained operating,
maintenance and running staff should be kept ready for manning the services. Planning the
recruitment and training of such staff well in advance is one of the most important tasks of the open
line administration. It is also necessary to establish sufficiently in advance suitable training schools
with the facilities for imparting the training by qualified instructors.

21202 Categories to be Trained

Categories of staff for whom special training is required to he organized are generally as under-

1. Degree and Diploma holders recruited directly as Supervisors

2. Apprentice Mechanics to be absorbed as Supervisors

3. Trade Apprentices to be absorbed as, skilled artisans

4. Artisans and supervisory staff to undergo Refresher Courses.

21203 Initial Training

1. Categories of staff mentioned below should receive a period of initial training in a training school
before they are posted to working posts-

a)Directly recruited supervisors;

b)Traction Power Controllers and Asstt. Traction Power Controllers;

c)Skilled and semi-skilled artisan staff for maintenance of OHE, PSI and RC equipment;

d)Any other category as approved by CEE.

2. The period of initial training for typical categories is given below, this may be modified by CEE in
accordance with local requirements :

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [234]

a) Directly recruited supervisors (Degree and Diploma Holders)-

i) OHE 12 months
ii) PSI 12 months
iii) Remote Control 12 months
iv) TPCs/ATPCS 18 months

b) Skilled artisans for maintenance-

i) Direct recruits 60 weeks

ii) To be absorbed from Diesel/Steam 30 weeks
or Electric general services

3. In addition to theoretical training, the trainees should receive thorough practical training on the
work they will have to perform on completion of training. In all cases they should have a period as
under-study to senior and experienced staff in actual execution of the type of work they have to
perform on completion of training.

4. For artisan staff the practical training should be so oriented as to enable them to understand and
be able to carry out independently skilled work of the type covered by 'Inspection books', 'Inspection
charts', 'trouble- shooting charts' and' technical charts'. Courses of training for each separate branch
viz. OHE, PSI and RC should be carefully planned and implemented for each category of staff.

21204 Promotional Courses

1. No employee should be promoted unless he passes the trade test or other prescribed
departmental test.

2. Before an employee can be promoted, he should, as a rule, receive training to enable him to
discharge his responsibilities in the higher post e.g., a semi -skilled fitter on promotion as a skilled
fitter. Such training should precede the departmental tests which determine suitability for promotion.
The training should be generally on the same lines as initial training, but the period may be curtailed
since the employee would already have a certain amount of background knowledge on account of
his experience.

Particular attention should be paid to the older men, who although very proficient in the practical
aspects of their work, are unable to pass the prescribed trade tests etc. In regard to the theoretical
aspects because of their poor educational background. It often happens in consequence that they
are blocked from being promoted although they are fit in every other respect. By paying individual
attention to such men and teaching them elementary theory, they could be made sufficiently trained
to enable their passing the trade tests. This not only ends their frustration, but boosts staff moral as
a whole.

21205 Refresher Courses

1. In accordance with extant instructions current on the subject, refresher courses should be
arranged. This is obligatory for those categories of staff dealing with safety of train operation or
having daily contact with the public. The following is an illustrative list of traction distribution staff
coming with in the scope of these instructions.

-Traction Power Controllers

-Asstt. Traction Power Controllers
-Supervisors of OHE
-OHE Inspection Car Drivers
INDIAN RAILWAYS - AC TRACTION MAN4JAL VOLUME 11 PART [2351
-linesmen authorized to take power blocks and permit-to-work

2. Refresher courses are also desirable for other categories of maintenance staff. The categories
of staff for whom refresher courses are to be arranged can be decided by the General Manager in
accordance with para 117(a) of the Indian Railway Establishment Manual.

3. The object of a refresher course is to reinforce and update the knowledge of the staff and bring
them up- to-date in regard to the latest rules and procedures and Instructions regarding operation
and maintenance in the light of experience gained. The duration of the refresher course for each
category may be decided by CEE to suit local conditions. The duration for typical categories is given
below for guidance :

a) Supervisors 3 weeks
b) Artisan Staff 2 weeks

4. For categories of staff liable for inter-divisional transfers, programming of refresher courses
should be arranged by the headquarters office. For staff confined to a particular division, the
programming should be done at the divisional level.

5.Apart from rules and regulations, the refresher courses for the operating staff should lay
emphasis on trouble shooting procedures for various types of euipments. Actual drilling during the
refresher course will be of great benefit. This involves repetition of the same exercise several times
so as to make a lasting impression on the staff and should not to be forgotten easily.

6. For Linesmen and Supervisors of the OHE section the main emphasis during the refresher
courses should be on standards to be obsrved in adjustments of OHE, safety rules applicable to
OHE work and methods of quick restoration of OHE in the event of breakdowns/accidents.

7 . During refresher courses, it will be very useful to arrange group discussions amongst the
trainees on specific problems encountered during the course of work. Such group discussions will
be of great assistance in view of the opportunity for exchange of information based on actual
experience in working.
21206 Facilities for Training

1. Facilities have been provided on an All India basis f6r the intensive specialized training of
officers and staff of the Electrical Department. The facilities available should be utilized to best
advantage.

2. Training schools for OHE staff have also been set up where the specialized techniques of work
on 25 kV OHE are taught to skilled artisans as well as supervisors with particular reference to safety
rules applicable to OHE work and methods of effecting emergency repairs. For example a cat-walk
at a height of about 5 m from ground level is provided, so that a trainee can climb up a post, walk
across the cat-walk and get rid of the fear of height, he can be taught the methods of protecting
himself by means of ropes and safety belts, the correct method of testing and earthing, the
technique of erecting a mast, the correct method of using the various specialized OHE tools and
equipment, the method of splicing various OHE conductors etc.

3. In a training school, the essential equipment to be provided for instructional purposes should
include the following:

a) Special tools and instruments used in electric traction.

b) Cut-models to show constructional details of equipment.

c) Circuit diagrams, sectioning diagrams, etc. illuminated and arranged to show the sequence of
operations.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [236]
d) Samples of damaged equipment with tablets explaining the nature and causes of failures and
preventive cheeks.

e) Publicity boards with slogans and illustrations emphasizing safe methods of working

f) Boards illustrating Do's' and "'Don'ts',

g) Preferably full working models.

21207 Training in General and Subsidiary Rules

Supervisors, when required, should receive initial training as well as refresher courses in General
and Subsidiary Rules norwilly In the Zonal Transportation Schools, which usually have model rooms
to facilitate the proper understanding of the rules and systems of working. In exceptional cases
when such training cannot be arranged conveniently in the Zonal Schools, CEE may authorize the
training in GRs & SRs to be included in the syllabus for training in TrD Training Schools. Separate
Instructors well versed in the subject should, however, be deputed for imparting the training.

21208 Responsibility of Officers and Supervisors

Apart from those in-charge of training schools, other officers and supervisors in-charge of operation
and maintenance should also take a keen personal interest in the trainees of all grades attached to
them. They should deem it as part of their duty to guide the trainees and watch their progress.
Training is a continuous process which helps the officers as much as the trainees not only in
developing contacts on a personal level, but also in understanding the finer points of operation and
maintenance. A record of progress achieved, the period of training given etc. should be maintained
for every trainee.

21209 Examination at the End of Training

All trainees should pass the prescribed examination on completion of training. The scope of
examination and the level of officers and supervisor responsible for examining will be laid down by
CEE, The examination should have a practical bias.

21210 Specialized Training

1. Selected staff from different categories should be deputed to work with the Contractor's staff
during OHE,
PSI and Remote Control construction work, so that they become fully proficient in the
various operations including erection final adjustment, testing and commissioning.
2. Similarly when large contracts are entered into for supply of electric traction equipment
incorporating new designs and technology, it is usual practice to include in the contract a clause
which permits some staff of the consignee railways to be deputed to the manufacturer's works
during the production stage for practical training on the equipment, so that they may get thoroughly
acquainted with the operation and maintenance of the equipment, taking advantage of the training
facilities available with the contracting firms.

21211 Syllabi

Outline syllabi for OHE Linesman is given below as examples. Syllabi on the same lines are
prepared for all courses of training.

1. OHE Linesman (Initial Training) - Duration: 60 weeks.

A. Theoretical:
(a) Basic principles of electricity - clear understanding of "Current", "Voltage", "Power" "Resistance'
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [237]
"Impedance" - use of common electrical measuring instruments, micrometer devices.

(b) Power supply arrangements for ac traction.

(c)Understanding the lay-out of OHE at feeding posts, running lines, turn-outs, crossovers, overlaps,
neutral sections, yards etc.

(d) Standard values of clearances, setting distances, contact wire height, permissible gradient,
stagger etc. applicable to. 25 kV OHE.

(e) Detailed. study of various fittings used on OHE viz. insulators, cantilever assembly, clamps,
splices, section insulators, anchor fittings, isolating switches, jumpers - constructional details of such
fittings and details of assembly and installations.

(f) Study of different types of masts and their foundations.

(g) Detailed study of various tools, tackles. and other gadgets used in OHE section.

(h) Various types of bonds and earthing connections installed and maintained by OHE section.

(i) Safety rules for OHE work.

(j) Types of power blocks for OHE-work. Detailed procedure for imposition of power blocks and
exchange of messages. Precautions to be taken before commencement of work and study of
relevant GRs and SRs.

(k) Detailed study of common OHE defects to be looked for during patrolling and inspection.

(l) Prescribed forms for submission of patrol and other reports,

B. Practical
(a) Climbing up different types of masts and walking across a cat-walk at a height of 56 m to get
over the fear of height.

(b) Practicing the use of various tools, tackles and gadgets used in OHE work.

(c) Practicing in the repair shop the correct way of assembly and installation of various OHE fittings.

(d) Study of the detailed procedure for imposition of power blocks and precautions to be followed for
typical sections by mock drills including speaking over telephones and issue and receipt of
messages.

(e) Drills in correct method of earthing the OHE.

(f) Field work with maintenance and construction staff so as to get acquainted with important items
of work e.g. erection of mast and cantilever assembly, replacement of Insulators, installing splice-
fittings, anchoring of wires, replacement of equipment, recording height and stagger etc ..

(g) Patrol given section of OHE to spot out and report on defects.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [238]

 11. COMPETENCY CERTIFICATES

21212 Authorized Person

An "authorized person" is one who is duly authorized to perform specific duties pertaining to his
Employment, the authorization being made by the competent authority empowered for the purpose
by, the Railway Administration.

21213 Competency Certificate

Each authorized person will be given a "Competency Certificate", defining the works which he is
certified as competent to carry out after he has been trained, examined and found fit.

The following categories of traction distribution staff shall be issued with the certificates by the
official indicated against each category after written/oral test as shown:

Designation of staff Category of certificate To be issued by

A. OHE SECTION

1. Khalasi TR-1 ATFO or CTFO after oral test

2. Linesman TR-2 AEE(TRD) after oral test.

3. Supervisor TR-3 DEE(TRD) after written and oral test.

4. OHE Inspection Car Driver TR-4 DEE(TrD) after written and oral test.

B. PSI SECTION

5. Khalasi TR-1 ATFO or CTFO after oral test

6. Skilled staff TR-5 AEE(TRD) after oral test.
7. Supervisor TR-6 DEE(TRD) after written and oral test.
8. Artisans/Supervisors for Protective TR-7 AEE/DEE(TrD) after written, oral and
Relays and Instruments practical test.

C. REMOTE CONTROL

9. Skilled Staff TR-8 AEE(TrD).

10. Supervisor TR-9 DEE(TRD) after written and oral test.

21214 Qualified Person to be in Charge of Motor Trolley

Officers and certain categories of supervisors of the traction branches will be required to use Motor
Trolleys in electrified sections. Only those qualified in accordance With GR and SR and certified for
the purpose shall be in charge of motor trolleys.

21215 Period of Training

The period of training mentioned in the following paragraphs may be modified as considered
necessary by CEE, taking local requirements into account.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART [239]

21216 OHE Inspection Car Driver

An OHE Inspection Car Driver should undergo courses of training and tests indicated below before
the competency certificate is issued to him:-

1. General and Subsidiary Rules in the Zonal Training School or other approved establishment
followed by a written, oral and practical test conducted by the school.

2. An oral and practical test by CTFO(OHE) to see if the employee is fully conversant w4th the
mechanism and operation of the engine and running gear of the Inspection Car, as well as the
details of maintenance he is required to carry out.

3. Training for a period of one month to learn the road in the section in which he is required to work
the Inspection Car, at the end of such training the employee should sign a declaration that he is fully
conversant with the road.

4. A period of practical training for 2 months in the actual driving of the Inspection Car under the
supervision of a qualified Car Driver at the end of which a driving test will he taken by DEE(TrD).

5. Prescribed medical examination.

21217 Knowledge of Rules

Competency Certificate No. TR-1 may be issued to unskilled staff after the safety rules pertaining to
their work are explained to them personally by ATFO or CTFO who should satisfy himself that the
person concerned has fully understood the instructions, in particular what he is not permitted to do.
For other categories of staff, copies of the relevant chapters of the "Manual of AC Traction" and
other rules pertaining to their work should be issued to the employee along with the certificate and
necessary endorsement to this effect made in the office copy of the respective certificate. That they
continue to be aware of the rules prescribed and that they do inpractice comply with them shall be
checked from time to time by the CTFO and AEE and an entry made of such checks in the Register
of Certificates (para 21218).

21218 Register of Certificates

A register of Competency Certificates issued shall be maintained in the office of every supervisory
official,' as per proforma given in Annexure 12.01 , shoving the names and designations of staff
under him who have been Issued with the Certificates.

21219 Service Record

An entry should be made in the service sheet of every employee who has been issued with a
Competency
Certificate.

21220 Inspections

During inspections Officers and Supervisors should make it a point to check the competency
certificates in the possession of the staff and also test-check their knowledge of the rules pertaining
to their work. -
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART (240)
 Annexure 12.01
Proforma
Register of
Competency Certificates
Name Designation Certificate Date of Name of the Station Date of
No. test and official who where periodic
issue conducted the emp- check
the test loyee is
posted at
present
-------------------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------------------

............... RAILWAY
. ELECTRICAL DEPARTMENT
CERTIFICATE OF COMPETENCY No. TR-1
(For unskilled Class IV staff)

No........................

Shri ................. S/o shri .................. is authorized to work as an unskilled Khalasi in the OHE/PSI'
section to assist skilled staff and supervisors in maintenance, repair and installation work. The
ysafety rules pertaining to his work have been personas explained to him by me.
He is NOT authorized to work independently on any OHE line or Power Supply installation except In
the presence of and under the direct supervision of an authorized person.

Date....................
....................
CTFO/ATFO
*Strike out item not applicable.
A fresh certificate should be issued when he is transferred to a new section after the safety rules
pertaining to the new section are explained to him.

. .............. RAILWAY
ELECTRICAL DEPARTMENT
CERTIFICATE OF COMPETENCY No.TR-2
(For OHE Linesman)
No. ...............
Shri ....................................... S/o Shri................. has been examined for his knowledge of rules and
is authorized to work as Linemen grade ................in the electrified section from .......................... to
.........................
He is authorized to*-
a) Take power block from TPC for 25 kV OHE/66/132/220 kV transmission lines and
underground cables
b) effect shut down in yards and sidings by operating isolator switches;
c) operate switching stations on local control under instructions from TPC;
d) carry out repair, installation and maintenance work on 25 kV OHE; duly observing the
prescribed rules.

He is.NOT authorized to-

a) issue 'permits-to-work'; and
c) bring into operation any new installation.
Date ..................
.. ......................
AEE(TRD)
Strike. out item not applicable.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME ii PART [241]
.............. RAILWAY
 ELECTRICAL DEPARTMENT
CERTIFICATE OF COMPETENCY No. TR-3
(For OHE Supervisor)

No. ...............................

Shri .............................................. has been examined for his knowledge of rules and is authorized
to work as a Supervisor on the installation, maintenance and repairs of 25 kV OHE and 66/132/220
kV Transmission lines and underground cables. He is authorized to.

a) issue permits-to-work ; and

b) bring into operation new installations after they have been inspected by an officer, duly observing
the prescribed rules.

Date ...........
.............. DEE(TRD)

............ RAILWAY
ELECTRICAL DEPARTMENT
CERTIFICATE OF COMPETENCY No. TR-4
(For OHE Inspection Car Driveis)

No. ...............

Shri ............................................... is authorized to drive an OHE Inspection Car in the section

between .......................................... and ..................................................... duly observing the safety
rules and standing instructions. His written declaration* dated ..................................................
that he is familiar with the road signals in the above section has been noted in issuing this
certificate.

He is further authorized to carry out routine maintenance of the OHE Inspection Car in accordance
with the prescribed schedules.

Date ....... ....

..................
DEE(TRD)

*This declaration must be countersigned by Driving Inspector and personally scrutinized by the
Officer before issue of this certificate. The Driving Inspector before countersigning the declaration,
shall orally examine the employee for his knowledge of the road.

INDIAN RAILWAYS -, AC TRACTION MANUAL - VOLUME 11 PART 1 242

....................RAILWAY
 ELECTRICAL DEPARTMENT

CERTIFICATE OF COMPETENCY No. TR-5

(For Skilled PSI staff)

No. ......................

Shri ................................................. has been examined for his knowledge of rules and is authorized
to work as a Fitter In the installation, maintenance and repair of Traction Power Supply installations
at sub-stations, switching stations, booster transformer stations and auxiliary transformer stations.
He is authorized to -

1) .effect shut down on 25 kV equipment under instructions of TPC;

ii) take power block from TPC for working, on 25 kV equipment;

iii) operate equipment at traction sub-stations and switching stations under instructions from TPC,
duly observing the prescribed rules.

He is NOT authorized to-

a) issue permits-to-work;

b) effect shut downs or take power block for extra high voltage (EHA installations and

C) bring into operation any new installation,

...............
AEE(TRD)

....... RAILWAY
ELECTRICAL DEPARTMENT
CERTIFICATE OF COMPETENCE No. TR-6
(For Supervisors of PSI)

No.................

Shri ................................................ has been examined for his knowledge of rules and is authorized
to work as a. Supervisor on the installation, maintenance and repair of 25 kV and extra high voltage
(EHV )Traction Power Supply Installations at sub-stations, switching stations and booster
transformer stations. In addition to items covered by Certificate No.TR-5, he is authorized to -

a) issue permits-to-work on 25 kV and extra high voltage ((EHV )equipment;

b) bring into operation new 25 kV and extra high voltage installations after they have been inspected
by an Officer, duly observing the prescribed rules.

Date .............................

...........................
DEE(TrD)

INDIAN RAILWAYS - AC,TRACTION MANUAL - VOLUME 11 PART I [243]

............................. RAILWAY
ELECTRICAL DEPARTMENT
 CERTIFICATE OF COMPETENCY No. TR-7
(For staff dealing with Protective Relays and Instruments)
No............................
Shri ............................................................ (Designation) has been examined for his knowledge of
rules as well as his skill pertaining to the maintenance, testing and repair of protective relays and
associated circuits and instruments in traction substations and switching stations and is authorized
to*-

a) work as a skilled artisan to perform the above type of work;

b) supervise the above works.

He is authorized to bring into operation new installations only after they have been inspected by an
Officer.

Date. ..............................
.........................................
DEE(TrD)/AEE(TrD)

*Strike out item not applicable.

........... RAILWAY
ELECTRICAL DEPARTMENT
CERTIFICATE OF COMPETENCY NO.TR-8
(For Skilled staff of Remote Control)
No.............................
Shri ................................................. has been examined for his knowledge of rules and is authorised
to work as a skilled Fitter in the installation, maintenance and repair of Remote Control
equipment*/FMVFT equipment at Remote Control Centre and controlled posts.

He is NOT authorized to work on any 240 V medium or higher voltage equipment.

Date. .........................
........ ...............
AEE(TRD)

*Strike out item not applicable.

.......................RAILWAY
ELECTRICAL DEPARTMENT
CERTIFICATE OF COMPETENCY No. TR-9
(For Supervisors of Remote Control)
No..................

Shri ..................................................... has been examined for his knowledge of rules and is
authorized to work as a Supervisor in the installation, maintenance and repair and testing of Remote
Control equipment including FMVFT equipment.

He is authorised to bring being into operation new installations only after they have been inspected
by an Officer.
Date........................
.........................
DEE(TRD)

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME 11 PART 1 [244]

 VOLUME II
PART II

FIXED INSTALLATIONS
LIST OF APPENDICES

No. TITLE PAGES

I Principles for lay out plans and sectioning diagrams 2----50

For 25 kV a c Traction.

II Code for Bonding and Earthing for 25kV, ac, 50Hz, 51---56
Single Phase Traction System

III Code of Practice for Earthing of Power Supply 57---74

Installations for 25kV, ac, 50 Hz

IV Regulations for Power Line Crossings of Railway 75---98

Tracks

V Guidelines for Relay Setting at Traction Sub-stations and 99118

Sectioning Posts.

VI Guidelines for Provision of Maintenance Depots, Tools 119--133

And Plants and Transport Facilities.

VII General Guidelines for Anti-Theft Charging of OHE 134---141

VIII Model Circulars 142152

IX List of Specifications and Drawings for Equipments and 153---214

Materials for Railway Electric Traction

X 25kV OHE Diagrams of General Arrangement and Fittings 215---240

XI Electrification of Private and Assisted Sidings 241

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [1]

 APPENDIX I

PRINCIPLES FOR LAYOUT PLANS AND SECTIONING DIAGRAMMS FOR 25kV AC

TRACTION
(This is a re-production of RDSO document No. ETI/OHE/53 issued in June 1988.)

1.0 INTRODUCTION

1.1 These principles for preparation, checking and finalization of over head equipment lay out plans,
have been framed from standardization and guidance of Railways/Railway Electrification Projects.
In some cases, the principles are obligatory and should be followed. In other cases, principles have
been evolved to standardize designs and to speed up the work. The principles could be relaxed in
special cases, after studying individually the implications to arrive at the best solution both from
economical and technical points of view. The fundamental aim of design of overhead equipment is
to install all the contact wire at the requisite height and to keep it within the working range of the
pantograph under all circumstances.

2.0 DEFINITIONS
The technical and other terms used in this book, shall have the same meaning as defined in
General and Subsidiary Rules/ac Traction Manual, unless, there is any thing repugnant to the
subject or context:

2.1 BOND
An electrical connection across a joint in or between adjacent lengths of rail:

i) Bond, continuity A rail bond used for maintaining continuity of the rail circuit at crossings
and junctions.

ii) Bond, cross A rail bond used for connecting together two rails of a track or rails of adjacent
tracks.

iii) Bond impedance A special rail bond used to bridge an insulated rail joint in ac track
circuited sections in areas equipped for electric traction.

iv) Bond rail An electrical connection across a joint between two adjacent lengths of rail as
part of the track return.

v) Bond, Structure An electrical connection between the steel work of track structures, bridge
or station building, to which the traction overhead equipment is attached and the track return.

2.2 Cantilever assembly

It is an insulated swivelling type structural member, comprising of different sizes of steel tubes, to
support and to keep the overhead catenary system in position so as to facilitate current collection by
the pantograph at all speed without infringing the structural members. It consists of the following
structural members.

i) Stay arm It comprises of dia 28.4/33/7 mm (Small) size tube and an adjuster at the end to
keep the bracket tube in position. It is insulated from mast by stay arm insulator.

ii) Bracket tube It comprises of dia 40/49 mm (Small) or dia. 30/38 mm (standard) bracket
tube and insulated by bracket insulator. Catenary is supported from this member by
catenary suspension bracket and catenary suspension clamp.

iii) Register Arm It comprises of dia 28.4x33.7 mm tube to register the contract wire in the
desired position with the help of steady arm.
INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [2]
iv) Steady arm assembly It is 32 x 31 mm BFB section made of aluminum- alloy to register the
contact wire to the required stagger and to take the push hp of contact wire. It is always in
tension.

2.3 Crossings

The electrically live member/conductor passing over another electrically live member/conductor,
without physical contact.

i) Power line crossing An electrical overhead transmission or distribution line or underground

cable placed across railway track(s) whether electrified or not for transmission of electrical
energy.
ii) Crossing OHE Crossing of two conductors of OHE crossing without physical contact.

2.4 Dropper

A fitting used in overhead equipment construction for supporting the contact wire from catenary.

2.5 Electrical Clearance.

The distance in air between live equipment and the nearest earthed part.

2.6 Encumbrance

The axial distance on vertical plane between the catenary and the contact wire at support.

2.7 Feeder

A conductor connecting (a) a substation with a feeding post, or (b) a feeding post with the OHE

2.8 Height of contact wire

The distance from rail level to the under side of contact wire.

2.9 Interruptor

It is a single phase Vacuum SF6/oil circuit breaker used as load switch to close the circuit on fault
but does not open on fault. It is operated either by remote or manually at site. Different methods of
connection of interruptors are:

a) Bridging Interruptor An interruptor which is provided at the neutral section to extend the
feed from one substation to the overhead equipment normally fed by the other substation in
emergencies or when the latter is out of use. This normally remains in the open position.

b) Sectioning Interruptor An interruptor which connects adjacent sub-sectors together to

maintain continuity of supp This normally remains in closed position.

c) Paralleling Interruptor An interruptor which connects overhead equipments of two different

tracks. This normally remains in closed position to reduce the voltage drop.

2.10 Jumper

A conductor or an arrangement of conductors for electrical continuity not under tension, which forms
electrical connection between two conductors or equipments.

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [3]

2.11 Mast

A single vertical post embedded in the foundation or otherwise rigidly fixed in vertical position to
support the overhead equipment with cantilever assembly. It may be rolled section or fabricated.
The uprights of portals and TTCs are also called masts.

Note: Pre-stressed concrete spun poles for traction overhead equipment are under development.

2.12 Neutral Section

A short section of insulated dead overhead equipment which separates the sectors fed by two
adjacent substations which are normally connected to different phases.

2.13 Overhead Equipment (OHE)

The electrical conductors over the track together with their associated fittings, insulators and other
attachments by means of which they are suspended and registered in position.
All overhead electrical equipment, distribution lines, transmission lines, and feeder may be
collectively referred to as overhead lines.

2.14 Overlap

An arrangement of overhead equipment over a track where two sets of traction conductors are run
parallel to each other for short distance over span(s) providing a smooth passage for the
pantograph of an electric rolling stock. In the un-insulated overlaps two sets of conductors are
separated by 200 mm and connected by a jumper. In insulated overlaps the two sets of conductors
are separated by 500 mm in air. Electrical continuity is provided by an isolator. Interruptor or
booster transformer.

2.15 Over line structures

Any fixed structure provided over the track. The prescribed clearance is normally provided as laid
down in the Schedule of Dimensions for unrestricted movement of rolling stock.

2.16 Pantograph

A collapsible device mounted on an insulated from the roof of an electric engine or motor coach for
collecting current from the overhead equipment.

2.17 Return Conductor

A conductor which carries current from the tracks to the sub-station in the booster transformer
system.

2.18 Regulating Equipment

A device for maintaining the tension of OHE conductors constant under all ambient temperature
conditions.

Note: Such OHE is called regulated OHE.

2.19 Setting Distance (Implantation)

The horizontal distance from the nearest face of traction mast to the centre line of the track.

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [4]

2.20 Suspension Distance

The horizontal distance from the centre of the eye of catenary suspension bracket to the face of the
mast for a single cantilever assembly or to the face of cross arm channel in case of multiple
cantilever assembly (Ref. Fig A.1.01)

2.21 Span

The distance between the centre lines of the adjacent supporting masts for overhead
equipment/lines.

Clear span in case of portal structure, is the distance between the inner faces of portal uprights.

2.22 Stagger

Stagger of the contact wire is the horizontal distance of the contact wire from the vertical plane
through the centre of pantograph plan at the contact surface.

The stagger of the catenary is the horizontal distance of the eye of the catenary suspension bracket
from the vertical plane through the centre of the track.

2.23 Section Insulator

A device installed in the contact wire for insulating two elementary electrical sections from each
other while providing a continuous path for the pantograph without break of current.
2.24 Supply Control Post

It is general term which refers to an outdoor assembly of control gear, such as interruptors,
isolators, potential transformers, auxiliary transformers, etc. including remote control equipment
installed in a cubicle, for controlling power supply to overhead equipment.

a) Feeding Post (FP) It is a supply post where the incoming 25 kV feeder lines from the
substation are terminated, and connected to the overhead equipment through interruptors.

b) Sectioning and Paralleling Post (SP) It is a supply control post situated mid-way between two
feeding posts at the neutral section and provided with bridging and paralleling interruptors.

c) Sub-sectioning and paralleling post (SSP) It is a supply control post where a sectioning and
paralleling interruptor is provided.

d) Sub-sectioning Post (SSP)- (For single line section) it is a supply control post where a
sectioning interruptor is provided.

2.25 Sector

A section of overhead equipment of a track which can be energized by closing a feeder circuit
breaker at the sub-station.

a) Sub-sector The smallest section of overhead equipment which can be isolated remotely by
opening of interruptors.

b) Elementary Section The smallest section of overhead equipment which can be isolated from
the rest of the system by manual operations.

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [6]

2.26 Tension Length

Length of conductor which is stretched between the two anchor points.

2.27 Versine

The versine is the maximum offset of the rail on which spans have been measured (Para 5.1) of the
curved track from the chord connecting two points, each opposite adjacent masts.

3. Electrical Clearance

3.1 Clearance

The clearance between 25 kV live parts and earthed parts of fixed structures or moving loads shall
be as large as possible. The electrical clearances to be maintained under the worst conditions of
temperature, wind, etc. are given below:

a) Minimum vertical distance between any live part of overhead equipment or pantographs and
parts of any fixed structures (earthed or otherwise) or moving loads:

i) long duration 320 mm

ii) Short duration 270 mm

b) Minimum lateral distance between any live part of overhead equipment or pantographs and
parts of any fixed structure (earthed or otherwise) or moving loads.

i) Long duration 320 mm

ii) Short duration 220 mm

Note: I) These clearances may be reduced to 250 mm (long duration) and 200 mm (short duration)
with the personal approval of the Chief Electrical Engineer in very difficult locations (Rly.
Boards letter No. 76/RE/240/1 dt. 27.3.80).

ii) A clearance study should be made for every over line structure/tunnel and, if required,
should be referred to RDSO for advice.

3.2 Working clearance

Minimum clearance between live conductor/equipments and such earthed structure/live parts of
different elementary sections where men are required to work shall be 2 m. Where the clearance is
not obtained the structure shall be protected by earthed metallic screens or prescribed warning
boards (refer para 22.2 and 22.3)

4.0 Wind Pressure

4.1 Wind Load

Wind pressures for design of all masts and determination of spans are based on IS: 875-1964
Code of Practice for Structural Safety of Buildings Loading Standards Vide an amendment
issued in 1971 to this specification, wind pressures for structures of height less than 30 m were
reduced by 25% Accordingly the standard wind pressures adopted are as follows for all new works
for different zones as indicated in the specification:

i) Green zone (light) -75 kg/m2

ii) Yellow zone (medium) -112.50 kg/m2
iii) Red zone (heavy) -150 kg/m2

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [7]

4.2 Loading calculation

For working out the wind loading the total projected area for the rolled sections, 150% of the
projected area for fabricated structures and 2/3rd of the projected area for conductors and other
circular member is taken into account.

Note: The safety of masts and portals is checked for two conditions.

a) At 35 degree C temperature and full wind pressure.

b) At 4 degree C temperature and 20% of the governing wind pressure.

5.0 Spans

5.1 Measurement

Spans shall be accurately measured by means of a steel tape. On curves, these measurement
shall be taken on the outer rail of the middle track in the case of an odd number of tracks and in the
case of an even number of tracks on the inner rail of the first outside track (from the centre of the
formation). On single track, measurements shall be made on the outer rail.

5.2 Standard Span

Standard spars shall be determined in accordance with:

i) Drg. No. ETI/OHE/G/00202 for conventional OHE.

ii) Drg. No. ETI/OHE/G/04201 for regulated tramway OHE and

iii) Drg. No. ETI/OHE/SK/375 for composite OHE (Aluminum- alloy catenary and copper contact
wire)

5.3 The spans shall be as large as practicable, but should enable the contact wire to be erected
with permissible stagger. For a stipulated maximum stagger, the length of the span is governed by
curvature, blow off of overhead equipment, sway of pantograph and deflection of the mast under
wind condition. Standard spans shall be used to maximum extent possible.

5.4 Mid span stagger

Where the two adjacent spans are located on curves of different radius or when the two versines
are in opposite directions, the spans shall be determined so as to keep the mid span stagger in the
two spans within the limit given in the span and stagger chart (ETI/OHE/G/00202), taking into
account the stagger at the common support and the stagger at the extreme supports (see para 8)

5.5 Restrictions

The following restrictions are applicable.

i) On main tracks, the lengths of two consecutive spans shall not normally differ by more than
18 m.
ii) The length of spans with unequal encumbrances shall be such that the axial distance
between the catenary and the contact wire at the minimum dropper is not less than 150 mm. For
example the length of the span with 1.4 m and 0.9 m encumbrances at the two ends shall not
exceed 67.5 m. This restriction is applicable to the two spans on each side of the structure,
equipping a turnout for the main OHE.
INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [8]
iii) Spans in the vicinity of over line structures with restricted head room shall be determined
with reference to the electrical clearances available (See para 3)

iv) The lengths of spans loaded with section insulators may require to be restricted (See para 11)

v) Non-standard spans may be adopted in difficult locations, e.g. in rocky cuttings, on through
girder bridges, for locations of masts on bridge piers and within station limits.

vi) With crossed type equipment with actual crossings of OHEs at facing turnouts, the anchor
spans shall be restricted to 54 m.

vii) Where earth wire is provided, the maximum span over level crossings should be 58.5m.

5.6 Overlaps

The spans at insulated and un-insulated overlaps should be designed in accordance with Drg. Nos.
ETI/OHE/G/02131/Sheet 1 and RE/33/G/02121 Sh. 1 respectively.

Note: If feasible, overlap shall be avoided under overhead power line crossings.

5.7. Neutral sections

The spans at neutral sections should confirm to Drg. No. ETI/OHE/G/02161 sheet No. 1 and no
deviations are normally permissible.

6.0 Masts, Portals, Head Spans and Foundations.

6.1 Types of masts.

OHE conductors are suspended from swivelling cantilever assembly generally erected on individual
masts.

6.1.1 Nine types of masts are used. These are designated as 150x150 BFB, 200x150 RSJ, K-
100, K-125, K-150, K-175, K-200 K-225 and K-250. The first two are rolled sections and remaining
seven are fabricated masts. B-series (Drg. No. ETI/C/0071) masts can be used in lieu of K-series
masts.

Note: Sometimes 200x200 (8x8) BFB have been imported. These are used in lieu of 200x150
RSJ as specified in mast employment schedules,

6.1.2 Selection of masts

The masts for standard applications viz. masts for single OHE, anti-creep and overlaps should be
selected from the mast employment schedules. Separate mast employment schedules have been
made for each wing pressure zone as under:

a) Conventional OHE ( 65mm2 Cd-Cu catenary and 107 mm2 copper contact wire)

Light wind pressure Drg. No. ETI/C/0702

( 75 Kgf/m2) Sheet 1 to 5

Medium wind pressure Drg. No. ETI/OHE/G/00153

(112.5 kgf/m2) and 00154, sheet 1 to 4

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [9]

 Heavy wind pressure Drg. No. ETI/C/0726
( 150 Kgf/m2) Sheet 1 to 4
ETI/C/0727,0728 and 0729

b) Composite OHE (comprising of aluminum alloy catenary and 107 mm2 copper contact wire
with 1000 Kgf tension in each conductor)

Light wind pressure Drg. No. ETI/C/0721 sheet

(75 Kgf/m2) 1 to 4 & ETI/C/0722, 0723 & 0724

Medium wind pressure Drg. No. ETI/C/0717

(112.5 Kgf/m2) Sheet 1 to 4 & ETI/C/0713,0719 & 0720

The mast employment schedules are prepared only for standard setting distance as given in Drg.
No. ETI.OHE/G/00111 Sh. 1 For higher implantations and other locations like masts for turnouts,
diamond crossings, umbrella type OHE etc, the load on the mast should be calculated separately
for every locations and safety of the mast checked in accordance with Drg. No. ETI/OHE/G/00141
sheet 3. The permissible bending moments of the mast are given in Drg. No. ETI/SK/C/122

6.1.2.1 On long (more than 150m) bridges and within 100m from their abutments on either side and
on banks where the height of the catenary above surrounding mean retarding surface is more than
30 m 25% reduction in wind pressure (para 4.1 ) should not be taken into consideration. These
masts should be designed for full wind pressure i.e.

Heavy ( red) wind pressure zone 200 Kgf//m2

Medium (Yellow) wind pressure zone 150 Kgf/m2
Light ( Green ) wind pressure zone 100 Kgf./m2

The maximum span should be restricted to 54 m for heavy wind pressure zone and 63 m for
medium wind pressure zone. In case of curves on the banks of such bridges, the span should be
4.5 m less than the maximum span permitted by relevant span and stagger chart, but should not
exceed 54 m for heavy (red) wind pressure zone and 63 M for medium (yellow) pressure zone.

6.2 Two Track Cantilever

In the yards and sidings when the mast cannot be erected near the track to be equipped, it may be
erected spanning one or two tracks using a two track cantilever (Drg. No. ETI/C/009, Sheet 1). This
is generally used for supporting OHE near turnouts and X-overs. This arrangement should not be
used for supporting OHE of two main lines. The OHE can be supported upto a distance of 10.5 m
from the upright with this arrangement.

6.3 Portals

On multiple track sections, where adequate track centres are not available and tracks cannot be
slewed, portals are used. Each portal consists of two fabricated uprights and one fabricated boom
consisting of with or without one central piece and two end pieces.

6.3.1 Three types of portals have been standardized. N type portal is used for clear spans of 10
m-20m (4 track maximum), O type portal is for clear span of 20m-30m( for 6 tracks maximum) and
R type portal with span of 30m-40m (for 8 tracks maximum).

6.3.2 Where the upright of standard portals cannot be erected due to limited track centres, P type
portal may be used in place of N type and G type may be used in place of O type. The width of
upright of these portals

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [10]

is 300 mm and 250 mm as against 450 mm of N type and 550 mm of O type respectively. In
exceptional cases, BFB uprights of 152 mm width (Drg. No. ETI/C/0026 Sheet 1) may also be used
with N type portal boom. Special BFB portals with 3 legs (Drg. No. ETI/C/0027 Sheet ) may also
be used in exceptional cases where N type portal can not be used.

6.3.3 The cantilevers for the extreme track are provided on the uprights of the portals in
accordance with para 19. The cantilevers for the intermediate tracks are provided on the drop arms
suspended from the boom (ref. Para 19.6)

6.4 Head spans

In yards where un-regulated/regulated OHE is used head span may also be used to cover more
than 6 tracks. Standard head span arrangement is given in Drg. No. ETI/OHE/G/03201. The head
span arrangements are not used normally.

6.5 Foundations

6.5.1 Volume charts

The foundation bending moment codes (FBM) for each location are obtained from the mast
employment schedules or by actual calculation (Para 6.1.2) Bearing capacity of the soil is
determined at the outer toe of the bottom of foundation at a representative number of locations.
Where foundations are placed on the slope of banks due to increase in setting distance, the bearing
capacity of the soil should be determined on the slope. Bearing capacities determined thus would
be considerably less than those determined on the top of formation.

Selection of the type and size of foundation is done from the volume chart. ( Drg. No. ETI/C/0058)
on the basis of FBM code, type and bearing capacity of soil/shoulder width and the extent of
projection above ground level.

6.5.2. Type of foundations.

The following types of foundations are for OHE mast and portals.

1) For Masts

i) (A) Side bearing Drg. No. ETI/C/0058 Sh. 1

(Type B)

(B) Side gravity -do-

(Type BG)

(C) Pure gravity -do-

(Type G )

(D) Pure Gravity -do-

For black cotton soil
(Type WBC

ii) New Pure Gravity -do- Sh. 2A

(Type NG)

iii) NBC type foundation for dry black -do- Sh 3A

cotton soil (16500 & 11000 Kgf/m2
3.0 m depth.
INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [11]
2) For portals

i) In ordinary soil Drg. No.ETI/C/0005/68

ii) In dry black cotton soil Drg. No. ETI/C/0063

6.5.2.1 In the case of OHE foundations in deep rock cutting the foundation should be below the
drain.

6.5.2.2.For all future constructions of pure gravity foundation Drg. No. ETI/C/0058 sheet 2A only
shall be followed.

6.5.3. Selection of foundations

Side bearing foundations are used for masts where the soil bearing capacity is 11,000 or 21,500
Kgf./M2 and 300 mm wide shoulder is available on the bank. However for overlap inter masts and
masts on the inside of curves, 550 mm wide shoulder is necessary ( Drg. No. ETI/C/0023) . (Ref.
Fig. A1.02).

6.5.4 New pure gravity foundations may be used for masts where soil bearing capacity is 5500,
8000 and 11000 Kgf./M2 or where adequate shoulder width as mentioned in para 6.5.3 is not
available. In such cases, it should be ensured that foundation is not exposed.

6.5.5. Side gravity foundations may be used for masts where soil bearing capacity is 8000 and
11000 Kgf./M2, or adequate shoulder width is not available. No portion of the foundation should be
exposed.

6.5.6 Pure gravity foundations (type G) are used for independent masts where soil surrounding the
foundations is loose and cannot exert passive pressure on the foundations. G type foundation have
been designed for soil bearing capacity of 5500 , 8000 and 11000 Kgf./M2. Pure gravity foundations
(Type P) are used for portals and are designed for soil bearing capacity of 8250 and 11000 Kgf./m2.

6.5.7 Foundations in black cotton soil

6.5.7.1 The foundation of the black cotton should be done preferably in dry season i.e. from November to
May. Excavations should be avoided as far as possible in case of unexpected rains in dry season also.

6.5.7.2 In black cotton soils. WBC and NBC type of foundations are used. Primarily WBC foundations are to
be adopted where swelling/shrinkage is not expected to take place at the founding level and NBC foundations
have to be provided where swelling/shrinkage is expected to occur.

6.5.7.3 The safe bearing capacity should be determined in accordance with IW: 6403

6.5.7.4 When in doubt regarding classification of BC soil as to dry or wet, it is preferable to make NBC type
foundation.

6.5.8 Where foundations are constructed on the slope of banks, the foundations should be so located that
generally no part of it is exposed. The top of foundation may then be brought to the desire level (rail level-
500 mm) by providing a super block of length and breadth equal to the top dimension of foundations. The
increase in bending moment due to increased setting distance should be calculated and the designation of
foundation to allow for this BM should be selected. The arrangement is shown in the Fig. No. A.1.03

6.5.9 The top of foundation should be 50-100 mm above the surrounding ground level. The length of mast
below rail level should be minimum 1850 mm for regulated OHE and 1750 mm for un-regulated OHE. A 1350
mm embeddment of mast in concrete is necessary. Concrete cushion of 150 mm below the bottom of mast is
also necessary. Wherever necessary, these may be achieved by providing a super block of length and width
equal to the top dimension of foundation.

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However portion of existing pure gravity foundations to Drug. No.ETI/C/0058 She. 1 corresponding
to a depth of 500 mm of embankment having slope of 1:2 may be exposed.

6.5.10 Giving due consideration to the above, the most economical type of foundation should be
adopted.

6.0 Contact Wire Height.

7.1 Standard height

Normally the height of contact wire ( under side surface) above the track plane shall not be less than
5.50 m at any point in the span under the worst temperature conditions. To ensure this, the normal
height at the suspension point shall be as under:

Type of OHE Normal height of contact wire at the support point.

i) Regulated

a) Normal with 10 cm pre-sag 5.60 m

b) Old electrification 5.55 m
works with 5 cm pre-sag

Note: 5 cm pre-sagged OHE was provided upto 1968. For new works 10 cm pre-sagged OHE shall
normally be provided. However, OHE with 5 cm pre-sag may be provided in long tunnels and
through girder bridges to achieve the minimum electrical clearance.

ii) Unregulated
a) Unregulated OHE designed 5.75 m
for areas with a temp range of
4C to 65C.

b) Unregulated OHE designed 5.65 m

for areas with a temp range
of 15C to 65C

7.2 The height may be reduced under over line structures after a clearance study. The minimum
height shall be 4.92 m for the broad gauge and 4.02 m for the meter gauge to permit movement of
C class ODC without physical lifting of wires. In case C class ODC movement is not required,
the height could be reduced to 4.80 m (BG) . Height may be further reduced to 4.65 m if rolling
stock higher than 4.265 m are not allowed on such lines. ( Ref. Fig. A1.04)

7.2.1 At electric locomotive sheds and loco inspection pits, the minimum height shall be 5.80 m for
the broad gauge and 5.50 m for the metre gauge.

7.2.2 At level crossings, the minimum height shall be 5.50 m for both broad and metre gauges.

7.3 Erection tolerance

A tolerance of +/- 20 mm is permissible on the height of contact wire as measured at a point of

support except on either side of an over bridge, here a tolerance of +/- 10 mm will be allowed. But
the difference between the heights of contact wire at two adjacent supports shall not exceed 20 mm.
In spans with gradient of contact wire, this difference of 20 mm is measured over and above the
approved gradient.

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8.0 Stagger

8.1 Tangent track

On tangent track, the contact wire is normally given a stagger of 200 mm at each support alternately
on either side of the centre of the track. This is relaxed in special cases for ensuring requisite
clearances in difficult locations such as in the vicinity of signals, subject to stagger at midspan not
exceeding the permissible values given in Drug. No. ETI/OHE/G/00202.

8.2 On tangent track, the catenary stagger is zero for masts supporting a single equipment. The
catenary is fixed vertically over the contact wire at all supports at which more than one equipment is
supported, at flexible head spans and at supports with reduced encumbrance, on tangent as well as
curved tracks.

8.3 Curved track

On curves, the stagger of the contact wire at supports should not exceed 300 mm. The stagger of
the catenary on curved track shall be determined with reference to Drug. No. ETI/OHE/G/00202.
The standard values adopted are 0, +200 and 200

Note: For maximum permissible stagger refer para 4 of Chapter V-A of Schedule I, BG Metric
Schedules of Dimensions 1973.

8.4 Turnouts and diamond crossing

At turnouts, the stagger of the contact wire on the main running line shall be in accordance with
Drug. No. ETI/OHE/G/00202. The stagger of contact wire of the branching line shall not exceed 300
mm at any point in the span. This is achieved by selecting a suitable location for the mast near the
centre of the turnout in the case of overlap type equipment, or by suitably adjusting the point of
crossing of the two contact wires in the case of crossing type equipment.

8.5 Un-insulated overlaps

At un-insulated overlaps, the stagger should confirm to Drug. No. RE/33/G/02121 sheet 1. On non-
uniform curves or at other locations where staggers different from those indicated in these drawings
are adopted, the following points should be observed.

i) The stagger of the in-running contact wire does not exceed 200 mm on tangent track and
300 mm on curved track at any support, at which only one contact wire is in-running.

ii) In any span at the centre of which only one of the contact wires is in-running (as in 4-span
overlap), the mid-span stagger of the in-running contact wire does not exceed the values given in
Drug. No ETI/OHE/G/00202

iii) The two contact wires run parallel to each other between the intermediate supports at a
distance of 200 mm from each other.

8.6 Insulated overlap

At insulated overlaps, stagger should conform to Drug. No. ETI/OHE/G/02131 Sheet 1. On non-
uniform curves and at other locations where stagger different from those shown in this drawing are
adopted, the points mentioned against un-insulated overlap spans also apply, with the difference
that between the intermediate masts the two contact wires run parallel at a distance of 500 mm from
each other.
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8.7 Neutral Sections

The stagger at overlap type neutral sections should conform to Drug. No. ETI/OHE/G/02161, Sheet
No. 1.

8.7.1 The stagger at section insulator type neutral section should be so adopted that the stagger
at the section insulator assembly is within the limit of +/- 100 mm (see para 11.1(iii).

8.7.2 PTFE type neutral section shall be erected on tangent track only. The stagger shall be zero
at support.

9 Encumbrance

9.2 Normal

The encumbrance shall normally be 1.40 m.

9.3 Reduced encumbrance

The preferred values of reduced encumbrance for erection of overhead equipment under over-line
structure are:
-------------------------------------------------------------------------------------------------------------------------------------
Span under Recommended encum- Largest per-
Over-line brances for span missible adj-
Structure under over-line acent spans
Structure
(m) (m) (m)
-------------------------------------------------------------------------------------------------------------------------------------
1 2 3
-------------------------------------------------------------------------------------------------------------------------------------
63.0 0.9 67.5
58.5 0.9 67.5
54.0 0.75 67.5#
49.5 0.6 63.0
45.0 0.6 63.0
40.5 0.5 58.5
36.0 0.40 54.0*
31.5 0.40 49.5
27.0 0.30 45.0
-------------------------------------------------------------------------------------------------------------------------------------

# Applicable where the encumbrance cannot be increased to 1.40 m in a single span from the value
given in column 2. The normal encumbrance of 1.40 m should be provided in subsequent spans. In
such cases, the encumbrance may be adjusted in such a way that the lowest point of the catenary
does not fall between first dropper and the support.

* See para 5.5 (1)

Note I) The above values are applicable only to regulated OHE with 10 cm nominal pre-sag of
contact wire.

II) Special droppers may be required in spans under and adjacent to over-line structures.

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9.4 Minimum Encumbrance

Normally, the axial distance between the catenary and the contact wire at the minimum dropper
should not be less than 150 mm. Smaller droppers may be adopted in exceptional cases. If the
shortest dropper is loop type and more than 150 mm, no speed restriction is called for. But it the
dropper is without loop or of rigid type or less than 150 mm, the overhead equipment is deemed
suitable upto 90 km/h speed.

9.5 If section insulators are to be installed in spans under over-line structures, special designs will
have to be evolved.

10.0 Droppers
10.1 The standard arrangement of droppers assembly shall be as per drawing No.
ETI/OHE/P/1190

10.2 The general distribution of droppers on an OHE span shall be as per drawing No.
ETI/OHE/G/00161. The arrangement of OHE span should be designed in such a way that standard
droppers are used.

10.3 Special droppers arrangement.

The special arrangement of dropper as shown in Drug. No. ETI/OHE/P/1400 may be followed in
exceptional cases wherever unavoidable.

10.3.1 The arrangement of the dropper to be adopted on the through girder bridges as shown in
Drug. No. ETI/OHE/P/1410, where the OHE is supported on member of girder bridge.

10.4 Rigid dropper

Adoption of rigid dropper ( made of contact wire only) should be avoided as far as practicable. It
should not be adopted, at all on main running lines.

11 Section Insulators
11.1 Location

Sectional insulators should be so located that the following conditions are fulfilled.

i) At location of section insulator, the axial distance between the catenary and contact wire
shall not be less than 450 mm in the case of single-wire section insulator and 600 mm in the case of
a double wire section insulator without increasing the encumbrance at the supports beyond 1.40 m.

ii) The section insulator is to be located beyond the point where the centre distance between
the two tracks is equal to or more than 1.65 m. If the section insulator is erected with the free ends
of the runners away from the centre of the turn out this distance may be reduced to 1.45 m.

iii) The stagger of the contact wire at the location of the section insulator should normally be
zero, but in no case should it exceed + 100 mm.

iv) On loops, the section insulator shall, as far as possible, be located close to the first support
of the overhead equipment for the loop.

v) The preferred location of section insulator on main running track is 2 to 10 m from the
support in the direction of traffic, though its provision on the main line should be avoided.

vi) In double line section, the runners should be in the trailing direction.
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13.0 Tension Lengths.

13.1Regulated equipment

With regulated overhead equipment every tension length is equipped with an automatic tensioning
device at each end and an anticreep located approximately midway between the tensioning
devices. The distance between the anticreep and the anchor mast/structures on either side should
not exceed 750 m or 15 supporting masts.

13.2 Half tension lengths

Half tension lengths of regulated overhead equipment, not greater than 750 m between anchorages,
may be adopted where necessary. The equipment is fixed at one end and provided with an
automatic tensioning device at the other, the fixed end being determined to suit convenience of
erection. The half tension-length on either side of the neutral section should not exceed 600 m
when the whole or a part of it is located on a curve. The distance of the axis of a 4 span insulated
overlap from the anti-creeps/fixed terminations on either side shall not exceed 600 m.

13.2Bridges and tunnels

Where the catenary is anchored on the face of an over line structure, the anchor shall be the anti
creep point. Termination of overhead equipment or provision of an anticreep, should be avoided ,
as far as possible, inside the tunnels and on the mast set on bridge piers.

13.4 Masts with three brackets

In the case of masts with three brackets supporting regulated equipment, anticreeps or fixed
terminations of the overhead equipment should be arranged so as to keep the relative movement
between brackets as low as possible so that the brackets do not foul with each other.

13.5 Unregulated equipment

With unregulated equipment tension, lengths of upto 2000 m.

between anchors may be adopted on tangent as well as curved track.

13.5.1 Unregulated OHE shall not take off from main running lines

13.6 Linkage of wire-runs

Wire-runs linking two or more main line wire-runs shall be as short as possible. For example, the
same wire run may not ordinarily be used for equipping an emergency cross over and a loop line.

13.7 Anti-creep

Anticreep arrangement: Anticreep is located approximately in the centre of a tension length. The
standard arrangement should be in accordance with Drug. No. ETI/OHE/G/02111.

13.7.1 Boom type anticreep arrangement (Drug. No ETI/OHE/G/02113) may be provided on multiple
track sections or in other areas where portals have been provided on account of other design
considerations, Portals should not be provided specifically for provision of boom type anticreep.

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the anchor mast and the point of crossing if there is crossing of the wires.

14.7 In case of regulated equipment, when the equipments to be anchored on a single span,
anchor height shall be the standard one to get the regulation of the overhead equipment within the
limit travel zone of counter weight assembly. However, single span anchoring should be avoided as
far as possible.

14.8 Anchor near buildings

No live anchor or equipment shall be provided near or over any hut/goomty and building, In such
cases the overhead equipment should be isolated by providing cut-in-insulator and earthed by
connecting it metalically to the anchor mast without providing the insulator in the anchor assembly.

14.9 Termination

The anchoring arrangement of OHE are given in Drug. No. RE/33/G/03121. In polluted areas, e.g.
tunnels, areas near sea-coast, neighbourhood of chemical/fertilizer/cement plants, near loco sheds,
ash pits, water columns, etc long creepage path (1050 mm) insulator should be used on the
anchoring arrangement.
15.0 Location of overlap

15.1Platform lines

Overlaps serving platform lines should not be located opposite platform to avoid location of
tensioning devices on the platforms. If it is unavoidable, half tension length may be adopted to
avoid the provision of the regulating equipment on the platform

15.2 Protection by signals

In the station area insulated overlaps on main running lines should be located after the stop signals.
(Refer to sectioning arrangement of OHE para 30.)

15.3 Cross over

In the case of emergency cross-overs insulated overlaps in the direction of the trailing end should
permit the longest train to be accommodated between the lock bar of the cross over switch and the
first intermediate mast of the overlap with a minimum margin of 50m. This distance may be taken
as 850 m. the overlap in the rear should be located as close as possible (Refer to sectioning
arrangement of OHE par a 30.)

15.4 Span

Location of insulated and uninsulated overlaps should be decided in such way that the maximum
span can be adopted to achieve parallel path of not less than 3 m for smooth change over by the
pantograph.

15.5 The arrangement of overlaps should be as per standard drawings (see para 5.6
15.6 Feeders to overlaps

Feeding overlaps should be sufficiently away (see para 16.2) from the stop signals to facilitate
coasting of trains (with pantograph lowered in the event of extension of feed from either side.
Feeders may be run, if required, from the substation which is usually located in the station areas.

16 Neutral Section
16.1Overlap type
The conventional overlap type neutral section(Drug. No. ETI/OHE/G/02161, Sheet-1) shall be used
except in
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16.2 Location of OPEN DJ and CLOSE DJ boards.

The indication boards to indicate the approaching neutral section and OPEN DJ , CLOSE DJ
boards shall be provided according to drawing No. ETI.OHE/G/02161 Sheet 3.

16.2.1 Separate CLOSE DJ boards are required for EMUs and loco hauled trains.

17 Points and Crossings.

17.1General arrangement

The equipment at points and crossings should preferably be of the overlap type. In unavoidable
circumstances it may be of crossed type.

17.1.1The general arrangement of regulated overhead equipment at turnouts and cross overs is
shown in Drug. Nos. ETI/OHE/G/02141 and 02151. For high speed running, the overlap type
should be provided.

17.1.2The general arrangement of unregulated overhead equipment at turnouts and cross overs is
shown in Drug. No. ETI/OHE/G/03151 and 03152, Sheet 1 & 2.

17.1.3The leading dimensions of standard turnouts and crossings are given Drug. Nos.
RE/33/G/01104, sheet 1 and 01105, Sheet 1 for the broad gauge and in Drug. Nos. RE/33/G/01104,
Sheet 2 and 01105, sheet 2 for the metre gauge.

17.2 Overlap type

In the case of turnouts for high-speed running a mast is located near the centre of the turnout and
the contact wire of the secondary track is raised in one or more spans (exclusive of the anchor
span) after the centre of the turnouts, before it is anchored. A cross over is equipped in the same
manner as two ordinary turnouts.

Note: Overlap type overhead equipment at turn outs taking off from main line shall be provided.

17.2.1 A diamond crossing with or without slips is equipped as two turnouts, the turnout centres
being coincident. The mast located near the common centre is, therefore, equipped with three
bracket assemblies (See Drug. No. ETI/OHE/G/02151).

17.3 Crossed type

The crossed type equipment for turnouts is normally adopted on secondary tracks but may be used
on main tracks, where speeds are less than 100 km/h. The overhead equipment of the secondary
track normally crosses the overhead equipment of the main track or does not have any overlapping
span before anchorage. The two contact wires are clamped together to prevent relative vertical
displacement. For this type of equipment, no support is necessary near the centre of turnout.

17.3.1 In case of diamond crossings with double slips, if crossed type of equipment is provided,
doubling of contact wire is necessary (See Drug. No. ETI/OHE/G/03152, sheet 2). Doubling of
contact wire is, however, not essential in the case of diamond crossings with single slip. In either
case, no mast is necessary at the centre of the crossings.

18 Arrangement of Masts
18.,1 Location of masts.

Masts should generally be arranged as far as possible in the same line parallel to the track and in
the same line transverse to the track. Normally, no masts should be located between any two main
running tracks.
INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [24]
18.9 Masts shall not be located in front of station entrances.

18.10 Masts shall not be located opposite to trolley refuges, close to culverts, subways and on
bridges of length less than 50 m.
18.11 No masts shall be located beyond a signal post at a distance less than 10 m. In case the
OHE mast is located in the front of the signal the distance between the OHE mast and signal post
should not be less than 30 m (Ref. Fig. A1.10)
18.12 Masts should be located sufficiently for away from level crossings and back of abutments of
bridges. The distance between the mast and the end of the level crossing/abutment shall not
normally be less than 10 m.

18.13 The sections having more than two tracks, independent masts should be provided if
adequate track centres are available or if the tracks can be slewed. Where adequate track centres
are not available portals will normally be adopted and they should be located in such a way as to
facilitate provision of drop arm/s and bracket assembly.
18.14 In case of bad formations, if it is possible to locate the masts on either side of a track,
preference should be given to the side with better stability.
18.15 Support for OHE in tunnels.

In the lines tunnels, stubs for supporting OHE cantilever assembly should be provided on
both sides of the tunnel, opposite each other. This would facilitate restoration of OHE in the
event of damage to stubs on one side.
18.16 Masts on bridges

Core holes for erecting masts on bridges should be provided as per Drug. No.
RE/31/0590/63 on both sides of all the piers. Holes on piers which are not used for foundation
should be filled with dry sand covered with a concrete slab.
18.17 In case of wiring a petroleum siding special precaution shall be adopted as laid down.

19 Cantilever Arrangement

19.1 Overhead equipment is supported from the masts by cantilever bracket assembly made of
galvanized steel tubes. The bracket assembly shall be of the swiveling type.

19.2 Cantilever arrangement

The arrangement of cantilever depends upon the height of contact wire, encumbrance, suspension
distance, stagger and super elevations. Standard cantilever arrangements are given in Drug. No.
ETI/OHE/G/02106, Sheet 1 & 3.

19.2.1 Platform location

The arrangement of cantilever on platform shall be as per Drug. No. ETI/.OHE/G/-2104, Sheet 2.

19.3 Allowance for adjustment

The bracket assembly shall be such as to permit easy adjustment of the whole equipment after
erection to cater for displacement of track during maintenance to the extent of 100 mm on either
side of the track centre.

19.3.1 Adjustment on bracket tube

It shall be ensured at the time of selection of bracket assembly that the free length of the bracket
tube beyond the

INDIAN RAILWAYS- AC TRACTION MANUAL- VOLUME II PART II [27]

catenary suspension bracket fittings is atleast 150 mm to facilitate future adjustment.

19.3.2 Adjustment on stay tube

The selection of stay tube at any location shall be such that its adjuster is free for adjustment of
minimum 90 mm in either direction.

19.3.3. In case of curve track when the rail level is raised or the super elevation is changed due to
strengthening of track structure, the pantograph axis will be shifted. If this shift is not within the
possible adjustment limit of bracket assembly as specified in Clause 19.3.1 and 19.3.2 above, new
cantilever may have to be provided taking care that at no stage the contact wire is beyond the
specified stagger.

19.4 Size of tubes

The size of stay tube and register arm tube is 28.4/33/7 mm dia. For all cantilever arrangements.
The size of bracket tube is either 30/38 mm or 40/49 mm designated as standard or large
respectively depending upon the location (See Drug. No. ETI/OHE/G/00158 sheet 1,2 and 3 and
00159 sheet 1,2 & 3).

19.5 Back to back arrangement

More than one cantilevers (on the same side) are provided on the masts for overlap, turnouts, cross
over and diamond crossings. The cantilever may be symmetrical (50 cm on either side of the mast)
or asymmetrical (65 cm on one side and 35 cm on the other side of the mast).

Note I) Adoption of more than three bracket assembly is not possible on a single cross arm.

II) Cantilever assemblies can be provided on both sides of the masts, if the OHE of the two
tracks are of the same elementary section. This is called Umbrella construction.

19.6 Bracket assembly on drop-arm.

On portals, bracket assembly for the intermediate track/s is erected on drop arms. Wherever the
track centre is inadequate (i.e. suspension distance less than 1.60 m), the equipment should be
supported on drop arm of reduced length so that the bracket assembly does not infringe with the
swept zone of pantographs. The arrangement is shown in Drug. No. ETI/OHE/G/02108.

19.7 Bridge & Tunnels

Bracket assembly of special design may be adopted on bridges and tunnels after making clearance
study.

19.8 Bracket chair

Bracket assembly can be designed upto suspension distance of 3.5 m only. If the suspension
distance is more, bracket chair to drawing No. ETI/OHE/P/3050 and RE/33/P/3100 shall be used.

19.9 Insulator for Bracket Assembly

In polluted areas e.g. tunnels, areas near sea coast, neighbourhood of chemical/fertilizer/cement
plants, near steam loco sheds, ash pits, water columns etc. long creepage path (1050 mm)
insulators should be used on the cantilever assemblies.

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20 Setting of Masts

20.1 Tangent Track

The standard setting i.e. the normal distance of the nearest part of the traction mast from the centre
line of tangent track shall be 2.50 m for the broad gauge and 2.35 m for the metre gauge. The
setting may be reduced to a minimum of 2.36m for the broad gauge and 2.14 m for the metre gauge
only in special circumstances such as yards, cuttings and bridges etc. with the approval of the Chief
Electrical Engineer of railway concerned. In case of portal uprights, masts carrying more than one
OHE and head span masts,a the setting should normally be less than 3.00 m for the broad gauge
and 2.50 m for the metre gauge.

20.2 Curved track

The minimum setting distance of masts including portals, head span masts etc. on curves is
obtained by adding the curve allowance and 150 mm slewing allowance to the setting distance
specified for tangent track in para 20.1. For trunk routes and main lines where the speed may be
increased in near future, curve allowance should be taken as per table-III. For other routes, branch
lines and yards where there is no prospect of increase in above 105 km/h in near future, the curve
allowance should be taken as per table- I for Broad gauge and Table-II for metre gauge. Normally,
the standard setting distance on broad gauge main lines on curves should not be less than the
values given below:

a) On outside curves Standard setting (m)

(i) Radius of curvature 2.50

greater than or equal to 875m.

(ii) Radius of curvature less 2.65

than 875m.

(b) On side curves

(i) Radius of curvature 2.90

greater than of equal to 3500m.

(ii) Radius of curvature 3.05

greater than or equal to 2350m. but
less than 3500m.

(iii) Radius of curvature 3.25

greater than or equal to 1150m
but less than 1150m.

(iv) Radius of curvature 3.30

greater than equal to 300m.
but less than 1150m.

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20.5 Masts near signals

The visibility of signals should be kept in mind while deciding the setting up masts in their
vicinity. The following principles should be observed for deciding the setting of masts near signals.

20.5.1 Colour light signals located outside all tracks.

a) Colour light signals without route indicators.

i) Where no approach signal is provided

The minimum setting of mast before signal should be 3.25, 3.10, 3.05, 2.90 and 2.75 m for distance
upto 80 m, beyond and upto 110 m ,beyond and upto 190 m, beyond and upto 270 m and beyond
and upto 400 m respectively.

ii) Where approach signal is provided and for signals other than distant signals.

The minimum setting of masts before the signal should be 3.25, 3.10, 3.05, 2.90 and 2.75 m for
distance upto 50 m. beyond and upto 70 m beyond and upto 115 m, beyond and upto 160 m and
beyond and upto 240 m respectively.

b) Colour light signal with route indicators.

i) With horizontal route indicator

The minimum setting of masts before the signal should be 3.72, 3.50, 3.25, 3.05, 2.90 and 2.75m for
distances upto 60 m, beyond and upto 125 m beyond and upto 170 m, beyond and upto 215 m,
beyond and upto 250 m, beyond and upto 310 m, respectively.

ii) With other than horizontal route indicator

The minimum setting of masts before the signal be 3.50, 3.25, 3.05, 2.90 and 2.75 m for distances
upto 70 m, beyond and upto 130 m, beyond and upto 170m, beyond and upto 215 m, and beyond
and upto 280 m respectively.

Note : 1 See Drg. No. ETI/OHE/G/00112 also. The setting may be reduced in special cases,
conforming to Figs. 6 to 9 of ibid.

2) Setting distance may be reduced for starter signals of loop lines and yard lines

20.5.2 Colour light signals located between tracks:

a) Signals without route indicators:

No OHE mast should, as far as possible be located in the same lane as the signal for a distance of
atleast 600 m before a signal. Drop arms of portals should also not normally be located in the lane
where signals are located, at least for a distance of 600 m before the signal.

Where this is not possible, for any reason, the signal should be mounted on an off-set bracket, In
addition, a special study should be made in each such case in respect of three drop arms before the
signal, to see whether the drop arms can be off-set from the centre line of the lane in a direction
opposite to the off-set of the signal or alternatively, whether it is possible to shorten the drop arms.
Reduction in the signals height may also be examined.

INDIAN RAILWAYS AC TRACTION MANUAL - VOL II PART I [33]

b) Signals with route indicators:

The principles mentioned under para 20.5 (a) should be observed in these cases also.

Note: 1 No part of a colour light signal without a route indicator should, as far as possible, be higher
than 5.2 m above all level. Great care should be exercised in deciding the locations of colour light
signals with route indicators so that the necessary minimum clearances are available between the
signals and live out of run conductors, or pantograph sway zone.

2. On single-line sections, signals (colour light as well as semaphore) should, as far as possible,
be located on the side of the track opposite to the OHE masts.

20.5.3 For semaphore signals located outside the track:

The minimum setting of masts before the signal should be 3.05 , 2.90 and 2,75 m for the first
second and next three masts respectively.

Note : For details, See Drg. No. ETI/OHE/G/00112.

20.6 Masts on bridge piers

The setting of masts on piers of bridges will be large as possible and indicated by the Railway.

20.7 Turnouts

The setting of masts located near theoretical centres of turnouts and diamond crossings should be
3.0 m from the nearest track for the broad gauge and 2.75 m for the metre gauge (Ref. Fig. A1.09)

20.8 Portals

Wherever portals are proposed to be used, they shall be selected with standard clear spans
(distance between face of the uprights) indicated in the tables IV and V. For this purpose the clear
span for any location obtained by adding the proposed setting of the two columns to the centre-to-
centre distances of the tracks spanned by the portal shall be rounded off to the next higher standard
span indicated in the tables. The setting of the uprights of the portal shall then be adjusted to suit
the standard span selected with a minimum setting distance as specified in para 20.2.

INDIAN RAILWAYS-AC TRACTION MANUAL VOL II PART II [34]

21.2 Where adequate clearance is available, the catenary should be erected so as to have
maximum clearance from the over-line structure to reduce the possibility of birds perching on the
catenary wire and coming in contact with earthed parts.
21.3 The catenary is normally passed freely under over-line structures. Where this is not possible
on account of restricted clearances, the following alternatives may be adopted.

i) The catenary may be suspended from the two-faces of the over-line structures.

ii) Suspension from over-line structure

The catenary may be suspended from the over-line structure at an intermediate point.

iii) The catenary may be anchored on to the over-line structure on either side or on to special
anchor structures. The anchor point should normally be the anticreep.

iv) Special designs may be adopted inside covered station areas and on through girder bridges,
employing even regulated tramway type equipment (contact wire only), where it is feasible.

Note: At over-line structures, the span should preferably be centrally located as far possible and
generally should not exceed 54.0 m.

21.4 Polluted zone

Double insulation or insulator for polluted zones shall be used in the following cases:

i) In tunnels (see para 19.9)

For insulators located on the axis of the track in areas where steam traction would be in extensive
use or where smoke is likely to accumulate.

22.0 25 kV Feeders

22.1 Suspension

Where a 25 kV feeder is run longitudinally on traction masts, it shall be carried on the masts as
shown in Drg. No. ETI/OHE/G/05143. The feeder may be run on either side of a mast. Two 25 kV
feeders, or one return conductor and one 25 kV feeder, may be carried on a single mast, if
necessary, with one feeder on each side of the mast.

Note: If the 25 kV feeder and OHE are of different elementary sections, Restricted clearance
board shall be provided.

22.2 Clearances from over head equipment

Where a 25 kV feeder crosses overhead equipment belonging to a different elementary electrical
section, the clearance between the feeder and the overhead equipment shall not be less than two
metres under any conditions.
22.3 Clearance from line side structures

Normally, no feeder should be erected over huts, cabins, goomties, platforms shed or other covered
structures. If unavoidable the clearance between the highest point of a covered structure and a 25
kV feeder passing over it shall be 2 m under all conditions. In the case of a 25 kV feeder passing
over an over-line structures which is not covered, a suitable metallic screen shall be provided on the
structure underneath the feeder. The clearance between the feeder and the highest point of the
screen shall be adequate. A clearance of 2 m is desirable between

INDIAN RAILWAYS AC TRACTION MANUAL -VOL II PART II [37]

the 25 kV feeder and any part of an earthed structure for facilitating maintenance work on the
structure.

23.0 Cross-Spans at Switching Stations

23.1 Cross span arrangement

All the switching stations have gantry with two or more main vertical supports. Cross span
wires/feeders are provided on the gantry to connect the various sections of overhead equipment by
jumper connections. The general arrangement is shown in Drg. No. ETI/OHE/G/05124

23.2 Setting distance

The minimum setting distance of the gantry upright which is normally aligned parallel to the track
shall be 4.30 m.

23.3 Multiple track

The general arrangement of connections at the switching stations on double track and multiple
track section are shown in Drg. No. ETI/OHE/G/05125 and 05126 respectively.

24.0 Tramway type overhead equipment

24.1 Regulated Equipment

In tramway type equipment only contact wire is provided and is auto-tensioned at the anchor by
weight. The contact wire is supported by swiveling type of brackets on individual masts as indicated
in DRg. No. ETI/OHE/G/04204. Generally the principles applicable to normal overhead equipment
are also applicable to regulated tramway equipment except as specified below:

24.1.1. Usage

The regulated tramway type equipment is to be adopted for loop lines, sidings, yards and spur lines
excluding the main running line and first loop or lines taking-off from the main running line.

24.1.2 Span

The maximum span is restricted to 63 m. The general arrangement is shown in Drg. No.
ETI/OHE/G/04203.

24.1.3 Section Insulators

Where a section insulator assembly is to be provided, the provision of a structure to support the
assembly is obligatory. The arrangement is shown in Drg. No. ETI/OHE/G/04207 sheet 1 & 2.

24.1.4 The arrangement of tramway equipment at anti creep and points and crossings are shown in
Drg. No. ETI/OHE/G/04205 and 04208 respectively.

24.2 Unregulated equipment

The general arrangement of tramway equipment to be adopted for head span and cantilever type
construction is shown in Drg. No. ETI/OHE/G/04101. The principles applicable to normal OHE are
applicable to this type of unregulated equipment except as specified below.
The maximum span is restricted to 30m. In station areas, where this type runs side by side with
conventional equipment with contact and catenary wires, the maximum span may be increased to
31.5 m.

24.2.1 Where a section insulator is to be provided the provision of a structure becomes obligatory.
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II 38
25.0 Booster Transformers

25.1 100 KVA Booster Transformer wherever necessary for suppression of inductive interference of
P&T communication lines running in close vicinity and parallel to 25 kV OHE may be provided
separately for each running tracks. The primary winding of the booster transformer is connected in
series with the OHE at insulated overlaps. The arrangement of mounting and connection is shown
in RDSO Drg. No. ETI/PSI/115.
25.2 The Booster Transformers are located at an approximate spacing of 2.66 km between each
other.
25.3 The location of the booster transformer should be decided considering the following aspects:

a) At feeding posts and sectioning and paralleling posts the booster transformers should be located
equi-distant on either side so that the mid-point falls in front of these switching stations.

b) In exceptional circumstances where the booster transformers are not placed equi-distant from
the feeding post or sectioning post, it must be ensured that the distance of the booster transformer
from FP or SP does not exceed 1.33 km

c) The booster transformer should not be located

- In the vicinity of the stop signals to avoid bridging of insulated overlap by locomotives
pantograph.
-
- Within the station limits except for very big stations.

26.0 Return Conductors.

26.1 Route

In deciding the route of return conductors the obstructions en-route should be taken into
consideration. Besides, adequate physical and electrical clearances should be maintained from
fixed structures.

The general objectives is to run the return conductor as close as possible to the associated
overhead equipment so as to secure maximum compensation. Subsidiary lines such as sidings,
loops etc. are not provided with return conductors.

The return conductor will be normally run on the traction masts on the same side as the overhead
equipment. The arrangement is shown in Drg. No. ETI/OHE?/05307. The clearance between the
return conductor and the overhead equipment should not be less than 400 mm under the worst
conditions.

26.2 Clearance
The static and dynamic clearance to any part of the return conductor from an earthed structure
should be 150 mm and 80 mm respectively.

26.3 Return conductors at over-bridges.

At over-bridges return conductors may be run straight through, if possible as on normal structures.

26.4 Return conductors in complicated areas.

In station areas having complicated track layout, it may not be practicable to position the return
conductor sufficiently close to the associated overhead equipment to secure the required
compensation. In such cases, the route of the return conductor should be decided on the merits of
each case. Care being taken to avoid running of return conductor over platforms.
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [39]
26.5 Tension lengths of return conductors

Return conductors are normally terminated at the masts where the return conductors are connected to the rail.
They may be anchored back-to-back at such masts.

26.6 Connections to booster transformers.

At all booster stations, the return conductors for each track should be provided with a cut-in-insulator. The
return conductor is connected in series with the secondary winding of the booster transformer and the
connections of the return conductor to the booster transformer should be carried out in accordance with Drg.
No. ETI/OHE/G/05413.

26.7 (I) The mid-point of return conductor shall be connected to the buried rail as per RDSOs Drg. No.
ETI/OHE/G/05306 and ETI/PSI/611. The mid-point is defined as a mid point between two consecutive
booster transformers.

ii) Mid-point of the return conductor before feeding posts shall be connected to the buried rail on either
side of the insulated overlap and in case of sectioning posts shall be connected on either side of the neutral
section.

iii) Inexceptional circumstances, where mid-point does not fall in front of feeding posts and sectioning
posts, the two rail links between return conductor and rail should be provided in front of feeding post and
sectioning post on either side of the insulated overlap/neutral section. In these cases, mid-point should not be
connected to rail.

27.0 LT Supply Transformer

27.1 Low tension power supply

230 V single phase power supply required for operation of sub-station equipment e.g. circuit breakers,
interruptors, etc.lighting of the station yard, tunnels and working of colour light signals, is obtained through 25
kV 230 V , 10 KVA 50Hz. single phase LT supply transformer. It is provided at substations feeding and
switching posts, stations, block-huts and at other outdoor locations e.g. level crossings with gate signals.

27.2 Capacity

LT supply transformers are of 10 KVA capacity. More than one transformer are provided at large station, yard
etc.

27.3 Protection

LT supply transformers are protected only by a 25 kV, Amp. Dropout fuse on the primary side and 63 A fuse
(rewireable d.c. type with 20 SWG tinned copper wire) on the secondary side.

27.4 Mounting Arrangement

The LT supply transformer is mounted on steel platform erected on the OHE mast and connected to the 25 kV
OHE through rigid aluminum bus-bar or 50 mm2 copper jumper wire. The general arrangement of mounting
and connection is shown in Drg. No. ETI/PSI/036

27.5 Substation L T supply.

At substation, in order to provide power to single phase transformer oil centrifuging /filtration plant, 100 KVA,
25 KV/230V 50 Hz. single phase transformers are provided. The general arrangement of mounting and
connection is shown in Drg. No. ETI/PSI/0312.

INDIAN RAILWAYS AC TRACTION MANUAL -VOL II PART II [40]

28.0 Mast and Rail Bonds

28.1Structure Bonds

All traction masts shall be bonded to a non-track-circuited rail as shown in Drg. No. ETI/OHE/P/7000
(see para 29.1) . In the case of portals, only one uprights of the portals, and in the case of head
spans, both masts of the head spans, shall be bonded to non-track-circuited rails.

28.2 Rail Bonds

The Rail bonds to connect the running rails longitudinally across a rail joint shall be in accordance
with Drg. No. ETI/OHE/P/7030.

28.3 The cross bonds connecting two rails of track of rails of track or rails of adjacent track shall be
in accordance with Drg No. ETI/OHE/G/05251

29.0 Earth Wires

29.1 Sectioning and earthing

In sections where a non-track circuited rail is not available, as in double-rail track-circuited sections,
all traction masts shall be connected together by a continuous aerial earth wire supported by the
traction masts. The earth wire shall be divided into electrical sections not exceeding 1000 m in
length by means of cut-in-insulators. Each section of earth wire shall be bonded to traction mast
which should be connected to an earthing station (Drg. No. ETI/OHE/P/7020). With two separate
earth electrodes in such a way that the interval between the earthed structures does not normally
exceed 500 m as shown in Drg. No. ETI/OHE/G/05201.

29.2 In Tunnels

In case of tunnels, all the traction support structures shall be connected together by a continuous
earth wire, which may be supported from tunnel surface. The earth wire shall be made into
discontinuous sections not exceeding 1000 m and shall be connected to earth electrodes provided
not more than 500 m apart and traction rail at both ends of the tunnel.

29.3 Layout

No earth wire shall cross any track. Where masts required to be connected to an earth wire are
located on opposite sides of a track, separate wire-runs shall be used for connecting the masts. In
complicated areas, masts may be connected to individual earthing stations.

29.4 Anchoring

Earth wires need be anchored only at termination of wire-runs.

30.0 Sections Arrangement.

30.1 Necessity of sectioning

OHE is divided into electrically isolated sections by provision of interruptors or isolators at overlaps
and with section-insulators at turnouts. Sectioning is provided to permit isolation of OHE in small
sections for maintenance or to isolate damaged OHE in case of breakdown/accident and to permit
diversion of trains from up line to down line and vice-versa. However, the sectioning should be kept
to the minimum consistent with operational requirement.

INDIAN RAILWAYS AC TRACTION MANUAL -VOL II PART II [41]

.
31.4 Multiple section

In multiple track section, suffix A is to be given to the multiple track mast. For instance in case of a
section consisting of Up main, Down main and Up slow and Down slow track the slow track masts
shall be numbered as 75/1A, 75/3A, etc. for Up slow line and 75/2A, 75/4A etc. for Down slow line.
Uprights of portals, erected in multiple track sections shall be numbered with reference to main line
only i.e. 75/1, 75/2 etc.
31.5 Numbering of masts of loops and sidings in station yards.

31.5.1 Individual masts.

Single cantilever and double cantilever mast supporting OHEs of tracks on either side (umbrella
type) for loops and sidings shall bear the station code and serial number in one thousands series
(1000). The station code shall be given on above the horizontal line and the serial number below it.
Masts of Up loops and siding on Up line side shall be given odd number of 1001.1003,1005 etc. in
the order of progressive chainage, irrespective of the number of loops and the masts on the Down
loops and sidings on the Down line side shall be given even numbers 1002, 1004, 1006 etc.

In case several independent cantilever masts for different loops are located at the same chainage,
loop mast nearest to the main track should bear the lowest number in the series (see Fig. 10). This
system of numbering is applied from one end of a yard in the kilometerage of the starting point and
progressively higher numbers is given in the direction of increase in chainage whether it is Up or
Down yard. The numbering does not indicate the kilometerage.

31.5.2 (a) In case a portal is provided, the upright of the portal nearest to the main track shall be
given a number in 2000 series, the other upright of the portal shall be given a number in 3000
series. In case of 3 leg portals, the farthest leg from the main track shall be given a number in 4000
serires.

31.5.2 (b) In case a portal is covering both Up and Down main lines as well as loops and siding, the
numbering shall be as for the main line tracks, irrespective of the fact that it also covers loops.

31.5.2 (C) In case of a portal covering Up main line and a number of Up side secondary tracks,
the upright which is located near the main track and service the main line shall be numbered with
respect to the main track. Other upright shall be given the same number with suffix A.

31.5.2 (d) The upright of portals in Up yard shall have odd numbers i.e. 2001-3001, 2003-3003 etc.
and the upright in Down yard shall have even numbers i.e. 2002-3002, 2004-3004 etc.

31.6 Head span mast.

Procedure of numbering the mast of a head span shall be the same as that for portals detailed in
31.5.2 except that the mast of the head span shall be given numbers in 5000, 6000 and 7000 series
as detailed in 31.5 .2 (a).

31.7 Branch line masts

All masts on branch lines taking off from the main line are to be given a prefix letter indicative of the
branch line, mast e.g. Pradhankanta-Pathardih which takes off from the main line at Pradhankanta
is given a prefix letter P which is indicating of Pathardih viz. 70/14 P.

31.8 Alternative numbering

Mast on loop/yard lines may also be numbered with a letter/word prefixed indicating the
nomenclature of the line e.g. the mast numbers on a goods line in passenger station area may be
numbered as G1, G2 etc. below the station code. The mast numbers on engine run-round line may
be numbered as EL1, EL2 etc. This method may be adopted when additional lines are provided or
wired subsequently.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [47]

31.9 Switching station masts

Mast at the switching station are numbered with the station code of the switching station for
example KGP/1 which means Kharagpur Switching Station, mast No. 1.

32.0 Numbering of Equipment

32.1 Abbreviation of equipments

To identify the location of the equipments covering OHE and Switching stations a code for
identifying the type of equipment followed by a S.No. is given.

AT : 25 KV/230V Auxiliary Transformers

BT : Booster Transformers
BM: Interruptor for main lines
BS: Interruptor for yard lines
BX: Bus coupler interruptor
BC: Bus coupler isolator
CB: Circuit Breakers
CT: Current Transformers
DP: Double pole isolators
LA: Lightening arrestor
PT: Potential transformer
SF: Single pole isolator at Switching Station
SP: Single pole isolator at sub-station
SM: Isolator for main lines
SS: Isolator for secondary lines loops and yards
TR: Power transformer.

32.2 Numbering circuit breakers

Each power transformer, current transformer, potential transformer is given a serial number in a
Railway starting from 01 except 25 kV circuit breakers which shall be according to para 32.2.2.

32.2.1 High voltage (132/110/66KV) circuit breakers are given two digit numbers progressively
increasing in the direction of increasing kilometerage starting from 01. For example, the first high
voltage circuit breaker will be numbered as CB/01,02,03

32.2.2. 25 kV circuit breakers are given three digit numbers - odd nos. e.g. CB/101, 103, 105 etc.
for feeder breakers and even nos. CB/100,102,104 etc. for transformers circuit breakers.

32.3. The serial number of transformers and circuit breakers also follow geographical sequence
within a substation/feeding post. Lower number is given for the equipment connecting at less
kilometerage and higher number of for the equipment connected to higher kilometerage.

32.4 Interruptors

The main line 25 kV interruptors numbered serial wise progressively increasing from a datum point
on railway. e.g. BM/01, 02, 03 etc.

32.5 Yard interruptors. The yard line interruptors are numbered serial wise on a railway i.e.,
BS 01, 02, 03 etc. Where there are different yards for Up and Down direction, the interruptor for Up
yard is given odd number and that for Down yard is given even number.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [48]

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [49]
32.6 Other equipment

The number of other equipments is serial wise progressively increasing irrespective of up or down
line on a railway preferably according to increasing chainage.

32.7 Numbering of elementary section

Elementary section for main line are given a number beginning with the number of interruptor which
feeds it (see Fig. A1.21)

32.7.1 The first two/three digits of the number for an elementary section indicate the governing
interruptor and last two digit indicate the progressive serial numbers. The progressive serial number
for Up line are odd number starting with 01 for example 3401, 3403 etc. and even number for Down
line starting with 02 such as 3502, 3504 etc.

32.7.2 Yard elementary sections

The elementary section number of yard lines shall be provided with the number of the isolator
which controls the feed of the line/s with a prefix X For example, if an isolator, no. 118 controls the
feed of the lines of the receiving yard the elementary section number of the lines is X 118.

32.7.3 Elementary section for two sides

If the line/s are fed by an inter-locked isolator numbering of the elementary section should
corresponds to the isolator number which normally feeds the line/s.

32.7.4 Type of number plates

The number plates shall be in accordance with drawing No. RE/33/P/7501.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [50]

 APPENDIX II

CODE FOR BONDING AND EARTHING FOR 25 kV a.c. 50 Hz. SINGLE PHASE
TRACTION SYSTEM
(This is a reproduction of RDSOs Code No. ETI/OHE/7(11/90)

1.0 Scope

This code shall apply to 25 kV a.c. 50 Hz. single phase traction system and covers the requirements
for bonding and earthing of overhead equipment masts, structures and associated rails of railway
track. The bonding and earthing at traction sub-station including feeding posts, switching stations,
booster transformer stations, 25 KV/240 V auxiliary transformer stations and switching gantry as
well as Signalling and telecommunication equipments are beyond the scope of this CODE.

2.0 Definitions
The following terms wherever appearing in this Code shall ,unless excluded by or repugnant to the
context, have the meaning attributed there to and apply as follows:

2.1 Bond means an electrical connection between two or more conductors of non-current
carrying metallic parts of traction masts or structures or supports and rails.

2.2 Cross bond means a bond between two rails of a track or two rails of adjacent tracks. It is
also called a transverse bond.

2.3 Earth wire means a conductor run on traction masts or structures or supports and bonded
to their metallic parts/supports and connected to earth.

2.4 Earth means a connection to the general mass of earth by means of an earth electrode.
An object is said to be earthed when it is electrically connected to an earth electrode, and the
object is said to be solidly earthed when it is electrically connected to an earth electrode without
intentional addition of resistance or impedance in the earth connection. The resistance of the earth
electrode shall not exceed 10-Ohm.

2.5 Earth electrode means a metal plate or pipe or any other conductor electrically connected
to the general mass of the earth.

2.6 Impedance-bond is a bond, installed by the Signal and Telecommunication Department,

which provides a low impedance path for the traction return current and a relatively high impedance
path for track circuit current.

2.7 Rail-bond means an electrical connection across a rail joint between consecutive lengths
of rails. It is also called a Longitudinal bond.

2.8 Rail length means a continuous length of rail with or without welded joints but with no fish
plate joints.

2.9 Structure bond means a bond connecting for non current carrying metallic parts of a
traction mast or structure or support to the traction rail.

2.10 Signal bond means an electrical connection across a rail joint, provided by the Signalling &
Telecommunication Department, to facilitate flow of track circuit current.

2.11 Short direct connection means a connection for electrical continuity, which shall be of the
shortest possible length with minimum bends.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [51]

2.12 Traction Rail means a non-track-circuited rail of a wired track, not required for signalling
purposes and which may be earthed. In non-track-circuited sections, both the rails of wired track
are traction rails and in single rail-track-circuited sections, the traction rail is the non-track-circuited
rail.

2.13 Welded bond means a bond which is made of standard copper conductors with M.S.
ferrules at either end, pressed on the conductors and bent to shape.

2.14 Wired track means a track provided with 25 kV a.c. 50 Hz. Single phase overhead
equipment.

3.0 Bonding

3.1 In the case of 25 kV a.c. 50 Hz. Single phase traction system, the traction current is drawn from the
overhead equipment by the electric rolling stock, operating in a section and passes through the traction rail.
The return current flows mostly through the earth leaving the traction rail except in a zone extending over a
few hundred metres on both sides of the electric rolling stock in operation in the section or in the vicinity of a
feeding station and returns to the traction sub-station. Bonding of all rails is, therefore, not absolutely
essential unlike in the case of d.c. traction where practically the whole traction return current flows through the
rail and hence bonding of rails is essential. However bonding of rail facilitates passage of the traction return
current from the earth to the traction rails which are connected to the rail to earth and vice versa and is,
therefore, provided in the vicinity of traction sub-station-feeding posts where the traction return current has to
flow back from the earth to the traction rails with are connected to the earthed leg of the traction transformer at
the sub-station, through a burried rail opposite the feeding post. Bonding of rails also ensures the spread of
flow of return current into the earth and, therefore, reduces the voltage between rail and earth. So bonding of
rails is done wherever it is essential to keep the rail voltage low to ensure safety of personnel.

3.2 The traction rail of a wired track when bonded or laid on metallic sleepers provides generally an earth
better than an earthing station with earth electrode. If, therefore, any non-current carrying part of an
equipment or metallic structure is required to be earthed, it shall ordinarily be connected to a traction rail.

3.3 Track Circuited Sections

3.3.1 In sections equipped with single rail-track circuits, the traction rail shall be bonded to ensure that:
i) The ac voltage drop along its length is reduced so as to minimize the risk of ac voltage being
applied to the track relays.
ii) As low a resistance path as possible is provided both for traction return as well as signalling
currents as fish plate joints cannot be relied upon for low resistance.

3.3.2 In sections with double rail-track-circuits, both rails are longitudinally bonded to ensure a low
resistance path for traction return and signalling currents; and also to distribute the return current more evenly
in both the rails. Impedance bonds are installed at insulated joints to provide a continuous path to the traction
return current. Al track-circuited-rails are, in addition, provided with signal bonds.

3.4 Structure bond

All non-current carrying metallic parts of traction masts or structures or supports or metallic parts of
concrete/wooden masts, supporting the traction overhead equipment shall be connected by means of a
structure-bond to the nearest traction rail or to an earth wire run on the traction masts/structures/supports or to
an earth. In the case of a portal structure, only one leg of the portal shall be provided with the structure bond,
whereas for head span masts, each mast of the head span shall be bonded to the traction rail nearest to it.

Where traction masts or structures or supports are located on railway platforms and are bonded to the nearest
traction rail, a cross bond shall be provided at the location of the structure-bond to connect the rail to the
adjacent traction rail.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [52]

3.5 Track Bonding
In station yards or elsewhere, where a track is not wired for its entire length, it shall be deemed to
be wired for a distance of upto 50 metres beyond the traction mast at which the overhead
equipment has been terminated. Rail bond and one cross bond shall be provided for a distance of
upto 50metres beyond the last traction mast.

3.6 Mode of Connection of Bond

3.6.1 All types of bond i.e. rail-bond, cross-bond and structure-bond shall be of mild steel of not
less than 200 mm2 cross sectional area.

3.6.2 A structure-bond shall be rigidly connected by means of galvanised steel fasteners to the
traction rail and the metallic part of traction mast or structure or support.

3.6.3 A rail-bond shall be rigidly connected by means of galvanized steel fasteners longitudinally
across the fish plate joint of the traction rail and the track-circuited-rail in a track circuited section
except at the insulated joint of the track circuited rail.

3.6.4 A cross-bond shall be rigidly connected by means of galvanized steel fasteners between
two traction rails of a track or non-track circuited rails of an adjacent track.

3.6.5 Where it is not possible to provide a rail-bond a welded bond shall be used. The bond shall
be connected to the rails by electric or gas welding.

3.6.6 The bond for connecting return conductor to the traction rail through the buried rail shall
normally be made with GI nuts and bolts with spring washer and check nuts.

3.6.7 The cross section of an earth wire used for bonding traction masts or structures or supports
or the metallic parts supporting the traction overhead equipment in a tunnel or in double rail-track-
circuited section shall be not less than 50 mm2 copper equivalent.

3.7 Bonding in Single Rail-Track-Circuited Sections

3.7.1 The traction rail in a single rail-track-circuited section shall be provided with rail bonds not
only over the entire length upto which the track circuited rail exists but also for a distance of 50 m on
both sides of the track circuited length. In addition, the traction rail shall be cross bonded to the
traction rails. If any, of adjacent tracks wherever they exist at intervals of not less than 100m. The
traction rails of such adjacent tracks shall also be provided with rail-bonds over the entire length of
the track circuits and for further 50 m on both sides. In case the length of a track circuited rail is not
more than 350 m, a cross bond shall be provided between the rails of the track immediately outside
the track circuited length at both of its end.

3.7.2 In single line section, whether or not doubling of the section is foreseen in the future,
provided with single rail-track-circuit, the non-track-circuited rail shall be provided with rail-bond over
the entire length and for a further 50 metres on both sides. It shall also be connected to an earth at
distances not exceeding 100 metres from each other. The connections of the non-track-circuited
rail to each of the earths shall be made by two separate mild steel strips/flats each of cross section
not less than 200 mm2. The need for providing an earth wire is thus obviated.
3.8 Bonding in Double Rail-Track-Circuited Sections.
In a double rail-track-circuited section, both the rails shall be provided with rail-bonds. At insulated
joints of the double rail-track-circuit an impedance bond shall be provided. Since no traction rail is
available for structure bonding, an earth wire shall be run on the traction mast or structure or
support. In case, the length of the earth wire exceeds 1000 metres it shall be made electrically
discontinuous by providing a cut-in-insulator so that no
.
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [53]
section of the earth wire is greater than 1000 metres electrically. Each such section of the earth wire shall be
connected to an earth at two traction masts or structures or supports at a distance not exceeding 500 m
apart

No cross bond shall be provided between the rails of the same track or between the rails of different tracks in
a double rail-track-circuited section.

3.9 Bonding Adjacent to Traction Sub Station/Feeding Post

3.9.1 Commencing opposite to a traction sub-station/feeding post, all the traction rails shall be provided with
rail-bonds for a distance of 1000 metres on either side of the traction sub-station/feeding post. In addition,
these traction rails shall be cross-bonded at approximate distances of 300, 500, 700 and 1000 metres from
the traction sub-station/feeding post.

3.10 Bonding of Rails on Wooden/Concrete Sleepers

A wired track shall be deemed to be on wooden or concrete sleepers if there are not more than six metallic
sleepers in any length of track not exceeding 350 m. The traction rails of such a track shall be provided with
cross bonds at distance of not more than 350 m apart. No rail bonds shall be provided.

3.11 Bonding of Traction in Loco sheds and Loco/EMU stabling sidings

All traction rails of loco sheds and loco/EMU stabling sidings shall be provided with cross bonds at distance of
not more than 100 m apart. Further all sidings and/or dead ends, whether wired or not, shall be connected by
rail bonds. The rails on wooden or concrete sleepers/supports in loco/EMU inspection pits shall be provided
with rail-bonds for the entire length of the pit and also upto a length of 50 m on both sides and connected to
an earth.

3.12 Bonding of Rails in a Tunnel

In a tunnel all the traction rails shall be provided with rail-bonds not only over the entire length inside the
tunnel but also for a length of upto 50 m or both sides outside the tunnel. Besides, a cross bond shall be
provided between the traction rails at either ends of the tunnel.

Note: If the tracks in a tunnel are track-circuited, the procedure in clause 4.0 shall be followed.

3.13 Bonding of Rails on a Weigh Bridge

Both the rails of a wired track on a weigh bridge shall be provided with rail bonds for a length of upto 50 m on
both sides of the weigh bridge. If the rails are on wooden or concrete sleepers/supports, they shall be
connected to an earth.

3.14 Bonding at a Level Crossing

All the traction rails shall be provided with cross bonds at only one location which shall be within five metres
from either of the transverse edges of the level crossing.

3.15 Bonding at Oil Depot Sidings

3.15.1 Unwired sidings leading to a oil depot or installation shall be provided with duplicate insulated block
joints as near as possible to the turn out from the main track from which they take off and before entry into the
oil depot or installation.

3.15.2 Where a siding or a secondary loop line is to be wired to serve the purpose of loading and unloading
of petroleum products, the arrangements to be made and precautions to be taken are:

i) A neutral zone shall be set up at either end of the length of the siding or secondary loop line over
which the vehicles containing the petroleum products are to be berthed and loaded/unloaded. The neutral
zone
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [54]
is created both in the track as well as in the traction overhead equipment (OHE) by provision of insulating
joints and section insulators with isolators as done for locomotive inspection pits respectively. The neutral
zone is to ensure that the rest of the railway network is kept isolated when the loading/unloading operations
are in progress so as to avoid propagation of stray currents.

ii) Both the rails of the siding or secondary loop line shall be provided with longitudinal-bonds. Besides,
transverse-bonds shall be provided between the rails at distance not exceeding 30 metres apart.

iii) The rails of the siding or secondary loop line shall be connected to an earth at both ends immediately
outside the neutral zone.

iv) An equi-potential link/switch shall be provided between the metallic portions of the petroleum
installations i.e. the earth and the rails of the siding or the secondary loop line. This equi-potential link/switch
is to be kept closed during the loading/unloading operations.

v) Each and every non-current carrying part of a traction mast or structure or support and other metallic
structures in the vicinity of the siding or secondary loop line shall be provided with structure-bonds. Only
copper rivets shall be used for connection between the non-current carrying metallic part or rail and the bond.

vi) During the time the loading and unloading of petroleum product is taking place, proper electrical
continuity shall be maintained between the petroleum installations, the rails on which the vehicles containing
the petroleum products are berthed and the OHE which has already been made dead and connected to the
rails.

3.16 Bonding of Girder Bridge

3.16.1 Steel structures of a girder bridge shall be connected to a traction rail or to an earth by means of two
mild steel strips/flats or cross section not less than 200 mm2 each. The traction rails (where there are two or
more such rails) on the bridge shall be connected by cross bonds at distances not exceeding 100 metres
apart.

3.16.2 In a single rail track circuited section, the non track circuited rail which is the traction rail shall be
provided with rail bonds (refer clause 3.7.1) and connected to an earth at either end of the bridge.

4.0 Bonding of Metallic Parts inside a tunnel

An earth wire connecting all non-current carrying metallic parts which form parts of the supports for the
overhead equipment, shall be run inside the tunnel. The earth wire shall be connected to an earth as well as
to the traction rails at both ends just outside the tunnel. In case, all the rails are track circuited, the earth wire
shall be connected to an earth at both ends just outside the tunnel. If the length of the earth wire exceeds
1000 m, the stipulation in regard to making it electrically discontinuous as contained in clause 3.8 shall be
followed.

4.1 Bonding of Over line Structure

The metallic parts of foot or road over bridges or other over-line structures over wired tracks shall be
connected either to a traction rail or to an earth by means of two mild steel strips/flats of cross-section not less
2
than 200 mm each.

4.2 Bonding of Exposed Metallic Parts

All exposed metallic parts such as platform structures/sheds, metallic fencing, wires, pipes and such other
items, not likely to come into direct contact with the 25 kV ac overhead equipment and located with a distance
of 20 m from the nearest electrified track and running parallel to it for a distance of more than 20 m but less
than 350 m shall be connected to an earth or traction rail. If parallelism with the nearest electrified track
exceeds 350 m all such exposed metallic parts shall be connected to a separate earth at distances not
exceeding 350 m apart.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [55]

No special precaution is required in case such metallic parts are fitted on metallic supports directly
buried in the ground if the earth resistance of such metallic support is less than 10- Ohm.

4.3 Bonding of Earthing Heel of Isolator Switch

The earthing heel of an isolator switch shall be connected by two mild steel flats of cross-section not
less than 200 mm 2 each to the supporting metallic traction mast or structure or support. The
connection shall be as short and as direct as possible. Such a traction mast or structure or support
shall, in turn, be connected to a traction rail or an earth wire and, in addition, to an earth.

4.4 Connection of Return Conductor

A return conductor connecting booster transformers shall be connected approximately at the mid
point between the adjacent booster transformer stations to the traction rail of the same track or to
the mid point of an impedance bond in the case of double rail track circuited section.

5.0 Drawings

The drawings issued by RDSO in connection with the practices prescribed in this CODE are listed
below:

SN. Description Drawing Number

1. General arrangement of earth wire ETI/OHE/G/05201

on OHE mast.
2. Arrangement of transverse bonds ETI/OHE/G/05251
3. Connection of R.C. to track ETI/OHE/G/05306
4. Structure bonds ETI/OHE/P/7000
5. Earthing station ETI/OHE/P/7020
6. Longitudinal rail bonds ETI/OHE/P/7030

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [56]

 APPENDIX III

CODE OF PRACTICE
FOR EARTHING OF POWER SUPPLY INSTALLATIONS
FOR 25 kVAC, 50 Hz. SINGLE PHASE TRACTION SYSTEM
(This is a reproduction of RDSOs CODE No. ETI/PSI/120 (2/91)

1. Scope

1.1 This code of practice caters for general arrangement of system and equipment earthing at
220/25 kV or 132/25 kV or 110/25 kV or 66/25KV traction sub-stations, 25 kV switching stations,
booster transformer stations and auxiliary transformer stations. Low voltage (LT) electrical
power distribution system, 25 kV overhead equipment system as well as signal and tele-
communication equipment do not come within the purview of this code.

2. Terminology

2.0 The following terms wherever occurring in this code shall, unless excluded or repugnant to the
context, have the meaning attributed thereto as follows:-

2.1 Combined Earth Resistance: The resistance of an earth electrode (s) with respect to earth, with
the earth electrode(s) connected to the metal work of electrical equipment other than parts
which are normally live or carry current and the masts/structures but without connection with the
traction rail(s).

2.2 Earth: The conductive mass of the earth, whose electrical potential at any point is
conventionally taken as Zero.

2.3 Earth electrode: A conductor mild steel (MS) pipe, or group of conductors in intimate contact
with and providing an electrical connection to earth.

2.4 Earthing grid: A system of a number of interconnected, horizontal bare conductors buried in the
earth, providing a common ground for electrical devices and metallic structures, usually in one
specific location.

2.5 Equipment earthing: Earthing of all metal work of electrical equipment other than parts which
are normally live or current carrying. This is done to ensure effective operation of the protective
gear in the event of leakage through such metal work, the potential of which with respect to
neighbouring objects may attain a value which would cause danger to life or risk of fire.

2.6 Mesh Voltage ( E mesh) : The maximum touch voltage to be found within a mesh of an
earthing grid.

2.7 Power supply installation : The electrical equipments and associated structures provided at a
Railway Traction Substation or Switching Station, or Booster/Auxiliary transformer Station on the
25 kV over head equipment.

2.8 System earthing : Earthing done to limit the potential of live conductors with respect to earth to
values which the insulation of the system is designed to withstand and thus to ensure the
security of the system.

INDIAN RAILWAYS-AC TRACTION MANUAL-VOL II PART II [57]

2.9 Step Voltage (E step) : The potential difference between two points on the earths surface
separated by a distance of one pace, that will be assumed to be one meter in the direction of
maximum potential gradient.

2.10 Traction Rail means a non track circuited rail of a wired track, not required for signalling
purposes and which may be earthed. In non-track circuited sections, both the rails of a wired
track are traction rails and in single rail circuited section, the traction rail is the non-track
circuited rail.

2.11 Touch Voltage ( E touch): The potential difference between a grounded metallic structure
and a point on the earths surface separated by a distance equal to the normal maximum
horizontal reach of a person, approximately one metre.

3. Object of Earthing

The object of an earthing system is to provide as nearly as possible a surface under and around a
station which shall be at a uniform potential and as nearly zero or absolute earth potential as
possible. The purpose is to ensure that generally all parts of the equipment, other than live parts
are at earth potential and that attending personnel are at earth potential at all times. Also by
providing such an earth surface of uniform potential under and surrounding the station, there can
exist no difference of potential in a short distance big enough to shock or injure an attendant when
short circuits or other abnormal occurrences take place. The primary requirements of a good
earthing system are:

i) It should stabilize circuit potentials with respect to ground and limit the overall potential rise
i) It should protect men and materials from injury or damage due to over voltage.

iii It should provide low impedance path to fault current to ensure prompt and consistent
operation of protective devices during ground faults.

ii) It should keep the maximum voltage gradient along the surface inside and around the
substation within safe limits during earth faults.

4. Governing Specifications

Assistance has been taken from the following standards/codes of practices in the preparation of this
code of practice.

i) IS : 3043 1987 Code of Practice for Earthing (first revision)

ii) Indian Electricity Rules 1956 (latest edition)

iii) National Electrical Code 1985 of Bureau of Indian Standards

iii) IEEE Guide for safety in a.c. substation grounding. No ANSI/IEEE Standard 80-1986

5. Earth Resistance

At each power supply installation, an earthing system as specified in this code shall be provided.

INDIAN RAILWAYS-AC TRACTION MANUAL-VOL II PART II [58]

The combined resistance of the earthing system shall be not more than the following values:-

SN. Name of Station The Limit of combined earth

Resistance in Ohms.
1. Traction substation 0.5
2. Switching Station 2.0
3. Booster transformer station 10.0
4. Auxiliary transformer station 10.0
6. Earth Electrodes
6.1 The earth electrode shall normally be of mild steel galvanized perforated pipe of not less than 40
mm nominal bore of about 4 m length provided with a spike at one end and welded lug suitable
for taking directly MS flat of required size at the other end. The pipe shall be embedded as far
as possible vertically into the ground, except when hard rock is encountered, where it may be
buried inclined to the vertical, the inclination being limited to 30 degree from the vertical. The
connection of MS flat to each electrode shall be made through MS links by bolted joints to
enable isolation of the electrode for testing purposes. A sketch for typical arrangement of an
earth electrode is shown in Figure 3.01.
6.2 Earth electrodes shall be embedded as far apart as possible from each other. Mutual
separation between them shall usually be not less than 6.0 m (which is twice the length of the
electrode).

6.3 If the value of earth resistance specified in clause 5 can not be achieved with a reasonable
number of electrodes connected in parallel such as in rocky soil of high resistivity, the earth
surrounding the electrodes shall be chemically treated. The earth electrode shall be surrounded
in an earth-pit by alternate layers of finely divided coke, crushed coal or charcoal and salt atleast
150 mm all round. Though substantial reduction in earth resistance can be achieved by coke
treated electrode, yet as this method results in rapid corrosion not only of electrode but also of
steel frame work to which it is bonded, coke treatment shall be used only where absolutely
necessary and such electrodes shall not be situated within 6.0 m of other metal work.

6.4 IN high embankments, it may be difficult to achieve earth resistance specified in clause 5 even
after chemical treatment of electrodes. In those locations, use of electrodes longer than 4 m so
as to reach the parent soil is recommended.

6.5 As far as possible, earth electrodes for traction substations/switching stations shall be installed
within and adjacent to perimeter fence. At large sites, apart from securing a sufficiently low
resistance and adequate current carrying capacity a reasonable distribution of electrodes is also
necessary.

7. Earthing Arrangement at Traction Substation

7.1 Earthing grid.

7.1.1 An earthing grid is formed by means of bare mild steel rod of appropriate size as indicated in
clause 7.1.2 buried at a depth of about 600 mm below the ground level and connected to
earth electrodes. The connection between the earth electrode and the grid shall be by
means of two separate and distinct connections made with 75 mm x 8 mm MS flat. The
connection between the MS flat and the MS rod shall be made by welding, while that
between the earth electrode and the MS flats through MS links by bolted joints. The earth
electrodes shall be provided at the outer periphery of the grid as shown in Fig. 2 As far as
possible the earthing grid conductors shall not pass through the foundation block of the
equipments. All crossings between longitudinal conductors and transverse conductors shall
be jointed by welding. The transverse and longitudinal conductors of the earthing grid shall
be suitably spaced so as to keep the step and touch potentials within acceptable limits; the
overall length of the earthing grid conductors shall not be less than the calculated length
(refer Annexure-I)
INDIAN RAILWAYS-AC TRACTION MANUAL-VOL II PART II [59]
7.1.2 The size of the earthing grid conductor shall be decided based on the incoming system
voltage and fault level (refer Annexure). The fault level considered shall take into account
the anticipated increase in fault current during the life span of the station. The size shall be
as given below:

SN. System Voltage Fault level Diameter of the grid

kV (MVA) conductor (MS rod) in mm

1. 66 Upto 4000 32
above 4000 upto 5000 36
above 5000 upto 6000 40

2. 110 Upto 6000 32

above 6000 upto 8000 36
above 8000 upto 10000 40

3. 132 Upto 7000 32

above 7000 upto 10000 36

4. 220 Upto 12000 32

above 12000 upto 16000 36
above 16000 upto 20000 40

7.2 Buried rail

7.2.1 A steel rail of section 52 Kg./m (the one used for the railway track) and length about 13 m
shall be buried near the track at the traction substation at a depth of about one metre to form
part of the earthing system. Two separate and distinct connections shall be made by means
of 75 mm x 8 mm MS flat between the earthing grid and the buried rail. The buried rail shall
also be connected by means of two separate and distinct connections with 75 mm x 8 mm
MS flat to the traction rail(s) in a single-rail track circuited section and to the neutral point(s)
of the impedance bond(s) in a double-rail track circuited section.

7.2.2 In cases where the feeding post is located separately away from the traction substation, the
buried rail shall be provided at the feeding post (where one terminal of the secondary
winding of the traction power transformer of the substation is grounded).

7.3 System earthing

7.3.1 One terminal of the secondary winding (25 kV winding) of each traction power transformer
shall be earthed directly by connecting it to the earthing grid by means of one 75 mm x 8 mm
MS flat, and to the buried rail b y means of another 75 mm x 8 mm MS flat.

7.3.2 One designated terminal of the secondary of each potential, current and auxiliary
transformer shall be connected to the earthing grid by means of two separate and distinct
earth connections made with 50 mm x 6 mm MS flat.

7.4 Equipment earthing.

The metallic frame work of all outdoor equipments such as transformers, circuit breakers,
interrupters and isolators, as well as steel structures shall be connected to the earthing grid by
means of two separate and distinct connections made with MS flat of size as indicated below; one
connection shall be

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME II PART II [61]

made with the nearest longitudinal conductor, while the other shall be made to the nearest
transverse conductor of the grid:

SN Equipment System voltage Ground conductor

And fault level size

1. Equipments on the primary 66 kV upto 3000 MVA 50mm x 6 mm

side of traction power trans- 110 kV upto 5000 MVA
former 132 kV upto 6000 MVA
220 kV upto 10000 MVA

66 kV above 3000 upto 6000 MVA 75 mm x 8 mm

110 kV above 5000 upto 10000 MVA\
132 kV above 6000 upto 12000 MVA
220 kV above 10000 upto 20000 MVA

2. Equipments on the secondary 50mm x 6 mm

side of traction power
transformer.

3. Fencing uprights/steel structures 50mm x 6 mm

4. Doors/fencing panels 6 SWG GI wire

7.5 Earthing inside control room

An earthing ring shall be provided inside the control room by means of 50 mm z 6 mm MS flat which
shall be run along the wall on teak wood blocks fixed to the wall at a height of about 300 mm from
the floor level. The earthing ring shall be connected to the main earthing grid by means of two
separate and distinct connections made with 50 mm x 6 mm MS flat. The earthing ring shall also
be connected to an independent earth electrode by means of two separate and distinct connections
made with 50 mm x 6 mm MS flat. The metallic framework of control and relay panels, LT a.c. and
d.c. distribution boards, battery chargers, remote control equipment cabinets and such other
equipments shall be connected to the earthing ring by means of two separate and distinct
connections made with 8 SWG galvanized steel wire. The connections shall be taken along the wall
and in recesses in the floor. All recesses shall be covered with cement plaster after finishing the
work. Connections between the MS flat shall be made by welding.

7.6 Earthing of lightning arrester.

In addition to the earth electrodes provided for the main earthing grid, an independent earth
electrode shall be provided for each lightning arrester. This earth electrode shall be connected to
the ground terminal of the lightning arrester as well as to the main earthing grid by means of two
separate and distinct connections made with 50 mm x 6 mm MS flat for the 25 kV side lightning
arrests, and with 75 mm x 8 mm MS flat for the primary side lightning arresters. The earth electrode
shall be provided as close as possible to the lightning arrester and the connections shall be as short
and straight as possible avoiding unnecessary bends. For lightning arresters provided for the
traction power transformers, there shall also be a connection as direct as possible from the ground
terminal of the lightning arrester to the frame of the transformer being protected; this connection
shall also be made by means of two separate and distinct connections made with 50 mm x 6 mm
MS flat for 25 kV side arresters, and with 75 mm x 8 mm MS flat for primary side lightning arrester.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [63]

7.7 Earth screen.
The area covered by outdoor substation equipments shall be shielded against direct strokes of
lightning by an overhead earth screen comprising 19/2.5 mm galvanized steel stranded wire strung
across the pinnacles of the metallic structures. The earth screen wires shall be strung at a height as
indicated in the approved traction substation layouts (not less than 2.5 m above the live conductors)
and shall be solidly connected to the traction substation earthing grid at each termination by means
of 50mm x 6 mm MS flat.

7.8 Earthing of fencing uprights and panels.

Each metallic fencing upright shall be connected to the traction substation main earthing grid by
means of two separate and distinct connections made with 50 mm x 6 mm MS flat. In addition, all
the metallic fencing panels shall be connected to the uprights by means of two separate and distinct
connections made with 6 SWG G.I. wire. All the metallic door panels shall also be connected to the
supporting uprights by means of two separate and distinct connections made with 6 SWG G.I. wire.

7.9 Earthing at the point of 240 V ac 50 Hz. Supply for oil filtration plant.

The 240 V a.c 50 Hz. Distribution board for power supply to oil filtration plant shall be connected to
the main earthing grid by means of two separate distinct connections made with 50 mm x 6 mm MS
flat.

8. Earthing Arrangement at Switching Station

8.1 A minimum number of three earth electrodes (excluding the one to be provided separately for
the remote control cubicle earthing refer clause 8.4) shall be provided at each switching station,
and they shall be interconnected by means of 50 mm x 6 mm MS flat forming a closed loop main
earthing ring. This ring shall be connected by two separate and distinct connections made with
50 mm x 6 mm MS flat, to the traction rail in a single-rail track circuited section and to the neutral
point of the impedance bond in a double-rail track circuited section of the nearest track, so as to
limit the potential gradient developing in the vicinity of the switching station in the event of a
fault.

8.2 System earthing

One designated terminal of the secondary of each potential, current and auxiliary transformer shall
be connected to the main earthing ring by means of two separate and distinct connections made
with 50 mm x 6 mm MS flat.

8.3 Equipment earthing

8.3.1 All masts, structures, fencing uprights, and all outdoor equipment pedestals including
auxiliary transformer tank shall be connected to the earthing ring by means of two separate
and distinct connections made with 50 mm x 6 mm MS flat. All fencing panels shall be
connected to the supporting uprights by means of two separate and distinct connections
made with 6 SWG G.I. wire. All the metallic door panels shall be connected to the
supporting uprights by means of two separate and distinct connections made with 6 SWG
G.I. wire.

8.3.2 The metal casing of potential and current transformers shall be connected to the
mast/structures by means of two separate and distinct connections made with 50 mm x 6
mm MS flat.

8.3.3 The ground terminal of lightning arrester shall be connected directly to the earth electrode by
means of two separate and distinct connections made with 50 mm x 6 mm MS flat. The
earth electrode shall be so placed that the earthing leads from the lightning arrester may be
brought to the earth electrode by as short and straight a path as possible.
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [64]
8.4 Earthing inside remote control cubicle

An earthing ring shall be provided inside the remote control cubicle by means of 50 mm x 6 mm MS
flat; the earthing ring shall be run along the wall on teak wood blocks fixed to the wall at a height of
300 mm from the floor level. The earthing ring shall be connected to the main earthing ring as well
as to independent earth electrode by means of two separate and distinct connections made with 50
mm x 6 mm MS flat. The metal casing of LT a.c. distribution board, battery chargers, terminal
board, remote control equipment cabinets and other such equipments shall be connected to the
earthing ring by means by two separate and distinct connections made with 8 SWG G.I. wire. The
connections shall be taken along the wall and in recesses in the floor. All recesses shall be covered
with cement plaster after finishing the work. Connections of earth strips to each other shall be made
by welding.

9. Earthing of Neutral of Local Power Supply System

At traction substations and switching stations where power supply at 415 V/240 V, ac,, 50 Hz is
taken from the local supply authority and having neutral earth at some distant point in the premises
of the supply authority, the neutral of such supply shall also be earthed by means of two separate
and distinct connections made with 6 SWG G.I. wire by connecting to an independent earth
electrode.

10. Earthing Arrangement at Booster Transformer Station

10.1The combined earth resistance at a booster transformer station shall be not more than 10 Ohm.
Normally one earth electrode shall be sufficient for a booster transformer station. The earth
electrode shall be connected to the lower end of each mast of the supporting gantry by means
of two separate and distinct connections made with 50 mm x 6 mm MS flat. In addition each
mast of the supporting gantry shall be connected by means of a 50 mm x 6 mm MS flat to the
nearest traction rail or to the neutral point of the nearest impedance bond in a double rail track
circuited section,.

10.2The booster transformer tank shall be connected to the masts of the supporting gantry by
means of two separate and distinct connections made with 50 mm x 6 mm MS flat. These
connections shall be as short and as straight as possible without unnecessary bends.

11. Earthing Arrangement at Auxiliary Transformer Station

11.1The combined earth resistance at an auxiliary transformer station shall be not more than 10
Ohm. Normally one earth electrode is sufficient for an auxiliary transformer station. The earth
electrode shall be connected to the mast on which the auxiliary transformer is mounted by
means of two separate and distinct connections made with 50 mm x 6 mm MS flat. In addition
the mast shall be connected to the nearest traction rail or to the neutral point of the nearest
impedance bond in a double rail track circuited section by means of a 50 mm x 6 mm MS flat.
11.2 The earthing terminal on the transformer tank shall be connected to the mast on which the
transformer is mounted by means of two separate and distinct connections made with 50 mm x 6
mm MS flat. One terminal of the secondary winding of the auxiliary transformer shall be connected
to the earthing terminal on the transformer tank and as well as to the mast by means of 50 mm x 6
mm MS flat. These connections shall be as short and straight as possible and avoiding
unnecessary bends.

12. Method of joining

All the joints between the MS flats, MS rods or between MS flat and MS rod shall be made by
welding only. No soldering shall be permitted. For protection against corrosion, all the welded joints
shall be treated with red lead and afterwards thickly coated with bitumen compound.
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [65]
13. Painting of MS flats.

For protection against corrosion, all the exposed surfaces of earthing connections (MS flats) above
ground level shall be given all around two coats of painting to colour grass green, shade 218 of IS.5

14. Crushed Rock Surface Layer

At the traction substations and switching stations, a surface layer of crushed rock shall be provided
to a thickness of about 100 mm. If considered necessary from the point of view of containing the
step and touch voltages within the acceptable limits, higher thickness may be provided depending
on calculation based on site conditions.

15. Step and Touch Voltages

15.1 The formulae for calculating the tolerable touch and step voltages, estimated mesh and step
voltages, earth resistance, earth potential rise, size of earthing grid conductor and length of
buried grid conductor are given in Annexure-I.

15.2 The design for earthing grid shall be done separately for each location depending on the
conditions obtaining and those foreseen.

16. Drawings

The following drawings (latest versions) issued by RDSO in connection with this code may be used
for reference:

I) Typical earthing layout of traction substation ETI/PSI/224-1

ii) Typical return current connection of buried

Rail at traction substation ETI/PSI/0212-1

i) Typical earthing layout of sub sectioning

And paralleling station ETI/PSI/201-1

iv) Typical earthing layout of sectioning ETI/PSI/202-1

and paralleling station

v) Typical earthing layout of booster ETI/PSI/211-1

transformer station

vi) Typical arrangement of an earth electrode ETI/PSI/222-1

at a traction substation

vii) Typical earthing arrangement for an ETI/PSI/708

auxiliary transformer station

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [66]

 APPENDIX IV

REGULATIONS FOR POWER LINE CROSSINGS OF

RAILWAY TRACKS
( ISSUED BY RAILWAY BOARD IN 1987)

GENERAL

1. Definitions

1.1 The following terms wherever occurring in the Regulations shall, unless
excluded by or repugnant to the context, have the meaning attributed thereto as under:

Chief Electrical Engineer means the officer designated as such by the Zonal Railway or his
successors in office or on whom his duties devolve.

Power line crossing means an electrical overhead line or under ground cable placed across railway
track(s) for the transmission and/or distribution of electrical energy. It may also be referred to as a
Crossing in these Regulations.

Electrical Inspector means the officer appointed by the appropriate Government under Section 36
of the Indian Electricity Act, 1910, to exercise the powers and perform the functions under the said
Act. On the Zonal Railway, the Chief Electrical Engineer is the Electrical Inspector.

Owner means the owner of an electrical crossing.

Railway means the Zonal Railway administration in whose territorial jurisdiction the electrical
crossing is located or proposed to be located and includes the Chief Electrical Engineer, the
Divisional Railway Manager (Electrical) of the Zonal Railway Administration.

Writing includes all matters written, typewritten or printed either in whole or in part.

2. Scope

2.1 The regulations apply to electrical overhead lines and/or underground cables crossing railway
tracks operated by the Indian Railways, Railway Companies and Port Commissioners Railways,
including assisted and private sidings on which rolling stock of Indian Railways may work, unless any
special section or railway tracks are exempted from these Regulations by specific written orders of
the Electrical Inspector.

Notes:

i) If any existing crossing infringes the provisions of the Regulations at the time of its issue, the
infringement(s) shall be treated as permissible infringement(s) provided that necessary relaxation
has been granted in respect of the clearances under clause 21 thereof.
ii) The Regulations do not apply to crossing(s) of railway track(s) laid underground/inside tubes
and tunnels.
iii) The Regulations do not also apply to Railway Traction systems (1500 V d.c. and 25 kV, 50
Hz. A.c. Single phase) whose feeders/conductors/wires run along or across the tracks for traction
purposes.

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [75]

iv) On sections proposed to be electrified on or to be converted to suit 25 kV , 50 Hz. Ac single
phase traction system, the crossing existing at the time of electrification/conversion proposed shall
be specially studied with a view to avoiding modifications to the extent possible without jeopardising
safety. If any modifications are considered essential to obtain the minimum clearances, specified in
clause 21 thereof, they shall be carried out.
v) In special cases, where the Electrical Inspector has specifically permitted reduction in
clearances under clause 21 thereof, a clear declaration to this effect shall be recorded in the
CERTIFICATE OF COMPLIANCE (in the form at Annexure II) to these regulations.

3. Approval of Works by the Railway:

3.1 I) Designs, Drawing etc.

Before the Owner commences any work on a crossing, he shall obtain the approval in writing, of the
Railway for the proposed location, the detailed design and the method of execution of the crossing.
For this purpose, the data designs, calculations and drawing(s) relating to the crossing shall be
furnished by the owner to the Railway as stipulated in Annexure A 4.01 to these Regulations. On
receipt of written approval from the Railway, the owner shall execute an Agreement in the Form at
Annexure A.4.02 to these Regulations.

ii) Construction

The owner shall notify the Railway in writing at least 15 days in advance of the date on which he will
commence the work of construction of the crossing. The Chief Electrical Engineer, or his
representative, may, if he so desires, inspect the site/work of the crossing during its construction to
ensure that it is being constructed in accordance with the approved designs and drawings. Only
good quality of materials shall be used in the construction of the crossing which shall be executed in
a workman-like manner.

i) Bringing crossing into use.

Prior to bringing the crossing into use, the owner shall:

a) Notify the Railway in writing at least 15 days in advance of the date the crossing is intended to
be brought into use.

b) Submit to the Railway a CERTIFICATE OF COMPLIANCE, (In the form at Annexure A 4.03 to
the Regulations) to the effect that the works have been constructed in compliance with the
Recalculations and in conformity with the design(s) and drawing(s) approved by the Railway. Only
on receipt of written approval. From the Railway, the crossing shall be energised and brought into
use.

4. Compliance with Indian Electricity Act 1910 and Indian Railway Act ,1890 and Rules made
thereunder etc.

4.1 Except as otherwise provided for in the Relgulations the contents of relevant section of the
Indian Electricity Act 1910 the Indian Railway Act ,1890 and the rules made under these Acts and as
amended from time to time and the relevant provisions of Indian Railways Schedule of Dimensions
for Broad Metre and Narrow gauges together with the latest amendments thereto shall apply to the
crossing.

5. Compliance with Indian Standard Specifications:

5.1 All materials used in the construction of the crossing shall comply with the latest Indian Standard
specification(s) relevant and where these are not available, with the latest British standard
specification(s) relevant.
INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [76]
6. Works to be executed by the Railway:

6.1 The disturbance of any rail, road or ground or any attachment to any railway structure as may be
necessary for the placing and/or maintenance of the crossing shall be effected by or under the direct
supervision of the Railway and any conduit, culvert or similar work passing under Railway premises
shall be constructed by the Railway in such manner and of such materials as it may approve of and
the entire cost of such works shall be borne by theowner of the crossing.

7. Method of Crossing overhead line or underground cable:

7.1 For tracks already electrified or to be electrified in the foreseeable future:

All low, medium and high voltage upto and including 11 kV crossing(s) shall normally be by means of
underground cable(s). While for voltages higher that 11 kV, crossings may be by overhead lines or
underground cables, the use of underground cable to the extent possible would be advantageous,
particularly for 22 kV and 33 kV system.

8. Protection of Communication Lines:

8.1 The crossing shall in no way interfere with or endanger any Railway communication lines.
Approval given by the Railway for placing of any crossing shall not be construed as affecting in any
way the requirements of the Indian Post and Telegraph Deptt. In regard to the protection of their
communication lines.

8.2 The crossing shall also comply with the stipulations in the Code of Practice for the protection of
Telecommunication lines at crossings with overhead power lines other than Electric Traction Circuits
issued by Central Electricity Authority. Telecommunication Directorate, Power and
Telecommunication Coordination Committee (PTCC Unit), Government of India, B-67/19 Safdarjung
Enclave, New Delhi-29 and the latest amendments if any, thereto.

9. Maintenance of Crossing:

9.1 No work whatsoever on any crossing shall be undertaken by the Owner without obtaining the
consent in writing from the Railway. All such works shall be carried out under the direct supervision
of the Railway.

9.2 The crossing shall always be maintained in a state of good repair so as to reduce hazards to life
and property. It shall be inspected by the Owner at interval not exceeding 12 months in order to
determine its fitness for service. Defects, if any, noticed or as pointed out by the Railway shall be
rectified by the owner expeditiously. The decision of the Railway in regard to defects noticed and
rectification(s), if any, to be done by the owner shall be final and binding on the owner.

9.3 The crossing span as well as two adjacent spans on either side of the overhead line crossing
shall be kept free by the owner from any trees and branches which, if they fall on these spans, would
foul with the overhead line. The growth of bushes and wild vegetables shall not be permitted on
either side of the overhead line for the same reason.

9.4 Where galvanized steel structures support the crossing span, they shall be maintained free of
rust, corrosion, etc.

9.5 If at the instance of the Railway, the crossing is to be shifted or modified or dismantled, the work
shall be carried out by the owner at the cost of the Railway. However, in those cases where the
need for such works on account of Railways anticipated developments/requirements was foreseen
in time and the owner had agreed in writing prior to the construction of the crossing to meet the cost
of such works. Such works shall
INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [77]
be carried out on a priority basis by the owner within a fixed schedule, as mutually agreed upon
between the owner and the railway and to the satisfaction of the electrical Inspector. The Railways
shall have the right to claim compensation for any loss and/or inconvenience caused if there is
avoidable delay in completing the works.

10. Defects and Failures:

10.1 I) All defects/failures like snapping of conductors in the crossing span, breaking of insulator
string in the overhead line crossing or any defect that is likely to affect the safe movement of the
railway traffic or the safety of the railway property or personnel shall be reported forthwith by the
owner to the Station Master on duty at the railway station on both sides of the crossing as well as to
the Chief Electrical Engineer, the Divisional Railway Manager (Electrical), the Electrical Inspector
and the Director (Transmission), Central Electricity Board, S 907, Seva Bhavan, R.K. Puram,New
Delhi 66. A detailed report of the failure or defect, shall also be sent to the Chief Electrical
Engineer, the Divisional Railway Manager, the Divisional Railway Manager (Electrical), the Electrical
Inspector and the Director (Transmission), Central Electricity Board,New Delhi as soon as possible
preferably within 48 hours of the first report.

i) In the even of an accident to Railways tracks/rolling stock in the vicinity of an overhead line
crossing, the owner shall, if required by any official acting on behalf of the Railway, expeditiously
switch off the overhead line and effectively connect the conductors to earth as long as is necessary
to enable Railways cranes if any, to work safely in the area.

II OVERHEAD LINE CROSSINGS

11. Angle of crossing

11.1 An overhead line crossing shall normally be at right angles to the railway track, in special cases
a deviation of upto 30 degree may be permitted. Deviations larger than 30 degree shall have to be
specifically authorised by the Electrical Inspector of the Railway.

12. Structures

12.1 Steel poles/masts fabricated steel structures or reinforced or pre-stressed concrete poles either
of the self-supporting type or guyed type conforming in all respects to the Indian electricity Rules
1956 ( as amended upto November 1984) and complying with the latest editions of codes of practice,
IS 800-1962 for Code of Practice for use of structural steel in general building construction, IS 875-
1964 for Code of Practice for structural safety of buildings; loading standards and IS 456-1978 for
Code of Practice for plain and reinforced concrete shall be used on either side of the track to
support the crossing span. These structures shall be of the terminal type. For arriving at the
crippling load, the wind loads as detailed in the latest edition of IS 802 (Part I) 1977 for Loads and
permissible stresses shall be adopted. The steel structures shall normally be galvanized in
accordance with IS 2629-1966 for recommended practice for hot-dip galvanizing of iron and steel.

12.2 The minimum distance of the structures (supporting the crossing span) from the center of the
nearest railway track shall be equal to the height of the structure in meters above normal ground
level plus 6 meters. In special circumstances, the Electrical Inspector may permit a lesser distance
being adopted subject to any conditions he deems fit to impose.

12.3 The crossing span shall be restricted to 300 m or to 80% of the normal span for which the
structures are designed, whichever is less.

13. Wind Pressure

13.1 The maximum wind pressure for design of the structure shall be as prescribed in IS 802 (part-I)

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [78]

1977 for load and permissible stresses.

14. Temperature

14.1 The maximum and minimum temperatures for design of the conductors and other wires shall be
as prescribed in the latest edition of IS 802 (Part I, Clause-4) with necessary correction for conductor
maximum temperature.

15. Provision for Ice/Snow Loading:

15.1 Where provision has to be made for ice and/or snow loading, it shall be determined in the light of
local conditions with the approval of the Railway.

16. Factor of Safety

16.1 The factor of safety of all structures, conductors, guards, guys and ground wires used in the
crossing shall be as stipulated in the Indian Electricity Rules, 1956 (as amended in November 1984)
and the relevant codes of practice.

17. Clearance between the overhead line and railway track:

17.1 An overhead line crossing over railway track already electrified shall be located at the middle of
overhead equipment span supported by two adjacent traction masts/structures. The distance
between any of the crossing conditions and the nearest traction mast or structure under the most
adverse, conditions shall not be less than 6 m.

17.2 No overhead line crossing shall be located over a booster transformer, traction switching station,
traction sub-station or a track cabin location in an electrified area.

17.3 Vertical Clearance:

The minimum height above rail level of the lowest portion of any conductor of a crossing, including
guard wire, under conditions of maximum sag shall be as follows:-

Sn. Voltage Broad, Metre & Narrow Gauges

1. Upto and including 11 kV Normally by cable

2. Above 11 kV and upto 66 kV 14.10 m

3. Above 66 kV and upto 132 kV 14.60 m

4. Above 132 kV and upto 220 kV 15.40 m

5. Above 220 kV and upto 400 kV 17.90 m

6. Above 400 kV and upto 500 kV 19.30 m

7. Above 500 kV and upto 800KV 23.40 m

Note I) While including the above clearance, Railways high tension lines running over the 1500 V
DC traction structure in some sections have not been taken into consideration. Where such high
tension lines exist, the height above the rail level of the highest high tension line shall be taken into
account for calculating the clearances.
INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [79]
Note ii) If for special reason, it is not practical to have an underground cable crossing for systems
upto and including 11 kV on sections not likely to be electrified in future, the Chief Electrical Engineer
of the Railway may permit the electrical crossing to be an overhead one. In such a case, the
clearance(s) specified in clause 21.4 shall be maintained.

Note iii) The working of a Railway crane under an overhead line crossing shall normally be avoided.
If it becomes absolutely essential for a crane to work under such a crossing, the minimum clearance
required to be maintained between the highest working point of the jib and the lower crossing
conductor shall be as under:-

Normal System Min. safe clearance

Voltage (kV) ( In Metre)

33 1.50
66 2.00
110 2.25
132 2.50
220 3.50
400 6.00
500 7.25
800 11.50

The crane driver/supervisor shall be guided in this regard by the senior most official of the electrical
engineering department at site.

18. Minimum clearances between crossing conductors and any railway structure

18.1 The minimum vertical and horizontal clearances to be maintained between any of the crossing
conductors and any railway building and/or structure
18.2 , other than traction masts and structures and overhead equipment, under the most adverse
conditions shall be as specified in Rule 80 of the Indian Electricity Rules, 1956 (as amended upto
Nov. 84)

19. Minimum vertical clearance between power line crossings.

19.1 The minimum vertical clearances to be maintained between any of the power line crossings at
the same or at different voltages shall be as specified in Rule 87 of the Indian Electricity, 1956 (as
amended upto November 1984)

19.2 Separate guarding shall be provided above the lower power line in all cases except when the
voltage of the higher line is 33 kV and above. Where such guarding is provided, the clearance from
the guard wires to the lower power line shall be not less than 2 m and to the upper power line not
less than 1.5 m.

20. Clearance between power line & communication line

20.1 The minimum clearance to be maintained between a power line and a communication line shall
be as prescribed in the Code of Practice for the Protection of telecommunication lines at crossings
with overhead power lines other than Electrical Traction Circuits (latest edition) issued by Central
electricity Authority, Telecommunication Directorate, Power and Tele-communication Coordination
Committee (PTCC Unit), Govt. of India.

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [80]

21. Relaxation by the electrical inspector

21.1 In special cases, the Electrical Inspector of the Railway may permit reduction in the clearance
specified in clause 18, subject to the following minimum clearance being maintained between the
highest traction conductor and the lowest crossing conductor.

Voltage Broad, Metre & Narrow gauge (in Mtr.)

Upto & including 33 kV 4.44

Above 33 kV and upto & including 66 kV 4.44

Above 66 kV and upto 110 kV 4.75

For 110 kV and 132 kV 5.05

For 220 kV 6.58

For 400 kV 9.71

For 500 kV 11.45

For 800 kV 16.67

21.2 If the crossing is provided with a guarding, a minimum clearance of 2 m shall be maintained
between the bottom of the guard wire and the highest traction conductor.

21.3 The Railway may evolve, wherever feasible, special design(s) for traction overhead equipment,
return conductor, 25 kV feeder or other power line on traction masts/structure keeping in view the
need for economy and other requirements, if any.

21.4 In section where the track(s) is/are not likely to be electrified in future, the Electrical Inspector of
the Railway may, in special circumstances, permit crossing of systems upto and including 11 kV by
overhead lines with the minimum height above rail level of the lowest portion of any conductor
including guard wire under conditions of maximum sag being not less than 10..95 metres above
highest rail level provided that the owner of the crossing gives an undertaking in writing in the
COMPLIANCE CERTIFICATE (AS AT Annexure A 4.03 to the Regulations) to the effect that
whenever the Railway requires the crossing to be converted from an overhead one to an
underground one, the owner will carry out the work at his own cost.

Note (I) The minimum clearances have been derived with an allowance of 2.0 m for maintenance.
This allowance may also be reduced by the Electrical Inspector of the Railway, keeping in view the
yard remodeling, shifting of structures etc.

22. Insulators
22.1 A double set of strain insulator strings shall be used in crossing span in conjunction with a yoke
plate where necessary as illustrated in sketch No. 1 attached to these Regulations. Each string of
such strain insulators shall have one insulator more than the number used in a normal span of the
overhead line. The factor of safety of each string of insulators under the worst conditions shall not be
less than 2. The arrangements of power line crossing shall generally be as shown in sketch Nos. 1,2
& 3 attached to the Regulations.

23. Guarding

23.1 All overhead power line crossings upto and including 33 kV shall be provided with guarding
under the power line. Guarding need not necessarily be provided for overhead power line crossings
of voltages above
INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [81]
33 kV if the transmission/distribution line is protected by circuit breakers of modern design with total
trippings times of 0.20 seconds for voltages below 220 kV and 0.10 seconds for 220 kV and above,
from the time of occurrence of the fault to its clearance. Wherever guarding is adopted for the
crossing span, cradle guards shall also be provided.

23.2 The minimum height above the rail level to the lowest level of any cradle guard or guard wires
under conditions of maximum sag shall not be less than the values specified in clause 18. In special
cases, however, the Electrical Inspector of the Railway may permit lower heights under the
provisions of clause 22 of the Regulations.

23.3 The minimum height between any guard wire and a live crossing conductor under the most
adverse conditions shall not be less than 1.5 m.

24. Anti-climbing Devices and Warning Notices.

24.1 Where the voltage exceeds 650 V, the supporting structures, )(of the overhead line crossings)
on railway land shall be provided with anti-climbing devices. Besides, suitable caution/warning
notices shall be erected on all such structures, in the languages as may be prescribed for the
purpose. The anti climbing devices and the caution/warning notices shall be approved by the
Railway.

25. Protection from Moving Road Vehicles.

25.1 Supporting structures, (of the overhead line crossing) including guys, adjacent to roadways shall
be so located that the danger of their being struck by moving road vehicles is avoided or reduced to
the minimum. Wherever required, guard rails, suitably painted to make them conspicuous, shall be
provided for the purpose.

26. Communication Lines

26.1 The owner of a communication line shall provide adequate safety devices so that no damage is
caused in the event of snapping of conductors of a power line crossing. In addition to the safety
devices, the owner shall also provide necessary surge absorbers in the system to guard against the
effects of surges caused during switching operations or system faults.
26.2 Overhead communication lines may be permitted to be supported on the structures used for the
crossing span of a power line crossing, provided the owner of both lines is the same. The factors of
safety for conductors and insulators, the clearances above rail level and the method of supporting
such crossings shall be not less than those specified for power line crossing.

27. Earthing
27.1 I) Each structure on either side of the crossing span supporting the transmission/distribution line
conductors shall be earthed effectively by two separate and distinct earths and connections. Atleast
one separate earth electrode shall be provided for each earth connection.

ii) All guard and stay wires, shall be properly clamped to the structures connected to earth so as to
maintain proper electrical continuity to earth.

iii)Where struts are provided, they shall also be effectively connected to earth separately as well as
to the main structure earths.

IV) Where the earth resistance of the independent tower/structure is higher than 10 ohms, the owner
shall take necessary steps to improve the earth resistance either by providing multiple earth
electrodes or by suitably treating the soil surrounding the earth electrode or by resorting to
counterpoise earthing. The method of earthing the transmission/distribution line structures etc. for
the crossing span shall be approved by the Railway.

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [82]

V)The earth shall be inspected and tested annually on a hot dry day and results thereof furnished to
the Railway for verification and record. If the earth resistance is found to be high, i.e. above 10
ohms, steps shall be taken to reduce it and an advice given to the Railway.
VI)The cross section of the earth conductor/connections for the earthing system shall be adequate
for the application. They shall not be damaged or overhead or melt while carrying the short circuit
current.

28. Fire Hazards

28.1 Structures supporting the crossing span shall be so placed, guarded and maintained as to be
least exposed to bush, grass, rubbish and building fires as is possible.

III CABLE CROSSINGS

29. Cable Crossing

29.1 As far as possible cable crossings shall make use of any existing culverts, sub-ways etc. where
track(s) is/are already equipped for electric traction on 25 kV Hz. Single phase ac system, the
crossing shall be provided at locations at least 5 metres away from any traction sub-station or
switching station or mast or structure erected or proposed to be erected by the Railway for the
purpose of supply and distribution of power to the traction over head equipment. The exact locations
of such traction sub-station or switching station or mast or structure in any particular area shall be
obtained by the owner from the Railway.

30. Type of Cables

30.1 The owner shall specify and obtain prior approval of the Railway for the type of cable he intends
to use for the crossing. It shall preferably be armoured. Where cables are suspended from supports
and not laid in a protective pipe, they shall be of the anmoured and sheathed type.

31. Cathodic Protection

31.1 Cathodic protection of the cables shall not be adopted without the specific prior approval of the
Railway.

32. Method of Laying

32.1 Where the cable is laid under railway track(s) it shall be laid through cast iron pipes or spun
concrete pipes of suitable diameter and strength. In order to avoid disturbance to the railway
track/formation in case it become necessary to lay additional cable(s)_ in future, it would be
advantageous to provide protective pipes of adequate (larger) diameter initially to cater for additional
cables. The specifications for the pipes to be used shall be submitted to the Railway for approval.
The pipe shall be laid at not less than one metre below the formation level. It shall be possible to
withdraw the cable(s) for repair for replacement without disturbing the railway track or formation.
Long lengths of pipe shall be laid with gradient to facilitate drainage of water if any. The pipe shall be
laid upto the Railway boundary at both ends or upto the point as prescribed by the Railway. The
laying of the cable in the Railway premises shall be in accordance with the latest edition of IS 1255-
1967 Code of Practice for installation and Maintenance of Power Cables.
33. Works Carried out under or near Railway Track.

33.1 Where the cable is to be laid under a railway track(s) the use of case iron or spun concrete pipe
for protection of the cable is obligatory and such pipe shall be laid in accordance with the contents of
clause-7.
33.2 The armouring and sheathing of the underground cable laid across or near any electrified
railway track shall be earthed by independent earths at the two sealing ends of the cable. No further
earthing of the armouring and sheathing of the cable shall be done within 500 m of the electrified
track. The scheme and
INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [83]
method of earthing shall specifically be approved by the Railway.

34. Structures on which cable ends are supported and terminated.

34.1 Where the ends of a cable of an underground crossing are terminated on structures for
connection to an overhead line, such structures shall comply with the Regulations in so far as they
are applicable to overhead line crossing in respect of structures.

35. Marking of Crossings

35.1 Each cable crossing shall be indicated by at least two cast iron cable markers, one at each end
of the crossing, within the railway boundaries. The cable marker shall be fixed at both ends of the
underground crossings. They shall be of a design approved by the Railway. The following
information shall be clearly marked on the markers.

ELECTRICAL CABLE Volts

NUMBER Cables

DANGER In English, Hindi and the vernacular

Of the district

DEPTH OF CABLE Below track level.

DEPTH OF CABLE Below ground level between

The toe of bank and railway
Fencing.

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [84]

 Annexure A 4.01

DATA DESIGNS, CALCULATIONS AND DRAWINGS

TO BE FURNISHEDBY OWNER

The following data, designs calculations and drawings together with the application for the proposed
power line crossing incorporating the particulars as detailed below all in duplicate shall be
furnished by the owner to the Divisional Railway Manager (Electrical) for approval by the Electrical
Inspector of the Railway.

1. Overhead line crossings.

a) Data and Designs

1. Location of the proposed crossing, the names of railway stations on either side of the crossing,
the distance of the crossing from the nearest railway station, the painted numbers of Telegraph poles
and or traction mast or structures between which the crossing is proposed to be located and the
exact location in relation to such poles or masts or structures.

Note: The alignment of the crossing should, as far as possible be at the mid-point of the span
between adjacent traction masts or structures in the case of electrified tracks. (See Cl. 18.1 of the
Regulations)

2. Particulars of the overhead line, including voltage, frequency number of phases, size of
conductors etc. and whether the neutral is earthed or not and if earthed, the type of earthing.

3. Wind Pressure adopted.

4. Temperature data adopted

5. Particulars of ice/snow loading, if any, adopted

6. Factors of safety adopted in the designs, for conductors, structures, guard wires/cross wires if
provided, earth-wire, stay wire, insulator-strings, etc.

7. Design calculations of structures and foundations for the crossing span, communication lines or
guarding, if any.

Note: If the structures and foundations are of standard type used for the transmission/distribution line
concerned, the detailed design calculations shall be furnished.

8. Calculations leading to the minimum values under worst conditions of the following.

i) Vertical clearance between the lowest crossing conductor, communication lines and/or
guarding and the different railway tracks in the crossing span.
ii) Vertical clearance between the lowest crossing conductor, Communication lines and/or
guarding and railways conductors of the traction system or other conductors if any.
iii) Horizontal clearance to railway mast/structure/building, if any
iv) Lateral clearance to the nearest Railway mast/structure/building, if any.

Note: Full particulars of the number, size, material and characteristics of various wires and
conductors shall be furnished.

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [85]

9. Particulars of insulators, bridling of the conductors.

10. Details of guarding, size of guard and cross wires and their characteristics. A detailed drawing
showing the guarding arrangement, if provided, shall be given.

11. Size and characteristics of guy wire, if provided, and the number of supports.

12. Details of earthing indicating the earth electrode, size of earthing connection, method of
connection to the support and the method of article soil treatment if proposed. Details of
counterpoise earthing, if contemplated, shall be furnished.

13. Details of protection against moving road vehicles.

14. Particulars of anti-climbing devices, if provided, and warning and caution notices.

15. Detailed scheme of protection for the transmission/distribution line including particulars of relays,
operating times etc. and particulars of circuit breakers, if any.

b) Drawings

1. Layout and site plan of the proposed crossing indicating railways boundaries.

2. Longitudinal elevation of the crossing. The drawing shall indicate full particulars of one span on
either side of the crossing span with various clearances with respect to the Railway track(s). the
drawing shall show the cross section of the railway formation and tracks.

3. Drawing for warning and caution notices.

Note: I) All drawings shall be in standard sizes as prescribed in the latest edition of IS 696-1972
Code of Practice for General Engineering Drawing.

ii) All drawings are to be endorsed with a certificate as given below.

I hereby certify that the details of the equipment provided are designed with the object of minimising
danger in the event of breakage/fault and in accordance with recognized modern Engineering
Practice, and signed by the owner.

II. Underground cables

a) Data and designs

1. Location of the proposed cable crossing, the names of the railway stations on either side of the
crossing the distance of the crossing from the nearest railway station, the painted numbers of
telegraph poles or traction masts or structures between which the crossing is proposed to be located
and the exact location in relation to such poles or masts or structures.

2. Supply system particulars, particulars of cables, their number, size and number of cores,
voltage, type of insulation, armouring etc.

3. Full particulars of the protective pipe for the crossing.

4. Method of earthing of the cable armouring and sheathing, if any

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [86]

5. Method of making the cable crossing for identification.

6. Design calculation for masts/structures for supporting and terminating cable(s), and drawings to
show that the masts/structures would not foul the railway track(s) in the event of their failure in so far
as movement or railway vehicles is concerned.

b) Drawings

1. Layout and site plan including route, location of structures, if any, for supporting and terminating
the cable and railways boundaries.

2. Drawings showing cable/crossing marker.

Note I) All drawings shall be in standard size as prescribed in the latest edition of IS 696-1972 Code
of practice for General Engineering Drawings.

ii) All drawings are to be endorsed with a certificate as given below:

I hereby certify that the details of the equipment provided are designed with the object of minimizing
danger in the event of breakage/fault and in accordance with recognized modern Engineering
Practice.

III. Overhead line crossings and underground cables

Along with a reproducible print, eight copies of the drawings showing the completed power line
crossing shall be furnished to the Railway along with the Certificate of Compliance (as at Annexure
A 4.03 to the Regulations).

INDIAN RAILWAYS -AC TRACTION MANUAL VOL II PART II [87]

 Annexure A. 4.02

AGREEMENT FOR ERECTING AND MAINTAINING AN OVERHEAD POWER LINE CROSSING

OVER AND ACROSS RAILWAY TRACKS.

An agreement made this.................. day of .................. one thousand nine hindered and
.....................................................
Between the President of India acting through the Chief Electrical Engineer/ Divisional Railway
Manager/Divisional Railway Manager (Electrical) of the ..........................Railway administration (hereafter
called the Railway) of the one part and ................ (hereinafter referred to as the owner of the other part.
Whereas the owner wishes to erect and electric Overhead line and carry out the works connected herewith for
transmission of distribution of electrical energy over and across the railway tracks and/or land at Kilometrage
............. in the section..................at................Railway station, of the Railway, the said overhead line where it
crosses the railway tracks and/or land works connected therewith hereinafter referred to as the Crossing.
Now IT IS HEREBY AGREED AS folllows:

1. General : the Railway will permit the owner as from the......................day of ......................19, to lay the
crossings as per Drg. No. ........................approved by the Railway hereunto attached as Annexures, and in
compliance with Regulations for Power line crossing of Railway tracks hereunto attached as Annexures
hereinafter referred to as the Regulations, for the purposes hereinbefore mentioned subject to the terms and
conditions hereinafter contained.

3. Permission to erect and maintain the crossing :- The Railway will, subject to the provisions of clause 3
hereinafter contained, permit the owner to erect and maintain in accordance with the Regulations the crossing
over and across the Railway tracks and/or land at the place(s) shown on the said drawing and to execute all
repairs in connection therewith when necessary from time to time and all such works shall be executed at the
cost of the owner at such times as may be permitted and to the satisfaction of the Railway in all respects.

Provided that if shifting of or modifications to or dismantling of the crossing is required for the proper
functioning of the Railway and is to be carried out by the owner as desired by the Railway, the costs of such
works shall be borne by the Railway except in those cases where the need for such works on account of
railways anticipated development/requirements was foreseen in time and the owner had agreed in writing prior
to the construction of the crossing to meet the cost of such works.

3.Railway to carry out protection works :- In the event of it being necessary in the opinion of the Railway to
support or protect the railway tracks and/or land or works during the erection of the crossing or the execution of
any repairs hereto or any removal thereof the work of supporting of or protection the railway tracks or land and
resorting the tracks and/or land to its original condition or such part of the said work as the Railway shall deem
fit will be carried out by the Railway at the cost of the owner in all respects. The amount of such costs will be
determined by the Railway in its absolute discretion and will be paid by the owner to the Rly. On demand. The
owner will, if so required, deposit with the Railway prior to the carrying out of the said work such sum of money
as may be estimated by the Railway to be the cost of the work required to be done and the amount of the said
deposit will be set off against the said cost to be determined as aforesaid and the balance paid as aforesaid.

4. Cost of Supervision of works

All works in connection with the matters referred to in clauses 2,3 and 6 will be subject to such supervision by
the Railway as may be considered necessary by the Railway and the owner will pay to the Railway on demand
all costs of such supervision including the cost for the staff required to look after the safety of the railway tracks
and/or land while all or any of such works are/work is in progress. The costs of such supervision and other
costs as aforesaid shall be determined by the Railway in its absolute discretion.

5. Access

Neither the owner nor his employees will at any time enter upon the railway land for any purpose whatsoever in
connection with the crossing as aforesaid without the consent in writing of the Railway.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [91]

6. Modification, shifting or removal of crossing.

If for convenience of operation, unsatisfactory maintenance or for any reason whatsoever the Railway desires
special maintenance, repairs, modifications, shifting or removal of the crossing the owner will, subject to the
provisions of clause 3 hereof carry out such works or such portion thereof from the date of notice issued by the
Railway and to the satisfaction of the Railway within a reasonable period determined by the Railway in its
absolute discretion as the Railway shall not under provision of clause 3 hereof proposed to carry out the work.
If the owner so desires he may re-erect the same at this own expense but to the satisfaction of the Railway in
all respects on such other land or track of the Railway, as it may in its absolute discretion consider suitable and
available for the purpose. In the event of the crossing being so re-erected the land on which the same is re-
erected will be used and occupied upon the terms of the Agreement mutatis mutandis, as if the same has
originally been subject to the Agreement.

7. Termination of Agreement by the Railway.

The railway may be any time (and from time to time) be at liberty in its absolute discretion to suspend
temporarily and/or terminate this Agreement and all or any of the privileges hereby granted upon the expiration
of three months notice in writing of its intension to do so being left at or sent to the registered office of the
owner/and not withstanding that the owner may have executed any work of a permanent or temporary
character and incurred expenses in the execution thereof. The owner shall not be entitled to any damages or
compensation by the reason of such termination or suspension.

8. Same as otherwise provided in this contract, all notices to be given on behalf of the President of India and
all other actions to be taken on his behalf may be given or taken on his behalf by the Chief Electrical
Engineer/Divisional Railway Manager/Divisional Railway Manager (Electrical) of the Railway.

9. Termination of Agreement by the owner:

The owner may on giving to the Railway one months notice in writing terminate this Agreement and such
notice shall be sufficiently served if sent by registered post to the Chief Electrical Engineer/Divisional Railway
Manger/Divisional Railway Manger (Electrical) of the Railway or left at his office.

10. Termination of Agreement for default:

In the event of the Railway giving notice under Clause 7 hereof for special maintenance, repairs, modifications,
shifting or removal of the crossing and the owner failing within the time stipulated to carry out the said works
except such position thereof as the Railway may propose to carry out under the provisions of clause 3 hereof
or in the event of the owner committing any other breach of this Agreement or any part thereof, the Railway
shall be entitled in its absolute discretion (notwithstanding the provisions of clause 8 hereof) to terminate this
Agreement all and any of the privileges hereby granted upon the expiration of six monthsnotice in writing of its
intentions to do so being given in the manner provided in clause 7.

11. Removal of crossing:

Prior to the termination of this Agreement and subject to the provisions of clause 3 hereof the owner will at his
own cost remove the crossing from the property of the Railway and restore the land to its original condition to
the satisfaction of the Railway in all respects. In the event of the owner failing to remove the said crossing and
restore the land to its original condition in the manner hereinbefore provided the Railway will be entitled at its
option immediately after the termination of the Agreement to carry out the work of removal of the crossing and
restoration of the land without being responsible for any loss or damage whatsoever to the said crossing or any
part thereof. In such an event the owner will pay to the Railway on demand all costs incurred by the Railway in
connection with such work including supervision charges, the amount which will be determined by the Railway
in its absolute discretion. The said crossing and the materials used in connection therewith and belonging to
the owner will be and remain the property of the owner but the Railway will be entitled to retain the same but
without any liability therefore until the amount of such costs as aforesaid have

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [92]

been paid by the owner to the Railway.

12. Indemnity

The said crossing will be used at the sole risk and responsibility of the owner. If at any time owing
directly or indirectly to such use or to the existence of the said crossing or to the carrying out of the
work of erection and/or repair and/or removal of the said crossing and restoring the land to its original
condition or to be exercise by the owner of any privileges hereby granted or to any other cause
arising out of the operation of the Agreement any damage will be caused to the Railway or to the
permanent way and works, Rolling Stock or any other property of the Railway or if in consequence of
any of the matters aforesaid or of any default in fulfilling any of the conditions of the Agreement or of
any negligence on the part of the owner or any person connected with him, any claim or damage or
loss be substantiated by any person or perons against the Railway the Owner will upon demand pay
forthwith and make good the same and shall also make good to the Railway all costs and expenses
which it may incur in regard to any such claim or damage or loss as aforesaid. In the event of three
being any dispute as to what specific loss and/or damage has been caused by reason of any
decision hereon shall be final and binding.

13. Railway Accident

The Railway shall not be responsible for any damage to the crossing and other property of the owner
due to any accident in the working of the Railway due to any cause whatsoever

14. Sub-letting

The owner will not sub-let, transfer or assign this Agreement or any of the privileges hereby granted
without the previous consent in writing of the Railway.

15. Limitation of rights

Nothing herein contained will be construed as conferring upon the owner or his permitted assignee
any rights over the property of the Railway.

16. Cost of Agreement

All costs and expenses incidental to the preparation and completion of these presents including
Stamp duty will be borne and paid by the owner.

In witness whereof the parties have hereunto set and subscribed their respective hands and seals
the day, month and years respectively mentioned against their respective signatures.

(Seal of the Owner) (Signature)

Signed at......................................... by Shri................................

For and on behalf of the Owner in the presence of :

1. Name
Address
1. Name
Address
(Signature of witness)
Signed at ....................................by Shri ........................................... Signature
For and on behalf of the owner in the presence of

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [93]

1. Name
Address (Signature of witness)

1. Name
Address (Signature of witness)

Note 1. In the case of Railway Companies or Port Commissioners Railways, the term Chief
Electrical Engineer wherever occurring in this Agreement may be replaced by the designation of the
Officer on whom the duties of the Chief Electrical Engineer devolve.

2. The agreement should be signed on behalf of the President of India by an officer duly
authorised under Article 299 (1) of the Constitution of India.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [94]

 ANNEXURE A 4.03

AGREEMENT FOR ERECTING AND MAINTAINING AN UNDERGROUND POWER LINE

CROSSING ACROSS AND UNDER RAILWAY TRACKS.

An agreement made this ..............................day of ........................ one thousand nine hundered and
.......................
Between the President of India, acting through the Chief Electrical Engineer/ the Divisional Railway
Manager/Divisional Railway Manager (Electrical) of the ....................... Railway Administration (hereafter
called the Railway) of the one part and .............................(hereinafter referred to as the owner of the other
part. Whereas the owner wishes to lay an underground cable and carry out works connected herewith for
transmission or distribution of electrical energy across and under the railway tracks and/or land at
kilometrage.......................In the section .......... at .................... Railway station, of the Railway the
said cable and works connected herewith hereinafter referred to as the crossing NOW IT IS HEREBY
AGREED as follows

1. General : The Railway will permit the owner as from the .................................. day of ...............................
19, to lay the crossings as per Drg. No. approved by the Railway, hereunto attached as Annexures
and in compliance with Regulations for power line crossings of Railway Tracks, hereunto attached as Annexure
hereinafter referred to as the Regulations, for the purpose hereinbefore mentioned, subject to the terms and
conditions hereinafter contained.

2. Permission to lay and maintain the crossing: The Railway, will, subject to the provisions of clause 3
hereinafter contained permit the owner to lay, keep and maintain in accordance with the Regulations the
crossing under the Railway tracks and/or land at the place(s) shown on the said drawing and to execute all
repairs in connection herewith when necessary from time to time and all such works shall be executed at the
cost of the owner at such time as may be permitted and to the satisfaction of the Railway in all respects.

Provided that if shifting of or modifications to or dismantling of the crossing is required for the proper
functioning of the Railway and is to be carried out by the owner as desired by the Railway, the costs of such
works shall be borne by the Railway except in these cases where the need for such works on account of
Railways anticipated development/requirements was foreseen in time and the owner had agreed in writing
prior to the construction of the crossing to meet the costs of such works.

3. Railway to carry out protection works; In the event of it being necessary in the opinion of the Railway to
support or protect the railway tracks and/or land or works during the laying of the crossing or the execution of
any removal thereof the work of supporting or protecting the railway tracks or land and/or laying or removing
the encasing protective pipe to carry the crossing cable and restoring the tracks and/or land to its original
condition or such part of the said work as the Railway shall deem fit will be carried out by the Railway at the
cost of the owner in all respects. The amount of such costs will be determined by the Railway in its absolute
discretion and will be paid by the owner to the Railway on demand. The owner will, if so required, deposit with
the Railway prior to the carrying out of the said work such sum of money as may be estimated by the Railway
to be the cost of the work required to be done and the amount of the said deposit will be set off against the said
cost to be determined as aforesaid and the balance paid as aforesaid.

4. Method of laying: The cable shall be laid as indicated in the said drawing and shall be carried through an
encasing pipe in such manner that the cable can be laid, withdrawn without interfering with or endangering the
railway tracks and/or land. The costs of providing and laying such encasing pipe for the crossing shall be
borne by the owner as aforesaid.

5. Cost of supervision of works: All works in connection with the matters referred to in clauses, 2,3,4,7 & 11
will be subject to such supervision by the Railway as may be considered necessary by the Railway and the
owner will pay to the Railway on demand all costs of such supervision including the cost for the staff, required
to look after the safety of the railway tracks and/or land while all or any of such works are/works is in progress.
The costs of such supervision and other costs as aforesaid shall be determined by the Railway in its absolute
discretion.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [95]

6. Access: Neither the owner nor his employees will at any time enter upon the railway land for any purpose
whatsoever in connection with the crossing as aforesaid without the consent in writing of the Railway.

7. Modification, shifting or removal of crossing: If for convenience of operation, unsatisfactory maintenance

or for any reason whatsoever the Railway desires special maintenance, repairs, modification, shifting or
removal of the crossing the owner will, subject to the provisions of clause 3 hereof carry out such works or such
portion thereof from the date of notice issued by the Railway and to the satisfaction of the Railway within a
reasonable period determined by the Railway in its absolute discretion as the Railway shall not under provision
of clause 3 hereof proposed to carry out the work. If the owner so desired he may relay the same at his own
expense but to the satisfaction of the Railway in all respects on such other land or track of the railway as it may
in its absolute discretion consider suitable and available for the purpose. In the event of the crossing being so
re-erected the land on which the same is re-erected will be used and occupied upon the terms of the
Agreement mutatis mutandis, as if the same has originally been subject to this Agreement.

8. Termination of Agreement: The Railway may at any time (and from ti me to time) be at liberty in its
absolute discretion to suspend temporarily and/or terminate this agreement and all or any of the privileges
hereby granted upon the expiration of three months notice in writing of its intention to do so being left at or
sent to the registered office of the owner and notwithstanding that the owner may have executed any work of a
permanent or temporary character and incurred expenses in the execution thereof. The owner shall not be
entitled to any damages or compensation by the reason of such termination or suspension.

9. Same as otherwise provided in this contract, all notices to be given on behalf of the President of India and
all other action to be taken on his behalf may be given or taken on his behalf by the Chief Electrical
Engineer/Divisional Railway Manager/Divisional Railway Manager (Electrical) of the Railway of left at his office.

10. Termination of Agreement by the Owner: The owner may on giving to the Railway one months notice in
writing terminate this agreement and such notice shall be sufficiently served if sent by the registered post to the
Chief Electrical Engineer/Divisional Railway Manager/Divisional Railway Manager (Electrical) of the Railway or
left at his office.

11. Termination of Agreement for default: In the event of the Railway giving notice under clause 7 hereof for
special maintenance, repairs, modification, shifting or removal of the crossing and the owner falling within the
time stipulated to carry out the said works except such portion thereof as the Railway may propose to carry out
under the provisions of clause 3 hereof or in the event of the owner committing any other breach of this
Agreement or any part thereof, the Railway shall be entitled in its absolute discretion (notwithstanding the
provisions of clause 8 hereof) to terminate this Agreement and all and any of the privileges hereby granted
upon the expiration of six months notice in writing of its intentions so to do being given in the manner provided
by clause 7.

12. Removal of crossing: Prior to the termination of this Agreement and subject to the provisions of
clause 3 hereof the owner shall at his own cost remove the crossing from the property of the Railway and shall
restore the land to its original condition to the satisfaction of the Railway in all respects. In the event of the
owner failing to remove the said crossing and restore the land to its original condition in manner hereinbefore
provided the Railway will be entitled at its option immediately after the termination of this Agreement to carry
out such work of removal of the crossing and restoration of the land without being responsible for any loss or
damage whatsoever to the said crossing or any part thereof. In such an event the owner will pay to the
Railway on demand all costs incurred by the Railway in connection with such work determined by the Railway
in its absolute discretion. The said crossing and the materials used in connection therewith and belonging to
the owner will be and remain the property of the owner but the Railway will be entitled to retain the same but
without any liability therefor until the amount of such costs as aforesaid have been paid by the owner to the
Railway.

13. Indemnity: The said crossing will be used at the sole risk and responsibility of the owner. If at any time
owing directly or indirectly to such use or to the existence of the said crossing or to the carrying out of the

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [96]

work of erection and/or repair and/or removal of the said crossing and restoring the land to its original
condition or to the exercise by the owner of any privileges hereby granted or to any other cause
arising out of the operation of the Agreement any damage will be caused to the Railway or to the
permanent way and works, Rolling stock or any other property of the Railway or if in consequence of
any of the matters aforesaid or of any default in fulfilling any of the conditions of the Agreement or of
any negligence on the part of the owner or any person connected with him, any claim or damage or
loss be substantiated by any person or persons against the Railway, the owner will upon demand
pay forthwith and make good the same and shall also make good to the Railway all costs and
expenses which it may incur in regard to any such claim or damage or loss as aforesaid. In the
event of there being any dispute as to what specific loss and/or damage has been caused by reason
of any of the matters aforesaid such dispute will be preferred to the Chief Electrical Engineer of the
Railway, whose decision thereon shall be final and binding.

14. Railway Accidents: The Railway shall not be responsible for any damage to the crossing and
other property of the owner due to an accident in the working of the Railway due to any cause
whatsoever.

15. Sub-letting: The owner will not sub-let ,transfer or assign this Agreement or any of the privileges
hereby granted without the previous consent in writing of the Railway.

16. Limitation of rights : Nothing herein contained will be construed as conferring upon the owner or
his permitted assignee any rights over the property of the Railway.

17. Costs of Agreement : All the costs and expenses incidental to the preparation and completion of
these presents including stamp duty will be borne and paid by the owner.

In witness whereof the parties have hereunto set and subscribed their respective hand and seals the
day, month and year respectively mentioned against their respective signatures.

(Seal of the Owner) (Signature)

Signed at...............................by Shri................................for and on behalf of the owner in the

presence of:

1. Name
Address Signature of witness

2. Name
Address Signature of witness

Signed at ............................ by Shri....................................for and on behalf of the President of India

in the
Presence of :
1. Name
Address Signature of witness
2. Name
Address Signature of witness

Note: 1. In the case of Railway Companies of Port Commissioners Railway, the term Chief Electrical
Engineer wherever occurring in this Agreement may replaced by designation of the officer on whom
the duties of the Chief Electrical Engineer devolve.

2. The agreement should be signed by and on behalf of the President of India by an officer duly
authorised under Article 299(1) of the Constitution of India.
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [97]
 ANNEXURE A.4.04

CERITIFCATE OF COMPLIANCE

It is hereby certified that the electrical overhead line/underground cable crossing

No..........................at Km........ On the section ........................Of the Division of the
....................Railway has been constructed in compliance with Indian Electricity Act, 1910 and Indian
Railway Act., 1890, and the rules made thereunder and as amended from time to time and the
Regulations for Power line crossings of Railway tracks, 1987. The crossing has also been
constructed in accordance with the drawings approved by the ......................Railway and the
Electrical Inspector of the ...............Railway, the reference of which are given below:

SN. Drawing No. Title of Location of Reference Approving

Drg. Crossing under which authority
$ Drawing is
Approved.

1.

2.

3.

2.It is also hereby certified that the overhead line crossing specially released as per clause 22.4 of
the Regulations for Power Line Crossing of Railway Tracks. 1987 would be modified by the owner,
on an approved design whenever Railway will require to modify such crossings due to introduction of
electric traction on the section of the Railway.

Along with a reproducible print eight copies of the drawings showing the completed power line
crossing is/are enclosed.

Signature
(Seal of the owner) Name of the owner
Date
Place

Strike off, if not applicable

$ The location of the overhead line crossing or underground cable will be identified by indicating the
kilometerage with the painted number of the traction masts/structures and/or telegraph posts, as
available, between which the overhead line or underground cable crossing is located.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [98]

 X = Z1 x 1.25 (C.T. Ratio)
-------------------- x ----------------
Cos (theta-delta) (P.T. Ratio)

b) Assuming single line operation from the feeding post (FP) upto the sectioning post (SP) & double line
operation from SP to the adjoining FP, calculate the OHE impedance; say this is Z calculate Y from the
following relation:2

Y = Z x 1.25 (C.T. Ratio)

Cos (delta-delta) (P.T. Ratio)

a) Assuming an overload of 50% of the traction transformer and that the entire current is fed through one
feeder circuit breaker, critical impedance setting of the relay (to allow line operation at maximum loads) is
calculated from the following relation:

Critical impedance setting = 24,000V CT Ratio

------------- -------------
1.5x rated full load PT ratio
current of transformer
in Ampere x cos ( theeta-fyi )

Where Theeta= maximum torque angle of relay

Fyi = Load angle may be taken as 40 degree

Say, critical impedance setting is Z. For the relay not to operate under the said overload conditions, the
impedance setting of the relay must be lower than Z.

b) The impedance setting of the Mho relay should be a minimum of Y and a maximum of X. The setting
should also not exceed Z. In other words, when the value of Z lies between X & Y, the relay may be set to
Z. If Z is higher than Z,. then the relay may be set to Z. If Z is less than Y, then the relay should be set to
Y and it should be understood that the assumed overload will not be permitted by the relay. Note that the
values X, Y and Z are calculated along the maximum torque angle line of the relay.

iii. The relay settings may be calculated by following the procedure given at (I) or (ii) above for the two
sides of the feeding post separately. However, the distance protection relays of both the feeders
should be set to higher of the two calculated values. This is to ensure that when one feeder breaker
is taken out for maintenance, the relay should be able to see the faults on either side of feeding post.

2.2 Instantaneous over-current protection

This relay provides primary protection to the catenary on earth faults in the vicinity of the feeding post. The
current setting of the relay may correspond to about 200% of the continuous current rating of the traction
transformer. Assuming that a factor of 1.25 will account for the CT and relay errors and relay transient over
reach, the relay will allow loads of about 200/1.25 i.e. 160% of the rated load current.
23. Wrong Phase coupling protection using offset MHO type
YCG 14( English Electric Make)
The impedance setting of the English Electric make YCG-14 relay is given by K 1 K 2 (K3 + K4 ), where K1 &
K2 are plug board settings and K & KK are potentinmeter setting ( Refer Relay Catalogue). The maximum
torque angle of the relay is 125 and forward off set is about 10% of K K .. The WPC relay at that substation
where the 25 kV voltage is lagging with respect to the voltage at the substation with which it has been wrongly
coupled will operate.
The impedance setting of the WPC relays at TSS 1 may be determined graphically following the procedure

INDIAN RAILWAYS-AC TRACTION MANUAL [100]

h. impedance settings of wrong phase coupling relay for two sides of the TSS-1 may be calculated
individually following the above procedure. The higher of the two values may be adopted for both the
WPC relays at TSS-1.\

1. Traction sub-station Transformer protection:

Low Voltage side ( 25 kV side)

1. Restricted earth fault relay

The current setting of this relay may correspond to 10% of the rated current of traction power transformer.

ii. IDMT over current relay

The function of this relay is to act as back up protection to the feeder protection relays. The reach of the relay
should be as much as possible. However, to permit overloading of the traction power transformer of the
traction substation, the current setting of the relay may be selected to correspond to 150% of the rated current
of the traction power transformer.

The time-multiplier setting of the IDMT relay may be selected such that the relay operation time is 0.4 to 0.5
sec. For an earth fault on the 25 kV bus.

1.2 High Voltage side ( 220KV/132KV/110KV/66KV side)

I. Restricted earth fault relay

The current setting of the relay may correspond to 10% of the rated current of traction power transformer.

ii. IDMT over current relay with instantaneous over current element

The instantaneous element may be set to correspond to a current of 1.25 times the fault current, for an earth
fault on the 25 kV bus at the traction substation. The purpose of such setting is to avoid operation of this relay
for 25 kV bus faults at the traction substation.

The current setting of the IDMT relay may be such that it has maximum reach but permits overloading of
traction transformer. The setting may, therefore, be selected to correspond to 150% of the rated current of
traction power transformer. To have time grading with the IDMT relay on the 25 kV side, the time multiplier
setting may be selected such that the relay operating time is 0.8 to 0.9 sec. For earth fault on the 25 kV bus at
the traction sub-station.

iii. Biased differential relay (type DDT)

The three settings of the relay may be selected as follows:

a) The percentage bias setting should be so chosen that the relay remains inoperative on differential
currents resulting from (1) tap changing on traction transformer, (2) mismatch in CT ratios and (3)
difference in CT saturation levels under through-fault conditions. Percentage mismatch resulting from
factors (1) and (2) may be calculated from actual data and an allowance of 7.5 to 15% may be made for
factor (3).

b) The operating current setting may be taken as 40%. If mal-operations of the relay are observed on
through faults and magnetizing inrush (switching in of power transformer), a higher setting may be
considered.

c) The time multiplier setting may be taken as 1. If mal-operations of the relay are noted on magnetizing in
rush but not on through faults, then the time multiplier setting may be increased.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [103]

 APPENDIX VII

GENERAL GUIDELINES FOR ANTI-THEFT CHARGING OF OHE

1. General
1.1 In the theft prone area the energisation of OHE at 2.2 kV as an anti-theft measure may be done
to avoid theft of contact/catenary wire. As energisation at 2.2 kV is purely for the purpose of
arresting the theft of catenary and contact wire and not for train operation, it is not likely to
produce any inductive interference affecting signalling and telecom. Installations due to
practically no current flowing in the circuit. Therefore, even though certain works like erection of
isolators and section insulators, installation of SWS, BTs,. Ats adjustment of OHE, SED checks,
tower wagons checks, provision of CLS, Telecom, cabling etc. are not completed in all respects,
OHE can be charged at 2.2 kV.

1.2 Period of anti-theft energisation will be restricted at night hours only i.e. from 7 PM to 7 AM.

2.0 Works to be completed prior to 2.2 kV Energisation

2.1The following works are essentially required to be completed prior to 2.2 kV anti-theft
energisation of OHE.

2.1.1 Stringing of catenary and contact wire complete with droppering, clipping, and insulation and
provision of automatic tensioning device.

2.1.2 Provision of structure bonds in open route and structure and rail bonding in station areas in
accordance with the Bonding and Earthing code. In station areas where Bonding and Earthing work
has not been completed, the return conductor (RC), if provided, may be used as earth wire and
connected solidly to the OHE structures/supports by means of suitable jumpers. At both the ends of
the station, RC shall be connected to rails.

2.1.3 All necessary LT modification works

2.1.4 Necessary modification to all HT crossings to meet atleast the requirements

for 2.2 kV as per the standards laid down in Appendix IV.

2.1.5 Provision of wire mesh screen on the working platform of existing semaphore
signals in case the requisite electrical working clearance of 2 m is not
available. No portion of the signal post or its fittings shall be less than 700
mm from the live conductor.

2.1.6 Replacement of existing dc track relays by ac immunized relays.

2.1.7 Conversion of all track crossings of communication lines into cables and
removal of overhead wires thereof.

2.1.8 Provision of height gauges and 25 kV caution boards at all level crossings.

2.1.9 Provision of protective screens with 25000 V caution boards on over line
structures like ROBs, FOBs Fly Overs etc.

2.1.10 Provision of Public Warning board for 25000 V and shock treatment charts
and First-Aid Boxes at all relevant places like stations, cabin buildings,
repeater stations, cable huts etc.

2.1.11 Supply of insulated tools to maintenance staff.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [134]
 2.1.12 Modification to carriage watering arrangements and water columns to suit
anti-theft energisation.

2.2 All the relevant rules and precautions in accordance with the Indian Electricity Rules
should be complied while carrying out the works.

3 2.2 kV Power Supply Arrangements

2.1 2.2 kV energisation will be done through local supply available at one of the stations through a
step-up transformer provided with fuse of suitable capacity with an audible and visual Indication
arrangements. A Schematic Diagram indicating the power supply arrangement and the controls
and scheme of connection for supply of power at 2.2 kV shall be prepared and submitted to EIG
for his approval.

2.2 The 2.2 kV supply arrangement will be manned round the clock by RE. The organisation to be
available for manning the feeding installation and duties of the staff and ASMs in case of both
normal operation and breakdown/abnormal operation shall be detailed out and issued in the
form of a circular.

2.3 As stated in para 1.2 above even though the OHE will be normally kept energised during night,
the OHE in the energise section shall be regarded as live at all the times and consequently
dangerous to human life. No person except those deputed to work on or near the overhead
electrical equipment and who are in possession of a permit to work: issued by an authorised
representative of RE, shall approach within 2 m from the OHE.

2.4 A joint procedure order indicating the detailed procedure to be followed for taking power block
and issue to permit to work for issuing notices to drivers, for attending to breakdowns shall be
make out and issued to all concerned. This order will be signed jointly by the concerned officers
of both RE and Division. A model circular is given in the Annexure A 7.01.

4.Procedure to be Adopted for Energisation

1.1 Publication and display of Notices.
1.1.1 Atleast a month in advance of energisation of any section or sections the following public
notifications should be got published in all the prominent dailies in English, Hindi and Local
Language and issued to all concerned as normally done for 25 kV energisation, (Reference
may also be made to para 21008)

i) General Notification to the users of Railway lines regarding section/sections to be energised.

ii) Notification to the users of level crossings.

4.1.2 Display of general caution notices for public and staff at prominent places at each station,
stenciling on the diesel/steam locos warning message to not to climb on the top of locos,
caution notices at all steam and diesel loco sheds at which locos working in the energised
section are maintained.
4.1.3 The steam/diesel loco drivers/firemen shall be warned not to climb on the roof of the tender
and the engine on the section proposed to be energised.
4.2 On completion of the work as mentioned in Para 2 above the following certificates from the
concerned officers will be obtained.
i) Certificate regarding removal of L.T. & H.T. infringements by Dy. CEE(G) of the project.
ii) Certificate regarding S&T works
iii) Department of Telecommunications (DOT) clearance certificate for 2.2 kV anti-theft
energisation.
iv) Certificate by Dy. CEE(OHE) or DEE(OHE) regarding completion of OHE works.
v) Certificate by OHE Contractors
vi) Certificate by Dy. CE/DEN/RE regarding provision of level crossing gauges and provision of
protective screens on ROBs and FOBs
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [135]
4.3 Besides the certificates regarding completion of works to suit 2.2 kV energisation as mentioned
in para 4.2 above, the following safety certificates shall also be obtained.

i) Joint certificate by CEE(P), CSTE(P) and CE(P) regarding safety to traffic as per draft at
annexure A 7.02.
ii) Certificate of concerned officers of Division of particular Railway about knowledge of their
staff regarding safety.

4.4 EIG Sanction

An application to EIG seeking his approval to the proposal of energisation of OHE at 2.2 kV as anti-
theft measure may be made in advance. While applying for sanction, the uptodate status of works
to be completed prior to 2.2 kV energisation should be given and the list of certificates for its
completion as well as other safety certificates proposed to be forwarded at the time of seeking EIG'
formal sanction may also be indicated, EIG' sanction shall be obtained prior to energisation.

4.5 Checks and Tests prior to Commissioning:

4.5.1 CEE and Electrical Inspector to the Government for the Railway may nominate at his
discretion one of his officers preferably Sr. DEE (TRD) for joint check and tests of the section
proposed to be energised. For such joint check by Dy. CEE(OHE)/RE will associate from
RE side. Alternately he may authorize Dy. CEE(OHE)/RE to conduct checks and tests
before energisation. The following checks and test shall normally be carried out.

4.6 Checks

4.6.1 That clearance between live and earthed structures is in accordance with the provision of
Schedule of Dimensions.
4.6.2 That earthing and bonding of the OHE have been carried out as per Bonding and Earthing
code with exception for station area as specified in para 2.1.2 above.
4.6.3 That height of contact wire at level crossings is proper and that height gauges have been
provided
4.6.4 That protective screens have been provided in FOB, ROBs and signalling structure
4.6.5 That the earthing and isolation of overhead equipment adjacent to the section to be
energised has been carried out properly.
4.6.6 Ac immunised track relays have been provided
4.6.7 Overhead P&T as well as Rly. Crossings have been cabled and wire removed.

4.7 Tests:

4.7.1 Megger tests for continuity and insulation of the OHE

4.7.2 With the above checks and test and after it is certified either jointly by Sr. DEE/TRD and Dy.
CEE(OHE)/RE or by Dy. CEE(OHE)/RE that the section can be energised at 2.2 kV for test
purpose, the following fault tests shall be conducted on the section energised at 2.2 kV.

a) By creating earth fault at the farthest end of energised OHE through discharge rod

b) By creating earth fault at the farthest end of energised OHE touching only ballast.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [136]

c) By creating earth fault at the farthest end of energised OHE touching only rail.

In all these cases of earth fault, lit should be ensured that fuse provided at the supply point is blown.

4.8 Immediately on the successful completion of the checks and tests of the OHE, OHE can be
energised provided that:

a) All the certificates as mentioned in paras 4.2 and 4.3 above are obtained

b) DOTs clearance and EIGs sanction are obtained.

4.9 Immediately after energisation, a notification to that effect may be issued as normally done for
25 kV energisation.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [137]

 Annexure A 7.01

JOINT OPERATING AND RAILWAY ELECTRIFICATION CIRCULAR NO.

ANTI-THEFT ENERGISATION IN SECTION

The OHE wires, in section are to be kept energised on high voltage continuously, In order
to guard the erected overhead equipment against theft. The energising work is being started
immediately on (Group) and (Group ) sections. Audible and visual indication
arrangements will be made in the office of the Assistant Station Master on duty at and
stations. These will be the controlling Masters for anti-theft energisation. Normally a green light will
be ON. The alarm will sound a buzzer as well as light a red lamp, whenever a defect, appears on
the OHE due to its coming in contact with earth or earthed structure. Immediately when such an
occurrence takes place it is necessary to ensure that (a) the equipment damaged does not obstruct
the traffic (b) also the line is patrolled, causes of earthing and the defects rectified as quickly as
possible. The OHE in the energised section, shall be regarded as being alive at all times and
consequently dangerous to human life. No person, except those deputed to work on or near the
overhead electrical equipment and who are in possession of a permit to work issued by an
authorised representative of RE, shall approach to with in 2 metres from the OHE.

1. Duty of ASM at controlling stations

1.1 He shall maintain the attendance of operator/lineman. The shift duty of this staff will be fixed by
the respective supervisor of RE, who will maintain their muster sheets.

1.2 In the case of abnormality observed through the indicator of Red light provided for the purpose,
the ASM on duty will direct the operator to take necessary action as required.

1.3 In the case abnormality indicated by an alarm or red light in any of the indication boards, the
ASM shall immediately direct the operator/lineman and inform him of the indication, arrange for
calling the respective Supervisor of RE. After the supervisor of RE has declared OHE to be
defective, the ASM will advise the Section Controller to issue caution order through the ASMs of
the previous train stopping stations where necessary, to drivers of all trains both in Up and
Down directions to be on a sharp lookout for the infringement of the track from OHE and to be
prepared to stop short of any infringement.

1.4 In addition to this on advice of the Supervisor of RE, the ASM of the station at the other end of
the faulty section to send the lineman/operator of RE with staff of the contractor to attend the
abnormality/breakdown. The ASM should also inform the Section Controller and the RE
Controller about the abnormality/breakdown to convey the message to the supervisor concerned
so that the breakdown gang can be moved on the line immediately.

1.5 If any message is received from section controller, or Driver about the location of the fault, he
will immediately inform the supervisor of RE and the RE controller.

1.6 When asked by the Supervisor of RE, the ASM make arrangements to stop a train or light
engine at the station for the transportation of staff.

2. Duty of RE Controller
2.1 He will assist the Section Controller, in case of any breakdown/abnormality, informing all
concerned.
2.2 He will immediately inform DOM/RE and DEE(OHE)/.RE concerned, on the autophone and also
on P&T phone, if necessary and also the EFO/OHE concerned and the representative of the RE
contractor immediately on receipt of breakdown message.
2.3 He will assist the breakdown gang in reaching the site by arranging light engine or train where
road facility is not available, in co-ordination with the Section Controller.
INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [138]
2.4 On receipt of the information about wire cutting, he will immediately inform the ASI/RPF concerned as well
as local/Railway Police and control/authphone and P&T phone also.

2.5 He will in constant touch with the Section Controller and ASM concerned until the infringement of the OHE
is cleared and normal conditions are restored.

2.6 He will pass on the requisition for permit to work when received to the supervisor of RE at the station.

3. Duties of Drivers and Guards

3.1 On receipt of caution orders from the ASM that the OHE in the section is faulty, he shall proceed
cautiously and shall lookout for any hanging OHE wire on Up and Down track.

3.2 In case OHE is found to be hanging and the same does not infringe the standard moving dimensions, the
Driver should pass the hanging wire under caution without further damage to the hanging wire, and on
reaching the next station he should inform about the location of hanging wires to the ASM.

3.3 In case the hanging OHE wires are infringing the standard moving dimensions, the driver shall stop short
of infringements and shall report the location and nature of infringement to the nearest ASM.

3.4 The driver or any other person shall not come in contact with any of the wires laying either on ground or
hanging loose and shall prevent others from doing so.

3.5 In case of passenger trains where the Guard is in possession of a portable telephone, the same may be
used for giving the information regarding the hanging of wires to the Section Controller, On the energised
sections, riding on the top of engine/tender by the crew is strictly prohibited.

4. Duties of the Section Controller

4.1 On receipt of the advice from ASM that there is a defect in the overhead equipment, he shall arrange to
give caution orders to all Drivers in the faulty section to be on sharp lookout for any obstruction or wires
hanging around, and report the same to the ASM of the station adjacent to the Block Section.

4.2 He should immediately advise the RE controller also for passing on the information to all concerned.

4.3 He should arrange for light engine/or train when asked for the movement of the breakdown gangs of RE

4.4 If any Driver/Guard/ASM informs him about the locations of hanging OHE wires or breakdown of OHE, will
advise the same to the RE controller.

4.5 On receipt of the advice from any of the ASMs or RE controller that the infringement has been cleared, he
will arrange for the cancellation of the caution order issued para IV(I) above.

5. Normal Operations

5.1 Permit to work for carrying out further construction work on the OHE and for works of other departments
viz. Engineering, signalling etc. within two metres of OHE, the energised OHE will have to be switched off.
All these works can be carried out only when the permit to work has been given by the authorised
representative of RE.

5.2 Calculation of Permit to work and recharging of OHE: After the work has been finished by the party
requiring permit to work the party will give back in writing to the authorised representative of RE at site,
who originally handed over the permit to work to them, that the work in the vicinity of the OHE has been
completed and there is no objection for the overhead equipment to be energised. The authorised RE
representative will then remove the discharge rods and return the permit to work to the Supervisors of
RE from whom he has taken in

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [139]

writing by exchange of private numbers. The Supervisors of RE will ensure that all permit to work
given by him, has been suitably returned to him. After he has ensured this, he shall remove
discharge rods from OHE, and shall then energise the transformer, thus energising the overhead
equipment on 2.2. kV ac.

6. Abnormal Operations

As already stated the OHE will normally be energised on 2.2. KV/ac and treated as live ty every
body and hence the permit to work has to be obtained from authorised supervisor of RE for any
work within two metres of OHE. In case of any accident/abnormality, or in case of miscreants
activity, if the OHE gets earthed and the L.T. fuse of transformer blows off, the same will be
indicated in the room of ASM by the sounding of buzzer and also by lighting a red lamp. In such
case the ASM should immediately call for the authorised representative of RE posted with him. He
should also send a message to the supervisor of RE who will take charge of the situation. He will
declare the section faulty after further checking if required. He should then, advise the ASM on duty
in writing to send necessary information to the section controller for issuing caution orders to the
Drivers of all up and down trains of the defective zone. The supervisor has to then isolate the faulty
section and send the patrolling party online. The patrolling party incharge will take permit to work
from the supervisor. The supervisor will not energise the OHE unless and until all the patrolling
parties in section return the permit to work: by exchanging private numbers or in writing.

7. Authorisation of staff

No body other than the person authorised will carry out Switching operations on OHE and other
installation, issue, receive and cancel permit to work. Such persons will be authorised only after
duly being tested by DEE/AEE (RE) and shall not be below the rank of skilled artisan.

8. Special Instructions

8.1 Every Railway employee is required to make himself familiar with the methods of first aid to be
rendered in case of Electric shock.

8.2 Proximity of a live conductor has to be avoided; since the risk of direct contact would occur while
working very close to a live conductor.

8.3 It is important to note that induced voltage may appear at any instant in metallic masses in the
vicinity of traction conductors.

8.4 Since there can be presence of return current in rails, use of Rails as a footpath, a seat or for
other purpose is stictly prohibited.

8.5 No persons should go on top of a wagons, Bogie, engine or any other structure, without properly
ensuring that OHE power supply is completely cut-off and the overhead equipment is earthed.

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [140]

 Annexure A 7.02
RAILWAY ELECTRIFICATION.....
GENERAL SAFETY CERTIFICATE OF WORKS...

It is hereby certified that all the electrification works to be executed by the Railway Electrification
..................... for 2.2 kV single phase anti theft energisation of section from ....... (
km. ) to ...... (Km ) over.........
Railway have been carried out properly and that the section can be energised without endangering
safety of the travelling public or employees of the railway.

CSTE(P)/RE CPM/RE CEE/P/RE

INDIAN RAILWAYS AC TRACTION MANUAL VOL II PART II [141]

 APPENDIX VIII
MODEL CIRCULARS
1. Joint Procedural orders are issued by Zonal railway laying down guidelines for officers and staff
of different disciplines to clearly demarcate role and responsibilities among these discipline .
Likewise circulars are issued to the all concerned to inform (I) new rules and procedures (ii)
changes in procedures due to some alteration in the system; and at times to reiterate extant
rules and procedures.

2. Extract from some of the JPOs/Circulars issued by Zonal Railways are appended for illustration
and reference.

1. Closing and Securing of Flap Doors of Wagons

Instructions exist that flap doors of the wagons, loaded or empty, should be properly closed and
secured before being taken out from goods sheds, siding in yards and on trains. Many cases have,
however, been reported when the wagons with open flap and other doors or with doors improperly
secured have created situations fraught with danger. Several accidents have taken place in the
electrified territories where the OHE masts were struck by the open doors of the wagons causing
serious dislocation of traffic. Determined steps should be kept to completely arrest such accidents.

2. Prompt and proper closing and securing of wagons doors and bottom hinged as well top hinged
dalas must be ensured while undertaking the following operations:-

a) At loading and unloading points

i) After loading and or unloading of wagons in goods shed lines and other railway sidings, the
goods clerk incharge of getting the loading and unloading operations will be responsible for
ensuring that all the doors of the dalas are properly closed and secured on completion of
work. Services of the train examiner where available will be availed in case of a stiff door or
dala.

ii) The shunting Jamadar or the traffic official deputed to draw out wagons from goods shed
lines and other sidings will ensure that the doors and dalas are closed and secured before
they start drawing out.

iii) Similarly, the incharges of the various departmental siding such as loco sheds, diesel sheds,
electric sheds, stores sidings, engineering sidings etc. will be responsible for closing and
securing of doors and dalas after loading and unloading of materials, fuels, stores etc.

b) In shunting operations in yards

Before starting the shunting operations in the yards, the shunting Jamadar will ensure that the doors
and dalas of all the wagons being pulled are properly closed and secured. He should call for the
assistance of a TXR in case of a stiff door or dala. He should observe this while sorting wagons,
while attaching wagons on trains, while detaching wagons from trains and in all other miscellaneous
shunting movements.

c) On train
The guard incharge of the train will ensure that doors and dalas of all the wagons put on his train
are properly closed and secured before he starts his train. He will point out any lapse in this regard
to the Station Master/Yard Supervisors on duty well in time so that the same is rectified without any
detention to the train. He will observe this while taking charge of an originating train as well as
through train taken over from the adjoining railway, adjoining divisions and the adjoining section of
the Division.
INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [142]
d) Examination of trains

During the course of examination of a train, the TXR will ensure that all doors and dalas of the
wagons on the train are closed and the stiff doors and dalas are rectified and closed by his own
staff. The issue of fit certificate for the train should be subject to proper closure of the wagon doors
and dalas.

e) Security staff involvement

The security arrangements by the RPF staff should be tightened so that no door or dala of any
wagon in the yard and sidings is opened by the trespassers.

Any laxity in observance of the above instructions should be seriously viewed and deterrent action
taken against staff at fault. For this purpose, checks should be organized by officers and
supervisors, particularly the safety officers and inspectors. Ambush checks should also be
undertaken by Sr. DSO/DSO.

2.Movement of Insulated Consignments on Open Wagons

Escorting consignments loaded on open wagons in electrified areas needs caution against electric
shock to escorting personnel. Approach to any point within two metres of the live parts of traction
equipments is strictly forbidden.

Cases of accident caused by electric shocks to the personnel escorting insulated consignments
loaded on open wagons, insulated from the body of the wagons by rubber tyres or wooden logs, etc.
are on record. To prevent such accidents the following procedure must be followed.

In cases where the consignment is kept on insulated supports, like military or civil trucks on rubber
tyres, over an open wagon shocks due to induced voltage might be caused. Induction causes
voltage of a high order on all metallic consignments while being underneath the traction wires. If the
exposed metallic surfaces of the consignment are in good electrical contact with the body of the
wagon, their potential will be same as at the body of the wagon. Presence of Insulation between the
body of the consignment and the wagon will result in dangerously high potential difference being set
up between the consignment and the wagon which may cause shock to a person on the wagon
escorting the consignment. For the movement of such consignments through electrified sections,
therefore, the following precautions are essential.

i) A temporary metallic connection should be made between the body of the consignment and
the wagon. For the purpose, standard steel wire or size 7/16 SWG (Cross sectional areas
14.5 mm 2) or any other available size higher in cross sections may be used to fasten the
metallic portion(s) of the consignment to the wagon at 4 independent points, without
tempering the consignment. Steel chains of equivalent cross sections can also be used in
lieu. The train examiners of train originating stations will effect and ensure such fastenings
prior to issuing fit memos for movement of the consignment.

ii) No train shall leave a train originating point without the above having been provided.

iii) However, prior to entry of such consignments in the electrified sections, the Guard incharge
shall check up the provision of such arrangements and ensure onward movement only after
confirming the following:

a) The wire fastenings are effected by the TXR staff if available.

b) It item (a) above is not possible, the escorting personnel should be detained from the wagon
carrying such consignments till such time the fastenings are provided for by the TXR staff or
by the nearest traction (OHE) staff as indicated in the working time table.
c) On entry into the electrified section the bonding used will be got checked by the TRD staff.
INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [143]
3. Joint Procedure Order for TPCs, Section Controllers, Drivers and Guards of Electric
Traction in the event of Hot Axle or other Abnormality in trains, in OHE, in Track etc.
necessitating Switching Off of OHE Supply.

In the event of Hot axle or other abnormalities in trains, OHE or in track, joint procedure for
switching off and switching on of OHE in indicated below:

1. In case any hot axle or any abnormality is seen in a running train in block sections or at stations,
power supply to OHE of the affected section shall be switched off immediately by TPC on duty
by opening of the feeder C.B. on advice from Section Controller, Station Master or others as the
case may be under clear exchange of private numbers.

If the block section is falling in the zone of two feeding posts, then feeder CBs of both feeding posts
may be switched off and the section isolated must be reduced to sub-sector after finding out the
details of train by TPC.

Regarding switching off of OHE power. TPC shall inform the concerned SCNL in writing and
Section Controller shall take immediate necessary action.

2. Station Master and Section Controller should thereafter in consultation with TPC should take
detailed information regarding damages, infringements or any other abnormalities of track.
Rolling Stock or OHE. Section Controller should ensure that no train is allowed to enter dead
section on either one direction to avoid snapping of OHE>

3. Look-out caution to driver of the first train of opposite direction which is likely to enter the
affected section will be issued by Section Controller. After issuing of caution order to the first
train which is likely to come in the effected section and after ensuring the safe position, TPC will
be asked by Section Controller under clear exchange of private number to charge the particular
healthy section which was switched off as a precautionary measure.

4. Joint Procedural Order for TRD, RSO staff and ASMs in Case of any Abnormality on OHE
1. In case of breakdown of OHE, when it is necessary for a train to proceed cautiously the
TFO(OHE) responsible for such notification shall arrange for issue of caution order, An
authorised person shall be present at the site and shall be responsible for showing signals.

2. A caution order detailing the kilometers between which such precaution is necessary, the reason
for taking such precaution and the speed at which a train shall travel, shall be handed to the
driver at the stopping station/other station in such a manner, as prescribed under special
instructions.

3. Showing of Signals

Whenever due to lines being under repair or due to any other obstruction it is necessary to indicate
to the Driver that he has to stop or proceed at a restricted speed, the following signals shall be
shown and where prescribed and detonators used, it on a double line the direction from which trains
approach, and if on single line in each direction.

a) When the train is required to stop and the restriction is likely to last only for a day or less

A banner flag shall be exhibited at distance of 600 m on the B.G. and the 3 detonators shall be
placed, 10 m apart, at a distance of 1200 m on B.G. from the place of obstruction. In addition, stop
hand signal shall be shown at a distance of 30 m from the place of obstruction, at the banner flag
and at distance of 45 metres from 3-detonators. The Railway Servant at the place of obstruction
shall give proceed hand signal to indicate to the Driver when he may resume normal speed after
the train has been hand signalled past the place of obstruction.
INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [144]
b) When the train is required to stop and the restriction is likely to last for more than a day

A stop indicator shall be exhibited at a distance of 30 m from the place of obstruction and a caution
indicator at 1200 metres on the B.G. from the place of obstruction. In addition Termination
Indicators shall be provided at the place where a driver may resume normal speed.

c) When the train is not required to stop and the restriction is likely to last only for a day or less

Proceed with Caution hand signal shall be exhibited again at a distance of 30 m and at a distance of
atleast 800 m shall be suitably increased by special instructions, where required. The Railway
Servant at the place of obstruction shall give proceed hand signal to indicate to the Driver when he
may resume normal speed after the train has been hand signalled past the place of obstruction.

d) When the train is not required to stop and the restriction is likely to last for more than a day

A speed indicator shall be exhibited at a distance of 30 metres from the place of obstruction and
again a Caution indicator at a distance of at least 800 metres shall be suitably increased by special
instruction, where required. In addition, Termination indicators shall be provided at the place where
a Driver may resume normal speed.

5. Safety Measures to be Observed in Case of Unusual Occurrences on Electrified Sections.

1. In the event of an OHE fault, the Traction Power Controller after segregating and isolating the
faulty section shall also immediately switch off the power to the healthy section on the adjacent
line/lines over the same route length as the faulty section. The TPC shall promptly inform the
Section controller details of the isolated faulty section (hereafter called the faulty section), as
well as the adjacent healthy section (hereafter called the healthy section) temporarily isolated.

2. On receipt of message from TPC the Section Controller shall take all precaution as per the
extent rules, treating this section as under emergency power block.

a) For the faulty section, the Section Controller shall take all precautions as per extant rules,
treating this section as under Emergency Power Block.

b) For the healthy section, the Section Controller shall take immediate action to inform concerned
Station Masters to arrange issue of caution orders to the driver of the first train due to enter into
any of the concerned block sections of the healthy section.

The caution order shall specify a speed restriction of 25 Km/H by day and 15 Km/h by night with
instructions to stop short of any obstruction or stop at the next station and report condition of the
track and OHE or any other infringement. The driver shall advise at the next station whether the
trains following his train should observe any precautions or speed restrictions.
As it will not be possible for caution orders to be issued to Driver of trains already in mid-section of
the concerned block sections, the caution orders shall be issued to drivers only as and when trains
are able to reach stations and are further to proceed through other block sections in the healthy
section .
In case OHE power supply failure exceeds five minutes and the Electric Loco Driver for any reason
is unable to establish communication with Section Controller through emergency sockets, the driver
shall arrange to check for power supply as laid down in Electric Locomotive Operating Manual and
on restoration of power, shall arrange to take the train cautiously to the next station, ready to stop in
case of any obstructions. A speed restriction of 25 Km./h by day and 15 Km.h by night shall be
observed for this movement to the next station. On reaching the next station, the Driver shall
contact SM/Section controller.

INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [145]

3. The Section Controller after exchanging message with Station Masters for issue of caution orders to
Driver as laid in para 2 (b) above shall immediately authorize TPC to take action to restore Power Supply
to the healthy section, unless based on information received meanwhile from site/stations, it would be
necessary to continue to keep the power off from the healthy section.

In the event of any obstruction or abnormality online/OHE is reported to the Section controller, directly from
station/site, the Section Controller shall inform TPC to switch off power both on affected line(faulty section)
and also on adjacent lines (healthy section) and then proceed as per para 2 above. This safeguard has been
stipulated as all obstructions on line may not necessarily reflect as an OHE fault giving indication to TPC.

Based on the no-abnormality report of Drivers who have completed their cautions runs through the block
sections on the healthy sections, Section Controller shall arrange to remove the caution orders to subsequent
trains passing the healthy section. The Section Controller shall also keep TPC advised regarding resumption
of normal traffic on the healthy section.

4. In order to minimize the repercussions to traffic on account of adoption of the above procedures, it is very
essential that the emergency telephone sockets all along on the electrified line and emergency telephones
provided with drivers/guard are maintained in good fettle. Joint checks of the Emergency Telephone
sockets on the line between TRD and S&T inspectors should be made to ensure their operational
reliability in case of emergencies.

6. Joint Procedural Order for TPC, SCNL, ASMs, Drivers & Guards in Case an Animal is Run Over in
Electrified Route.

When cattle or animals are run over, vultures generally assemble on the body nearby the track and
sometimes entangle with OHE and/or pantograph causing damage leading to major breakdowns.

Whenever such cases of run over of animals take place or are observed.

a) Drivers and Guards will make effort to advice the same to the SM/ASMs at the next stoppage for relaying
the same to SCNL/TPC or TLCs.

b) Other railway staff will immediately advice the same to ASMs, SCNLs, TLCs and Engineering Control.

On receipt of such information the ASM concerned shall take necessary action to remove the body to a safe
distance to avoid risk of damage to pantographs of passing trains and OHE.

7. Joint Procedural Orders for TPCs and ASMs in case of Electric Shocks with 25 kV OHE supply.

1. TPC shall arrange to cut-off 25 kV OHE supply of concerned sub-sector and also sub-sector of adjacent
line to reduce the effect of induction and shall advise all concerned.

2. TPC shall inform nearest electrical department official and simultaneously arrange an authorised person
to come to spot and move tower wagon/road vehicle from nearest depot if no authorised person is
available near site.

3. TPC shall also inform section controller for regulating the traffic so as to avoid possibility of accidental
charging of the section due to Loco entering the section so made dead.

4. TPC shall inform SM/ASM of nearest Railway Station for medical assistance.

5. TPC/SM/ASM shall inform nearest Railway Doctor for Medical assistance with available means of
communication.

6. TPC/SM/ASM shall inform GRP/RPF staff to reach site of accident provided RPF/GRP post is located at
the stations.

7. TPC shall advise for movement of medical van if situation warrants.

INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [146]

8. On arrival of authorised person on spot, he shall be advised to cordon off the area so that no
one else may get injured.

9. TPC shall advise authorised person to remove the victim with the help of some insulating rod.

10. TPC shall also advise authorised person to administer artificial respiration and other help as
needed.

11. TPC shall arrange quick shifting of victim from site to nearest hospital by

a) Stopping first available train

b) Sending Tower wagon or road Venice from nearest OHE depot.
c) Sending ambulance/stretcher

12. TPC shall advise controlling officer about the accident and take guidance.

13. On arrival of authorised person on spot, TPC must find out the detailed cause of electrical
accident and preserve the documents/materials related to it.

14. TPC shall restore 25 kV OHE supply after confirmation from the site by authorised person or
SS/ASM on duty that the victim has been dis-associated from the 25 kV OHE. Authorised
person, after dis-association should give it in writing to the nearest SM.

15. TPC shall collect details about the victim i.e. hospital where admitted, percentage of burns
injury, his day to day condition and apprise of the position to controlling officer.

16. In case of damage to electrical equipment on this account TPC shall make arrangements to get
equipment attended at the earliest to enable restoration of supply.

17. SM/ASM shall also inform TPC of electrical accident or possibility of accident by exchange of
private number for making the OHE dead provided SM/ASM is first to get such information.

18. If it is possible to keep the traffic moving by other line,TPC will advise to Section Controller in
writing to introduce single line working.

8. Joint Procedure Order Regarding OHE Voltage.

To take timely action for the problem of low/high OHE voltage, following procedure should be strictly
followed:

i) The half hourly voltage readings recorded by TPCs should be scrutinized by CTPC
concerned daily, in case where voltage of feeding point has gone below 23 kV steps should
be taken to improve the voltage. The taps of traction transformers should be changed so as
to improve the feeding voltage. If the problem still persists the Supply Authorities should be
contacted. The concerned Sr. DEEs/DEEs should be informed who will establish contact
with officials of the Supply Authority and get the voltage improved.

Normally the tap setting of Traction Transformer at Traction sub-station will be fixed so that daily
OHE voltage peaks do not exceed 27.5 kV. This will ensure that the voltage is well above the
minimum of 19 kV at the farthest point of the feeding zone.

ii) The cases of low/high voltages observed by the drivers during the run should be reported to
the concerned TLC before signing off indicating time, voltage observed and location/section
where abnormal voltage observed. The abnormal voltage in this case will be above 27.5 kV
and below 19 kV
INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [147]
iii) TLC would also immediately check the reports of other drivers in the same section and advise the
consolidated position regarding abnormal OHE voltage to traction power controller. The TPC/CTPC
would then take immediate measures as indicated above at para (2).

9. Working Instructions for Permanent Way, Traction and S&T staff for Changing the Rails, Carrying
out Track Circuiting and Automatic Signalling Works.

1. Before any alteration to alignment or level of electrified track is commenced, due notice of 48 hrs. in
advance shall be given to those responsible for the OHE so that OHE may be adjusted to conform to the
new condition (at PQRS site, work will be done under the Joint Supervision of Permanent way inspector,
Electric Chargeman/TRD, and S&T staff continuously).

2. A permit to work must be obtained, if work is to be carried out or any worker is required to come within 2
metres of the 25 kV live overhead equipment.

3. When unloading the rails along the track, care shall be taken by PWI/PWM or mate to ensure that the rails
do not touch each other to form a continuous metallic mass of length greater than 300 m.

4. In case of track renewals, temporary connections shall be provided with the other rail of the track at both
ends by TRD staff. In case of renewal of both the rails of track simultaneously, temporary connection
shall be provided within rails of adjacent track at both ends by TRD staff.

5. Before fish plates are loosened or removed, temporary electrical connection between the two rails shall
invariably be made.

6. In case of defective or broken rails bond, a temporary connection shall be made.

7. In case of rail fracture the two ends of the fractured rail shall be first temporarily connected by a
temporary metallic jumper of approved design. In all cases of discontinuity of rails. The two parts of the
rails shall not be touched with bare hands of uninsulated tools. Gloves of approved quality shall be used.

8. Permanent way staff shall keep clear of the tracks and avoid contact with the rails either when
approaching or reaching the work spot when an electrically hauled train in within 250 m.

9. In track circuited area, insulated joints shall not be bridged with bare hands or any metallic articles.

10. Use of steel measuring tapes or long metallic wires is prohibited in electrified sections.

11. Before replacing the rails/glued joints in track circuited area the permanent way inspector will ensure that
traction distribution staff and S&T staff are available at site for removing and replacing the traction bonds
and jumper/bonding connections where required.

In each cases, PWI will cancel the block to resume the normal traffic only after ensuring that the traction
bonds cable jumpers, bond wire etc. have been reconnected by TRD staff and S&T staff, TRD and S&T staff
should be made available at 48 Hr. notice given by PWI for changing rails in case of planned works and on
the same day in case of rail fracture.

12. The Traction Foreman shall see that all insulating sleeves on traction bonds passing under positive rail of
track circuits are intact and take prompt action to replace the missing/damaged one.

10. Joint Procedural Order for Ensuring Safety During Track Renewals.

Since the working of relaying unit involves removal of existing rails alongwith all the different types of traction
bonds, it is absolutely essential that temporary jumpers for passenger of return current are provided till such
time the permanent bonds are fixed to the new rails.

INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [148]

Following procedure shall be followed by the site Incharges of both the Engineering and TRD
branches associated with Relaying work.

1. Before energizing the OHE after completion of work at the end of each day, temporary
jumpers/temporary structure bonds shall be provided on the auxiliary rails and the new rail by
the TRD supervisors as per instructions contained in ACTM. This shall be jointly witnessed by
the PWI in a register provided for this purpose. TRD supervision shall keep the register in this
custody.
2. PWI at site should ensure that temporary rail bonds are connected through auxiliary rail before
opening/dismantalling of rails joins for replacing the panel.
3. It would be the responsibility of the PWI incharge to ensure the safety of the staff once the TRD
supervision has attended to the above work to ensure that temporary bonds jumpers are not
damaged by Engineering staff during the course of working.

4. The length of section of track provided with the temporary jumpers shall also be indicated in the
above register at the end of each working day.

5. NO bonds/temporary jumpers shall be opened by the Engineering Branch without first informing
the TRD Supervisors.

6. Formation of auxiliary track shall also be done in the presence of TRD Supervisor, who shall
provide necessary temporary earthing connection to ensuring safety of staff.

7. At the time of dismantalling/replacing track from the site, PWI concerned will provide continuity
jumpers as per instructions given in ACTM in addition to other instructions for the precautions to
be observed by permanent way staff.

8. The temporary jumpers shall be replaced by permanent bonds in the quickest possible time.

9. The implantation of OHE masts shall be maintained by the Engineering Branch as recorded in
the SED.

10. All the staff should be clearly instructed not be interfere with the track after the work has stopped
for the day and the entries in the register made.

11. All other bonds would be done by the TRD Supervision as per instructions contained in ACTM.

11. Joint Engineering and Electrical Department Circular.

Consequent upon Electrification of various sections of track on Railway/Division, la number of

additional assets have been created. It is therefore necessary to define the responsibilities in
respect of maintenance of such assets and precautions to be taken in maintaining existing assets.

1. General

a) Electrification System :

The system of electrification on the Railway is ac, Single Phase, 25 kV, 50 Hz. The sections under
electrification are from .........................to.................................
b) Rules :
Subsidiary rules for 25 kV ac traction issued by CEE and COM and Permanent Way Safety Rules
issued by Chief Engineer as supplement to Part J Chapter II of Indian Railway Permanent
Manual shall be in possession of every PWI, APWI, IOW. They shall be conversant with all rules
and shall also be responsible for ensuring that all staff under them know the rules and follows them
strictly.
INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [149]
c) Safety First Waning to Staff ;

All electrical equipment shall be regarded as alive at all times and consequently dangerous to
human life, save and except in cases where the electrical equipment has been specially made dead
in accordance with the provisions of these rules. All Railway servants other than those deputed to
work on or near electrical equipment shall keep away therefrom.

d) Admission to and permit-to-work in the supply control posts :

No person other than authorised traction maintenance staff, their assistants, when accompanying
them and persons provided with special permits issued by Sr. DEE/TRD and others is mentioned in
SR shall be admitted to supply control posts.

e) Work on electrical equipment in supply control posts and other electrical equipments:

No work shall be undertaken on any part of electrical equipment or adjacent to it until the person
has received a permit-to-work card. The PWI or IOW will get this from authorised persons as per
provisions of SR.

f) Engineering staff on track patrol shall look for any missing locks on the isolator switches
mounted on traction mast along the track and report the same to ATFO or the TPC without
delay.

2. Maintenance
a) Buildings :

A number of buildings have been constructed for locating various equipment for maintenance and
operation of traction equipment. These include Remote Control Centres, supply control posts (at
various points along the track), maintenance depots, OHE inspection Car Sheds etc.

The Engineering Department shall maintain all these buildings in a fit condition. Special care should
be exercised to ensure that Remote Control Cubicles along the track and Remote Control Centres
are maintained leak proof and vermin proof as these contain costly sophisticated equipment, whose
correct operation is vital for safety of staff and equipment on the Railway. The Engineers shall
therefore execute all such works that may be required for ensuring the above as expeditiously as
possible.

Painting and white washing of the interior of the building housing various equipments will be done
by Engineering Staff under the supervisor of Electrical Staff. All repair to fencing at supply control
posts around high voltage equipments including painting will also be done by Engg. Staff under the
Supervision of Elec. Staff.

b) Tunnel roofs are also to be maintained water proof by the Engineering Department to avoid
flashovers and breakdowns to OHE>
c) All OHE supporting masts and their foundations will be maintained by the Electrical Department.
Ballast, sand and cement will be supplied by the Engineering Department on demand.
Foundations at special locations like bridges will however be maintained and replaced by the
Engineering Department as per the requirements of the Electrical Department. The earth work
around the foundations block will be maintained by the Engineering Department.

d) Track Bonds :
All bonds between track rails and between rail and traction masts will be maintained by the
Electrical Department. During track patrol the engineering staff shall look for any damaged bonds
between rail & structure, or those between rail to rail and report such damages as they notice to the
TFO concerned without delay.
INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [150]
e) Level Crossing Gauges, Screens etc. on bridges :
The maintenance of level crossing including caution boards thereon will be done by the
Engineering Department. Special care shall be taken to prevent the approach road levels going
down below the mark given in level crossing gauges, to prevent passage of unsafe road traffic
under the OHE. The height of the top member of L.C. gauge above the road shall not exceed 4.67
metres. Similarly all screens provided on foot over, road over bridges etc. shall be maintained by
the Engineering staff.
f) Slewing of tracks and alteration to super elevation and heights of rails :

It shall be ensured that the level of rails under foot over bridges, road over bridges, and other
overline structures does not exceed the level marked under such structures Whenever any work on
track, which is likely to affect rail bonds, is undertaken by permanent way staff, adequate notice
shall be given to the Traction foreman (OHE) to enable him to arrange for bonding staff for removal
and replacement of bonds.

Bonding staff when working with a permanent way inspector, sub-inspector or Assistance Inspector
shall work under the instruction s of Permanent Way Inspector, Sub-Inspector or Assistance
Inspector who shall then be responsible for the safety of the track and of the staff.

g) Work involving traffic or power blocks and permits work on traction electrical or overhead
equipment :
All departments in the electrified area who require traffic blocks, power blocks, or permits-to-work in
the danger zone of the traction equipment or who require over head line bond/or bonding staff to be
present at site for scheduled maintenance works,shall deliver at the office of the Sr.
Divisional/Divisional Electrical Engineer (Traction Distribution) not later than 10.00 hr. on every
Monday morning, statements in the prescribed form showing (i) the nature of the work and the date
on which it is to be performed, (ii) by whom the work is to be carried out, (iii) location of the work and
the section of the lines to be blocked (iv) the trains between which the block is required and (v)
whether the track will be available for steam of diesel traffic.

The requirement of all departments will be co-ordinated in the office of the Sr. Divisional/Divisional
Electrical Engineer (Traction Distribution) and a consolidated statement forwarded to the Sr.
Divisional/Divisional Operating Manager concerned at 12.00 hrs. on every Wednesday for inclusion
in the weekly programme of traffic and power blocks.

Works of an urgent character shall be attended to by obtaining emergency blocks and permits-to-
work from the TPC.

A weekly programme of work involving traffic blocks, power blocks and permits-to-work shall be
prepared in the office of the Sr. Divisional/Divisional Operating Manager and dispatched to all
concerned by Friday evening, for the week commencing on the following Monday.

h) Work on station roof, signal gantries etc. Precaution to be taken by staff.

Measuring taps of all kinds, tools and metal articles ( such as paint pots, oil case, metal bars) shall
not be used where they can be lifted or be dropped or be carried by the wind on to overhead
equipment when such overhead equipment is alive.

i) Working on service building and structures in the vicinity of the equipment :

Railway staff when required to carry out work on service, buildings and structures in proximity to
overhead equipment, shall exercise special care to ensure that tools, measuring taps, materials etc.
are not placed in a position where there are likely to fall, or may contact with electric equipment.
Wherever such work has to be carried out under conditions which involve risk to the workmen or
other persons, arrangements shall be made for authorised overhead equipment staff to be present,
who shall take such precautions as may be necessary for the safety of the persons concerned.

INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [151]

j) Working near cables :

When excavations are being made adjacent to tracks and cable routes in an electrified area
adequate precautions shall be taken for the safety of staff and to avoid damage to underground
cables and rail bonds.

Markers are placed wherever possible, along the cable alignment and plans are available indicating
generally the position of burried cables. Excavation must not be undertaken in the vicinity of cable
routes until the exact position of the cables has been ascertained and a representative of the
department concerned is present. This is applicable to cables of Posts and Telegraphs
Departments also.

If circumstances make it imperative that work be undertaken without sufficient notice. Asstt. Signal
and Telecommunication Engineer concerned must be informed by telegram for arranging staff to be
present.

k) Working of Cranes :

NO steam or hand-crane shall be worked adjacent to traction overhead equipment unless such
overhead equipment is made dead and earthed and authorised OHE staff are present. All
movements of the crane jib shall be carefully controlled so as not to foul the traction overhead
equipment. Wherever possible the direct blast from the crane funnel to the over-head equipment
and particularly to section insulators shall be avoided.

Except in emergency, 24 hours notice of intention to work a crane adjacent to overhead equipment
shall be given to the Sr.Divisional/Divisional Electrical Engineer (Traction Distribution) in order to
make arrangements for overhead equipment staff to stand by. When possible the working of cranes
shall be included in the weekly programme. In an emergency, the Traction Power Controller shall
be advised and he shall make arrangements for overhead equipment staff to stand by.

l) Sanded catch sidings :

On sanded catch sidings, the rails shall be kept clear of bond for a length of about 25 metres
beyond live overhead equipment of the track.

m) Transport of heavy materials :

In the case of accidents and breakdowns involving OHE, PWIs/APWIs in charge shall arrange at
short notice for labour required for carrying heavy materials, erection of structures etc.

n) Caution Boards :

The caution boards at stations warning passengers and staff not to come in contact with the traction
installations should also be maintained by the Engineering Department.

o) No blasting is to be done in the vicinity of the electrified lines without the specific sanction of the
Sr. Divisional/Divisional Electrical Engineer (TRD)

p) Numbering of traction masts :

The kilometer number painted on the traction masts as well as the signs showing the direction of the
nearest emergency Telephone sockets will also be maintained by the Engineer Department staff.
The painting of masts themselves, as and when required, will be carried out by the Electrical
Department.

INDIAN RAILWAY-AC TRACTION MANUAL VOLII- PART II [152]

 APPENDIX - IX

LIST OF SPECIFICATIONS AND DRAWINGS FOR EQUIPMENTS AND MATERIALS

FOR RAILWAY ELECTRIC TRACTION
CHAPTER I RDSO SPECIFICATIONS
SECTION I OVERHEAD EQUIPMENT
1. Conventional OHE (Cd Cu Catenary + Cu Contact wire )

SN Specification No. Amend Subject

Remarks
1. ETI/OHE/3(1/83) 2(2/85) Annealed standard copper
conductor for jumper wire.
2. RE/30/OHE/5(11/60) Copper busbar
3. RE/OHE/10(3/66) Splices and ending
clamps. Withdrawn
4. ETI/OHE/11(5/89) Steel tubes.
5. ETI/OHE/13(4/84) 3(4/90) Hot dip zinc coating on steel
masts (rolled and fabricated),
tubes & fittings used on 25 Kv ac OHE .
6. ETI/OHE/14(7/86) 1(9/89) Stainless steel wire rope
7. ETI/OHE/15(9/91) Solid core porcelain insulators
for 25 kV 50 Hz. Overhead
lines.
8. ETI/OHE/16(9/84) 25 kV single and double pole
isolators.
9. ETI/OHE/18(4/84) 3(9/87) Steel and stainless steel bolts
nuts and washers.
10. ETI/OHE/21(9/74) Aluminum alloy section and
tubes.
11. RE/OHE/22(9/61) Dynamometers.
12. RE/OHE/23(9/61) Pull lifts
13. RE/OHE/25(3/66) Standard for drawing for
traction.
14. ETI/OHE/27(8/84) Standard insulator Assembly
Without sectioning insulator
15. RE/OHE/28(3/72) Double wire section insulator Obsolete
16. ETI/OHE/33(8/85) Enamelled steel plates
17. ETI/OHE/36(12/73) Galvanized steel wire
18. ETI/OHE/37(12/73) Hard drawn copper catenary For WKR
19. ETI/OHE/42(2/92) Hard drawn grooved copper
contact wire for ac electric
traction.
20. ETI/OHE/44(7/78) PVC hand rail covering used Withdrawn
for traction bond. (VideETI
Dt 18/19.7.84

21. ETI/OHE/48(7/84) 1(9/87) Winch type regulating

equipment for 25 kV ac
traction.
22. ETI/OHE/48a(9/85) 1(11/87) Three pulley type regula-
ting equipment (3:1 Ratio)
23. ETI/OHE/49(5/84) 5(4/90) Fittings for 25 kV ac OHE

INDIAN RAILWAY- AC TRACTION MANUAL-VOLII-PARTII [153]

24. ETI/OHE/50(8/83) 4(12/93) Cadmium copper conductor
for overhead/railway traction
25. ETI/OHE/51(9/87) Discharge/earthing pole assembly
for 25 kV ac traction.
26. ETI/OHE/52(10/84) Interlock for ac traction switchgears.
27. ETI/OHE/53(6/88) 3(6/90) Principles for OHE layout plans
and sectioning diagrams for 25 kV ac traction.
28. ETI/OHE/56(5/85) 1(12/89) Contact wire manufactured from Withdrawn
Continuous cast hot rolled electro vide
lytic copper wire rods. ETI/OHE/CC/1/4
Dt.11.4.99
29. ETI/OHE/59(12/90) 4(10/91) Tender specifications of 8 wheeler OHE Inspection Car.
30. ETI/OHE/63(5/91) Short neutral section assembly ( Phase break)
31/ ETI/OHE/64(10/88) 1(9/89) Solid core cylindrical post insul
ator system with nominal voltage
of 220, 132, 110 and 66 kV.
32. EI/OHE/65(8/87) 2(4/90) Continuous cast wire rods.
33. ETI/OHE68(11/87) Polymer insulators for 25 kV
single phase 50 Hz. Overhead traction line.
34. ETI/OHE/69(12/87) Toughened Glass Insulators.
35. ETI/OHE/70(10/88) Rubber mat for use below overline
Structure in the 25 kV ac,50 Hz.
Single phase electric traction areas.
36. ETI/OHE/71(11/90) 1(8/91) Code for bonding & Earthing for
kV, single phase, 50 Hz., ac Traction System.

37. ETI/OHE/72(11/91) For axle car for winding and/or

unwinding of contact wire & catenary wire.
2. Aluminum OHE
SN. Specification No. Amend Subject Remarks
1. ETI/OHE/54(2/85) 1(11/89) 19/2.79mm all Al. Alloy
standard catenary wire.
2. ETI/OHE/55(4/90) Bimetallic (Al-Cu) strip for
kV traction OHE.
3. AL OHE/101 (8/83) Al. Alloy grooved contact
wire 16.4 mm dia 193/190
mm2 cross section.
3. Civil
SN. Specification No. AmendSubject Remarks
1. ETI/C/1(1/80) Standard code of practice Not to be
painting of rolled steel used.
electrification mast.
2. ETI/C2(1/82) Indian Rly. Standard Spe-
cification for Prestressed
concrete (spun type) OHE
traction masts.
3. ETI/C/3(5/83) Indian Rly. Standard spec-
ification for spraying zinc
coating on the OHE masts.
4. ETI/C/4(5/88) Draft Indian Rly. Standard
specification for cold roll
formed mast for Railway
electrification.
5. ETI/C/4(5/88) Specification for FLO-COAT STEEL
TUBES.
INDIAN RAILWAYS-AC TRACTION MANUAL-VOLII-PARTII [154]
 CHAPTER I RDSO SPECIFICATIONS
SECTION II POWER SUPPLY INSTALLATION.

1. 25 kV ac System
SN. SPECIFICATION NO. Amend Subject Remarks

1. ETI/PSI/1 (6/81) Battery charger for 110 volt

battery, 40 Ah.

2. ETI/PSI/3(8/75) Lightning Arrestor, 7.5 kV

3. ETI/PSI/4(9/79) Interruptors, 25 kV.

Obsolete

4. ETI/PSI/8(12/79) Potential Transformers, 25KV. Superseded

by ETI/PSI 134(8/89)
5. ETI/PSI/11(12/81) Single pole circuit breakers,25KV
Obsolete
6. ETI/PSI/13(3/85) Booster transformer, 25 kV
Obsolete
7. ETI/PSI/14(1/86) 25 kV Dropout fuse switch
and operating pole.

8. ETI/PSI15(10/73) 25 KV/240 V LT supply

Add. Slipno.3
= 2(3/89) transformer 10 KVA
(12/81) applicable in
case of seal type
9. ETI/PSI/15A(7/82) 25KV/240V LT supply trans-
formers, 100 KVA
10. ETI/PSI/17(1/72) Admittance relay for 25KV

11. ETI/PSI/18(8/75) Lightning Arrestor, 120KV. Superseded by

ETI/PSI137(8/89)
12 ETI/PSI/19(7/85) Lightning Arrester, Valvetype 42 kV, Station class.
13. ETI/PSI/20(6/79) Double pole&Triple pole isolators, 132 kV )
14. ETI/PSI/20A(6/79) Earthing blade assembly Superseded
for double pole & Triple) by ETI/PSI
Triple pole isolators, 132 kV) 122(3/89)
15. ETI/PSI/20B(7/79) Double pole & triple pole
motor operated Isolators),132 kV.
16. ETI/PSI/21(6/81) Lead acid batteries 110V,400 Ah.
17. ETI/PSI23(4/72) Double pole & triple pole
circuit breakers, 132KV. Obsolete
18. ETI/PSI/23A(1/73) Double pole & triple pole
circuit breakers 110KV Obsolete
19. ETI/PSI/24(6/81) Battery charger for 110 V,battery, 220 Ah.
20. ETI/PSI/25(6/81) Lead acid batteries 110,200 Ah.
21. ETI/PSI/27(6/87) Rly. 1 Control & relay board for
=1(4/88),2(8/88),3(4/89) railway traction sub-station.
22. ETI/PSI/29(12/79) Low tension distribution panels for railway ac
traction sub-station
23. ETI/PSI/30(12/82) Lead acid batteries 24 V type I & II for RC
Equipment.

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLII-PARTII [155]

24. ETI/PSI/31(5/76) Standards for drawings for power supply
installations
25. ETI/.PSI/35(4/75) Potential transformers, 132 kV
26. ETI/PSI/36(5/75) Current transforerm, 132 Kv, (Type II)
27. ETI/PSI/37(7/74) Battery charger type I & II for
24 V lead acid batteries for remote control
equipment.
28. ETI/PSI/38(1/73) Selective frequency level meter Analyser.
29. ETI/PSI/39(5/75) Impulse recorder.
30. ETI/PSI/41(1/73) Double pole & triple pole Superseded by
isolator 110 kV ETI/PSI 122(3/89)

31. ETI/PSI/42(8/75) Lightening arrestors 96 kV. Superseded by

ETI/PSI 137(8/89)
32. ETI/PSI/43(10/90) Control & distribution panel
for color light signalling supply
33. ETI/PSI/44(12/73) Standard for electrical distribution
system in Station & Yards where kV ac traction
is to be Introduced.
34. ETI/PSI/46(8/90) Single pole vacuum circuits breakers,
= 3(1/92) 25 kV.
35. ETI/PSI/47(9/78) Telemetering equipment for 25 kV,ac traction.
36. ETI/PSI/50(8/79) Double pole & triple pole isolators Superseded by
66 kV ETI/PSI 122(3/89)
37. ETI/PSI/50A(8/79) Earthing blade assembly for double
pole & triple pole isolators, 66KV.
38. ETI/PSI/50B(4/80) Double pole and triple pole motor
operated isolators, 66 kV.

39. ETI/PSI/53(8/79) Lightning arrestors 60 kV Superseded

by ETI/PSI 137(8/89)
40. ETI/PSI/56(3/80) Potential transformers, 66 kV
41. ETI/PSI/58(8/82) 400 KVA, 25 KV/415V110V
single phase power transformers.
42. ETI/PSI/59(1/81) 25 kV dropout fuse switch & operating
pole emergency power supply equipment.
43. ETI/PSI/61(9/86) 13.5/20 MVA (I) 132/25KV, (II) 110/25KV
=36(6/88), 4(7/88) (III) 66/25 kV, Single phase, power
transformer.
44. ETI/PSI/62(7/82) Insulating transformer oil purification Superseded
plant (2500Ltr. Per hour capacity) work- byETI/PSI
able on 230 Vlts ac single phase supply
for railway ac sub-station. 103(7/89

45. ETI/PSI/63(7/82) Low tension distribution panels.

46. ETI/PSI/65(8/84) Control & relay pane board incorporating
=1(9/89) static type relay for 25 kV ac traction sub-
station.

INDIAN RAILWAY-AC TRACTION MANUAL -VOLII PARTII [156]

47. ETI/PSI/66(9/86) Rev II Single pole SF-6 circuit breakers 25 kV superseded by
= 3(9/86 ac for railway traction sub-station ETI/PSI 43(5/87)
48. ETI/PSI/67(3/89) 25 kV shunt capacitor equipment for
=4(8/91) railway traction sub-station

49. ETI/.PSI/70(11/84) Hollow porcelain insulator and bushing

50. ETI/PSI/71(1/87) Rev.I Metal oxide gapless type lightning
= 4(12/91) arrestor for use on 25 kV side of Rly.
Traction sub-station and switching Station.
51. ETI/PSI/73(10/88) Single pole outdoor SF-6 gas
=3(1/92) interruptor for 25 kV ac traction sub-station
52. ETI/PSI/74(6/90) Single pole vacuum interruptor
= 3(1/92) for 25 kV ac traction sub-stn.
53. ETI/PSI/75(8/85) 25 kV single phase series capacitor
54. ETI/PSI/76(7/890 Rev IV For SRC equipment and data superseds
=1(6/90) acquisition for control of 25 kV spec. ETI/
single phase 50 Hz. Traction PSI/48(10/76)
power supply
55. ETI/PSI/77(9/85) Distributed type 25 kV ac single phase
series capacitor for installation at boos-
ter transformer location.
56. ETI/PSI/78(4/86) 20/27 MVA, I 132/25 kV , (II) 110/25 Superseded by
kV(Iii) 66/325 kV single phase power ETI/PSI 118
Transformer. (7/88)
57. ETI/PSI/79(1/87) 280 KVA, 25 kV, single phase, 50Hz
= 1(9/89) oil filled conventional type booster transformer.
58. ETI/PSI/80(10/86) 25 kV 240 V dry type cast resin LT
= 1(9/89) supply transformer, 10 KVA for
railway ac traction sub-station.
59. ETI/PSI/81(11/86) 280 KVA, 25 kV, single phase, 50Hz
dry type cast resin booster transformer
60. ETI/PSI/82(2/87) Metal Oxide gapless type lightning Superseded
= 1(3/87_) arrestor for use on 132 kV side of ETI/PSI 137
railway traction sub-station (8/89)
61. ETI/PSI/83(4/87) 3.3 MVA 3 phase dry type cast epoxy
resin rectifier transformer for use in DC traction
sub-station.
62. ETI/PSI/84(3/87) Dry type cast resin potential transformer
= 1(5/89) 25 kV for use in railway ac traction substation.
63. ETI/PSI/86(3/87) Dry cast resin type current transformer
= 1(4/89) 25 kV for use in railway ac traction sub-station.
64. ETI/PSI/88(4/87) 220 kV ac double pole/triple pole isolato
(Superseded by ETI/PSI/122 (3/89)
65. ETI/PSI/89(4/87) Metal oxide gapless type lightning
Superseded by
arrestor for use on 220 kV side of
ETI/PSI/137
railway traction sub-station.
(8/89)
66. ETI/PSI/90(9/87) 25 kV current transformers with ratio
= 3(3/89) of (I) 1000-500 /5A (ii) 1500-750/5A

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME-II-PARTII [157]

67. ETI/PSI/92(5/87) 100 KVA, 25 kV dry type single phase
50 Hz. Cast resin booster transformer
68. ETI/PSI/93(5/87) 25 kV ac single pole SF-6 circuit breaker
= 5(1/92) for railway traction sub-station( for heavy haul train
section)
69. ETI/PSI/97(6/87) 100 KVA, 25 kV single phase 50Hz. Dry
= 1(9/88) type cast resin booster transformer
70. ETI/PSI/98 (6/87) 150 KVA, 25 kV single phase 50 Hz.,
= 1(9/88) oil filled conventional type booster
transformer
71. ETI/PSI/99(6/87) Trivector meter and maximum demand
indicator for railway ac traction substation.
72. ETI/PSI/100(10/.90) Specification for thyristor switched
shunt capacitor equipment for railway traction sub-
station.
73. ETI/PSI/101(8/87) Two zones static relay for distance protection for 25 kV
ac
single phase, 50 Hz traction over head equipment.
74. ETI/PSI/103(7/89) High vacuum type insulating/transformer
Supersedes
oil purification plant( capacity 3000 LPH)
specn. No. for railway traction sub-station
ETI/PSI/62 (7/82)
75. ETI/PSI/104 (9/87) Re-current surge generator for use in railway
traction sub-station.
76. ETI/PSI/105(9/87) Gas chromatograph for use in analysis
of dissolved gases of transformer oil.
77. ETI/PSI/106 (9/87) capacitance bridge and dissipation factor
bridge for the measurement of solid insulations of
insulating oil.
78. ETI/PSI/108(9/87) Power system disturbance recorder.
79. ETI/PSI/PSS/LAB/ Digital storage oscilloscope.
109(10/87)
80. ETI/PSI/PSS/LAB/110 Dual trace oscilloscope
(10/87)
81. ETI/PSI/PSS/LAB/112 Digital frequency meter
(10/87)
82. ETI/PSI/PSS/114(3/88) Waveform analyser
83. ETI/PSI/PSS/LAB/115 Data logger
(11/87)
84. ETI/PSI/116(4/88) 220/132/110/66 kV DP/TP SF-6
7(3/92) gas circuit breaker.
85. ETI/PSI/117(7/88) Current transformer
=5(6/90) I) 220 kV, 200/110/5
ii)132KV,400-200/5
iii)110 kV, 400-200/5
iv) 66KV,800-400/5
86. ETI/PSI/118(7/89 Power transformer 20 MVA single
Supersedes specn
= 1(3/92) phase 50Hz. 220/132/110/66 kV for No.
ETI/PSI/118
traction sub-station. (7/89)
87. ETI/PSI/119(7/88) Specification for 8 channel U-Vrecorder
88. ETI/PSI/120(2/91) Code of practice for earthing of power Draft.
Supply installation for 25 kV ac 50 Hz.
Single phase traction system

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME-II-PARTII

[158]
 APPENDIX XI

ELECTRIFICATION OF PRIVATE AND ASSISTED SIDINGS

(Ref. : R.B. Letters No. 79/W1/SA/34 dated 1-3-82 and 87/W1/SP/28 dated 18-2-88)

1. Rules governing the construction, working and maintenance of Private and Assisted sidings
are contained in the chapter XVIII of the Engineering Code.

2. Sharing of Cost

2.1 Private Sidings

a) In the case of new sidings where the line / section is electrified, the entire cost of
OHE will be borne by the siding owners, as in the case of track. Maintenance cost
will similarly be borne by the siding owners.

b) In the case of new sidings, where the line is not electrified, the siding owners
shall be required to give an undertaking that in the event of electrification of the
line within a period of 10 years, they will bear the full charges of electrification of
the siding. Maintenance cost will be borne by the siding owners.

c) With a view to expending the electrification of existing railway sidings, it has been
decided that if financially justified, incentive in the form of sharing of 50% cost by
the Railway may be agreed to. In such cases, no departmental charges shall be
levied while working out the cost of electrification. The siding agreement shall
provide that electrification assets so created will be property to the Railways and
maintained by the Railway at partys cost. In case the siding owner do not agree
to bear their share of cost of OHE, the movement to the siding will have to b e by
partys own locomotives.

2.2 Assisted sidings

a) The cost of retrievable part of the OHE will be borne by the Railways as in the
case of track and the cost of non-retrievable portion will be borne by the siding
owner. The interest and maintenance charges will be borne by the siding owner,
as in the case of track.

b) In case of new sidings, a provision should be made in the siding agreement that
in case electrification of the siding becomes necessary in future, as a result of
electrification of the section, the cost of OHE will have to be borne by the party as
indicated in para (b) above.

c) In case of existing sidings.

(i) With regard to sections which are being electrified, in case OHE for the
assisted siding is considered essential, the cost will be borne by the
Railways and partys concerned as para (a) above.
(ii) Where section is already electrified and OHE is to be provided for the
siding the provision of OHE will be at the cost of the Railways and party
concerned as para (a) above otherwise, movement to the siding will have
to be by partys own locomotives.
(iii) Where sidings has already been electrified efforts, should be made to
recover the cost as in case of para (a) above.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME II PART II [241]

 FOREWARD

The "A. C. Traction Manual" containing procedures and practices to be followed uniformly
throughout Indian Railways, was published for the first time in 1972.

Considerable experience has since been gained in the operation and maintenance of electric
traction assets. Technological upgradation has also been continuously taking place. Microprocessor
based SCADA systems for remote control of traction power supply have been introduced with
telemetering facilities. Vacuum and SF6 gas circuit breakers have by and large replaced
minimum oil circuit breakers. A pilot project of electrification with 2 x 25 kV State-of-art technology
on Bilaspur-Bina-Katni section has also been taken up. While earlier supply was being availed at 25
kV from power supply authorities. Railway owned traction sub-stations and transmission lines have
come up.

.As regards Rolling Stock. 6-axle WAM4 locos introduced in early 70s have given place to 3900 H.
P, WAG5 freight locomotives 5000 H. P. WAG7 locos & WAP 1 /WAP3 locomotives with speed
potential of 140 km/h for passenger services, A sizeable fleet of dual brake locos has come up to
offer better operational flexibility. Thyristors, electronic slip/creep control using Doppler radar
sensors, computerised self-diagnostic fault indicating systems have also been introduced.

These developments have given rise to a need for updating the Manual. The present Manual caters
to this requirement and is the result of developing efforts put-in by a number of Electrical Engineers
of Indian Railways. I hope the Manual, in its revised form will help towards better know-how of the
prevalent system in respect of Maintenance and Operation and thereby improve reliability and
safety.

(J. Upadhyay)
Member (Electrical)
Railway Board.

New Delhi
December, 1993
 INTRODUCTION

The "Manual of AC Traction - Maintenance and Operation" covering the maintenance and operation
of 25 kV ac 50 Hz single phase traction Installations, electric locomotives and electrical multiple
units and other connected matters including railway electrification - was issued in 1972.

The Manual Is generally procedural in scope and includes essential technical data of use to the
operating and maintenance personnel but does not cover the theoretical and design aspects of the
Traction Installations and electric rolling stock as these are contained In documents issued by the
RDSO as well as the respective manufacturers.

In the preparation of the Manual all relevant documents, rule books, operating manuals and stand.
ing instructions issued by the electrified railways are considered together with the knowledge of
procedures an d practices as observed during inspections of various Installations on the railways as
well as discussions with Chief Electrical Engineers of the Railways and concerned officers and staff
as also RDSO.

In what is considered to be the greatest common measure of agreement in regard to the

maintenance schedules and their periodicity, the forms and registers in use, the availability of staff
and operating conditions obtaining on the Railways the bases have been standardised, subject, of
course to the, condition that the Chief Electrical Engineer of the Railway may, where considered
essential, authroise deviations to the prescribed procedures and practices to the extent necessary.
Over the years since the issue of Manual in 1972 changes have taken place in certain aspect of the
traction installations as well as the electric rolling stock. Keeping these changes in mind, the Manual
has been revised and is brought out in three Volumes as indicated below though the style has by
and large been retained.

Volume 1 - General is of a general nature and contains descriptions of the traction Installations and
electric rolling stock. It indicates the organisation for operating and maintaining the traction
installations and electric rolling stock, both in the Headquarters and Divisional offices of the Zonal
Railways, describing the functions at various management levels. It also contains the rules and
procedures for the staff of other disciplines like Signalling and Telecommunication, Civil Engineering
etc. apart from subjects which all electric traction engineers and supervisors should be familiar with
and therefore this volume would necessarily be an omnibus one.

Volume II - Fixed Installations has been made in two parts. Part 1 covers the operation and
maintenance of traction Installations of fixed Installations as well as procedures for commissioning
of new traction Installations while Part 11 contains various guidelines and procedures Issued by the
Railway Board and RDSO in connection with fixed traction installations. -
Volume - III - Electric Rolling Stock is exclusive for the maintenance and operation of electric
rolling stock - locomotives and multiple units.

In the get up of this Manual the paragraphs are numbered with 5 digits. The first digit indicates the
Volume number, the next two digits Indicate the Chapter number and the last two digits the specific
paragraph number.

It will be appreciated that in a Manual of this nature, it will not be feasible to include material to cover
each and every contingency that may arise in the course of working of the traction Installations and
the electric rolling stock, though efforts have not been spared to make it as comprehensive as
possible. In the event of any contingency that might arise requiring supplementing what Is contained
In this Manual so as to suit the conditions on -a particular Railway, the Chief Electrical Engineer of
the Railway may issue necessary Instructions/orders 'for the purpose. It would be good practice to
copy such Instructions/orders to other Railways as well for their benefit. However, the provisions in
this Manual, the Codes,/Manuals issued by various authorities, the General and Subsidiary Rules
and any other statutory regulations in force shall not be contravened.
Any comments or suggestions for improving this Manual as well as any advice in regard to errors or
omissions if any requiring correction may be sent to the Railway Board.

The making of this revised Manual has been an arduous work and for the efforts put in by a number
of senior officers as well as staff of Railway Board, Railways, RDSO/Lucknow and RITES, New
Delhi to bring this out, no amount of words of appreciation and. gratitude to them will be adequate
for the purpose.

It is hoped that the Manual will serve the needs for which it has been made.

New Delhi
NOEL LOBO PRABHU
Adviser (Electrical)
 VOLUME III

ELICTRIC ROLLING STOCK

LIST OF CHAPTERS
NO. TITLE PAGES

I GENERAL 2---36

II MAINTENANCE OF ROLLING STOCK GENERAL 37----58

III MAINTENANCE & OVERHAUL SCHEDULES OF LOCOMOTIVES 59-101

IV MAINTENANCE & OVERHAUL SCHEDULES OF EMUs 102-123

V OPERATION OF ROLLING STOCK 124-132

VI OPERATION OF ELECTRIC LOCOS 133-158

VII OPERATION OF EMUs 159165

VIII COMMISSIONING OF NEW ELECTRIC LOCOS & EMUs 166-169

IX SAFETY, BREAKDOWNS &DISASTER MANAGEMENT 170185

X ROLLING STOCK STATISTICS 186191

XI TECHNOLOGICAL ADVANCEMENTS 192198

XII TRAINING AND COMPETENCY CERTIFICATES 199209

APPENDIX CODE ABBREVIATIONS FOR COMPONENTS OF 210224

LOCOs/EMUs

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [1]

 CHAPTER I

GENERAL

II. Para No. Subject

30100 EVOLUTION OF ELECTRIC ROLLING STOCK

INDIAN RAILWAYAC TRACTION MANUALVOLUME III [2]

 CHAPTER I
GENERAL

30100 Evolution of Electrical Rolling Stock

1 Electrical Concept
1.1 The development of mercury arc rectifier for rolling stock application, wherein the dc motor
could be used for traction became a single major factor for large scale application of single phase
50Hz 25kV for mainline electrification. Hitherto the performance of ac traction motor in locomotive
had always been considered inferior to its dc counterpart and dc traction was only a compromise
solution to save on the cost of OHE. The use of rectifier on the locomotive on the other hand
offered an alternative of a superior locomotive to a dc locomotive . Initially water cooled mercury arc
rectifiers known as ignitions, (ignited internally through an ignitting electrode) were used. Indian
Railway purchased two types of locomotives of this type (WAM-1 from Europe &WAM -2 from
Japan). But they gave way to neater and more reliable solution of externally fired air cooled
rectifiers i.e. excitrons. Excitrons had the additional advantage of reversibility i.e converting dc back
to ac and could be utilized for regeneration to a limited extent. Indian Railways imported a few
locomoitive of this design from Europe (WAG-1) and a sizable fleet was assembled and
manufactured at CLW as well. A few Japanese locomotives using silicon retifier were also
imported (WAG-2)

1.2 With the development of High Power Silicon Diode Devices the entire technological
development of ac traction stock took a new turn and more powerful units of ac locomotives were
conceived. The silicon diode is simple to maintain and is extremely reliable. At present bulk of the
fleet of Indian Railways consists of such locomotives.

1.3 Both with mercury arc and silicon rectifiers, the voltage control is achieved by an electro-
pneumatically operated tap changer. In the locomotives the high tension tap changer has been
utilized. Typical power circuit diagrams of WAG-5and WCAM-1 type locomotives are given in Fig.
1.01and Fig.1.02. On some of the WAG-1 and WAM-2 locomotives, silicon rectifier with tap
changer control has been replaced by the phase angle controlled thyristor convertor.

1.4 MG locomotives: These locomotives of YAM-1class (Japanese design) are in use in a single
isolated section viz. MAS-Villupuram section. They employ silicon rectifiers for conversion. Salient
data on electrtic locomotives is given in Annexure 1.01./A.

1.5 EMU (Electrical Multiple Units) both on MG and BG employ silicon rectifiers for conversion
and LT tap changers are used for voltage control. Salient features of EMU are given in Annexure
1.01./B. A typical power circuit diagram of EMU type WAU-4 is also given in Fig.1.03. Phase angle
controlled thyristor convertor has also been deployed on a few 25kVac MG EMUs in place of silicon
rectifier and LT tap changer on Southern Railway.

2.0 Sources of Electric Locos

2.1 Indian Railways imported 100 WAM-1 Bo-Bo locomotives from Europe, and 36 WAM-2 and 2
WAM-3 Bo-Bo locomotive from Japan. Subsequent to this, 42B-B high adhesion(mono motor
bogies)locomotives designated as WAG-1 were imported from Europe and 45designated as WAG-2
from Japan. Ten WAG-3 locomotive of B-B design of higher rating were imported from Europe

Manufacture of WAG-1type of locomotive was taken up in Chittaranjan :locomotive Works (CLW)

and later on CLW switched over to the manufacture of WAG-4 type of locomotives. After
completion of 186 WAG-4 locomotives, Indian Railways switched over to 6 axle locomotive of
indigenous design and CLW have manufactured a series of WAM-4 and WAG-5 locomotives.

INDIAN RAILWAYSAC TRACTION MANUALVOLUME III (3)

With a view to improving the performance of the locomotive, WAG-5 locomotives with minor
variations to suit specific application were also manufactured and designated as WAG-5 with
different suffixes.

2.2 Eighteen prototype 6000 HP thyristor control locomotives of 3 type designated as WAG -6A,
B&C were imported, six from ASEA and twelve from Hitachi in 1988. A prototype locomotive of
5000 HP capacity with high adhesion bogies, designated as WAG -7 has been designed and
manufactured by Chittaranjan Locomotive Works. A new prototype control is under development.

2.3.To meet the specific requirements of higher speeds for passenger services,CLW manufactured
WAP type locomotive using Co-Co flexi -coil bogies to work upto a speed of 130km/h designated as
WAP-1. This loco has been further upgraded for speed potential of 140km/h by providing improved
version of indigenously designed bogies. This loco is designated as WAP-3. A few WAM-2
locomotives were fitted with modified drive and designated as WAP-2 locomotive .

2.4 A chart exhibiting the salient features of ac electric locomotive is enclosed as Annexure 1.01/B
sheet No.1&2. Major dimensions of the various locos are shown in Annexure 1.02. Load table for
various locomotives are available at Annexure 1.03. Starting tractive effert is limited to 37.5t due to
limitation of bridges on Indian Railways. Brief write ups on 6000HP microprocessor controlled
thyristor locomotives are given in Annexure 1.04 and 1.05. Functional description of main circuit of
thyristor EMU is given in Annexure 1.06.

3.0. Mechanical concepts.

3.1 Four axle locomotives had the following types of drives:

i) WAM1 : cordon shaft drive
ii) WAM2 and WAM 3 : WN coupled gear drive
iii) WAG(1,3and4) : coupled gear drive through cordon
shaft monomotor bogie European
design and also built at CLW.
iv) WAG2 : Monomotor bogie with flexible
rubber couplings (quill drive )
arrangement (Japanese Design)

3.2 The monomotor bogie locomotives had a starting tractive effort of just under 32 tonne with motor
power of 790HP per axle. Except for a few WAG 1, WAG 2and WAG 3 class locomotives the bulk
to the series of WAG1 and WAG4 class were manufactured at Chittranjan Locomotive Works till
early seventies. The performance of these locomotives was also not found to be adequate for
meeting increased operating requirements.

3.3 WAM4 andWAG5 locomotives which were indigenously manufactured used Co-Co , trimount
bogies of ALCO design with axle hung nose-suspended traction motors. Same design of bogie was
also used in dual voltage locomotives (WCAM-I). In WAG-6A & B locomotives, with a view to have
a high tractive efforts and high speeds (beyond 160 Km/h), 6-axle locomotive having Bo-Bo-Bo
arrangement was adopted. WAG -6A locomotives utilises ASEA hollow shaft drive system whereas
WAG-6B locomotive uses WN coupling. In WAG-6 locomotives high adhesion Co-Co bogies using
unidirectional motor and secondary suspension arrangement was adopted. Indigenous bogies
similar to those of WAG -6C locomotives will be used in the prototype WAG-7 & 8 locomotives.

3.4 In WAP-1 locomotives, flexicoil bogie modifying the existing WDM-1 (General Motor Design)
has been used. WAP3 loco utilises an improved version of this bogie.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [4]

 ANNEXURE 1.03
WAP 1
SHEET 1/13
HAULAGE CAPACITY (WITH OUT 5% ACCELERATION RESERVE)
-------------------------------------------------------------------------------------------------------------------------------------
-------------------|
| SERVICE | GRADE | TONNES AT km / h (TANGENT TRACK)
| | | |
|
|---------------|-------------|------------------------------------------------------------------------------------------------------
--------------------|
| | 20 | 40 | 60 | 70 | 80 | 90 | 100 | 110 | 120 | 130 |
START* |
|
|
| | |--------------------------------------------------------------------------------------------------------
------------------|
| | LEVEL | ABOVE 1500 |
1235 | 4340 |
|
|
| -------------------------------------------------------------------------------------------------------------------
-------------------|
| | 1/500 | ABOVE 1500 | 1350 | 1100 | 835
| 3070 |
| |----------|------------------------------------------------------------------------- | | |
| |
| PASSANGER | 1/200 | ABOVE 1500 | 1460 | 1215 | 1010 | 860 | 715 | 545
| 2115 | | | | | | | |
| | | |
| | | | | | | | |
| |
| SERVICE | 1/150 | ABOVE 1500| 1415| 1360 | 1185 | 990 | 830 | 710 | 590 | 450
| 1790 | | | | | | | | |
| | | | |
| | | | | | | | | | |
| |
| ICF | 1/100| 1120 | 1060| 1000| 965 | 850 | 715 | 600 | 515 | 425 |
| 1370 | | | | | | | | | |
| | | | |
| COACHING | 1/50 | 540 | 520 | 500 | 490| 430 | | | |
| | 775 |
| | | | | | | | | | |
| | |
| STOCK | | | | | | | | | | |
| |
|------------------------------------------------------------------------------------------------------------------------------------
-------------------|

MAXIMUM STARTING T.E. -= 25.0 t

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [14]

 Annexure 1.04
Functional description of main circuit of WAG-6A

1. General Outline
Fig. 1 shows a simplified diagram of the main circuit. The current is taken from the 25 KV 50 Hz
overhead line by pantograph and passes through the main circuit breaker to the primary winding of
the main transformer, and then through the grounding transformer (GT) to the car body. The
purpose of the GT is to ensure that the current going through the car body finally finds its way
through the wheels and is then earth via the rails.

In addition to the four traction windings, secondary windings are connected to the auxiliary power
system, hotel load and motor field circuit respectively.

As can be seen in Fig. 1, the main circuit is divided in two parts, called traction motor modules.
These are controlled individually, depending on adhesion conditions.

2. Traction motor modules

Fig. 2 shows the armature circuit for one motor module. In the convertors, which are built up from
thyristors and diodes, the 50 Hz supply voltage is rectified and fed to the traction motors. To
smooth the current from the convertors smoothing reactor is connected in series with each motor.

Connected parallel to each traction winding, the power factor control has the form of three tuned LC-
links.

Between the transformer and the convertors, automatically operated module disconnectors (MD)
are connected (Fig.2) which also disconnect the field circuit of the module (Fig. 3)

3. The Convertors.
The convertors consist of thyristors and diode to allow a path for the free wheeling current when the
thyristors are not fired.

During acceleration, one bridge only is being fired until shortly before it is fully advanced. Then the
two bridges are both fired until the first one is fully advanced, after which the second is further
advanced, until it too is fully fired. This procedure is called overlapping control.

Phase angle control of the thyristors will introduce harmonics and because of this, both power factor
and psophometric current will vary considerably at different speeds. In order to minimize the
influence on the supply network, Power Factor Control equipment (PFC) is used.

4. The Motors
The traction motors are separately excited, bogie suspended dc motors. Each motor is individually
fed from a convertor, consisting of two rectifying bridges.

4.1 The Field Circuit

The field circuit (Fig 3) feeds the motor field windings, each of which is individually controlled.
During acceleration from stand still, the field current is kept approximately constant until maximum
motor voltage (or maximum available voltage) is reached. In order to further increase the speed,
field weakening must take place, which leads to lower tractive effort. At over speed i.e. when slip
tends to occur on one axle, the field is weakened, tractive effort of the motor concerned thus
lowered, thereby, lowering its armature current and subsequently decreasing the over speed.
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [27]
4.2 The PFC System

Parallel to each of the four of traction windings of the main transformer, Power Factor Control
equipment (PFC) is connected and this has the form of three tuned LC-1 links, switched in and out
by two anti-parallel thyristors as shown in Fig.4. The PFC has two purposes. One is to be a
capacitive compensation for the otherwise inductive traction circuit, thus raising the power factor.
The other is to filter the harmonics out from the transformer windings, thus further increasing the
power factor and, at the same time, the decreasing the psophometric current.

The two purposes are fulfilled by using tuned LC-links,in this case three links showing best filtering
performance at 3rd,5th and 7th harmonics respectively. The demand for capacitive compensation
and filtering performance varies strongly with the speed and with the tractive effort i.e. with the firing
angle of the main thyristors and the current through these. The PFC is controlled so that each
locomotive will appear as an inductive or a resistive load, seen from the overhead line at the
pantograph. When the ac current to the locomotive tends to go capacitive, one or more the PFC
modules are cut to avoid over compensation.

4.3 Safety monitoring and fault detection

For safety and monitoring purposes, current transformers and breakers are used (Fig.5). To curb
over voltage, a lightning arrestor (LA) is used, limiting the maximum voltage over the main
transformer. The current in all windings of the main transformers and all motor fields (Fig.3) is
monitored continuously, through the use of current transformer (CT).

Should an over current occur on any of the monitoring transformers, the main circuit breaker (MCB)
will open immediately. The potential transformer (PT) is used for monitoring the supply voltage.
When the supply is too high or too low, the MCB is opened. To enable the driver to immediately
discover any faults in the locomotive and, if possible, reset from the cab, a computerized fault
indicating system (FIS) has been incorporated. This system consists of a microprocessor which
supervises all running conditions. Together with a display panel in each drivers cab this gives the
driver all the necessary information during fault conditions and also provides possibility to reset most
of the faults from the drivers cab through a push button.

Indian Railways AC Traction Manual volume III [30]

 Annexure 1.05
Functional description of main circuit of WAG-6B/WAG-6C

1. General Outline

Fig.1 shows a simplified diagram of the main circuit. The current is taken from 25 Kv 50Hz
overhead line by pantograph and passes through the main circuit breaker to the primary winding of
the main transformer and then through the ground brushes to wheels and is then to earth via the
rails.
In addition to the four traction windings, secondary windings for auxiliary power system, hotel load &
motor field circuit have been provided.

2. Traction Motor Groups

Traction motor armature circuit is divided into two groups of three traction motors each. The output
from convertor is fed to the traction motors through smoothing reactors in series with each traction
motor.

Power factor correction LC banks are connected across the traction windings.

3. The Convertors
The convertors consist of thyristors and diodes to allow path for the free wheeling current when the
thyristors are not fired. During acceleration, one bridge only is initially fired untill shortly before it is
fully advanced. Then the second bridge is also fired. This procedure is called overlapping control.

Phase angle control of the thyristors will introduce harmonics and because of this, power factor and
psophometric current will vary considerably at different speeds. In order to minimise the influence
on the supply net work , power factor control equipment (PFC) is used.

4. Traction Motors
The traction motors are compound wound motors having a ratio of approximately 60:40 for the
separate field strength to series field strength. Motors are fully suspended in WAG-6B and axle
hung, nose-suspended in WAG-6C. Three motors in parallel are fed from a convertor consisting of
two sequence control bridges shown in Fig,1

5. The Field Circuit

The field circuit arrangement is shown in Fig.2. There is one field convertor for each of the traction
motor groups i.e., three traction motors are fed by one field convertor. During acceleration, the field
current is kept proportional to the armature current until maximum motor voltage reference is
reached. After this the field current is reduced to get a constant power characteristic till the weakest
field strength is reached

The field convertor also performs the required field current control during rheostatic breaking to get
the desired breaking characteristics.

6. Power Factor Correction System

Each traction group has a power factor correction equipment which consists of two independent LC-
links which can be switched on/off through thyristors. The arrangement in shown in Fig.3.
When the primary current of the traction transformer reaches about 100A, the switching thyristors
switch on the PFC unit No.1 of both traction groups to improve the power factor. If the current
increases to about 150A, the 2nd PFC unit is switched on.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [31]

7. Safety Monitoring and Fault Detection

For safety and monitoring purposes, current transformers and breakers are used (Fig.4). To curb
over voltage, a lightning arrestor (LA) is used, limiting the maximum voltage over the main
transformer.The current in all windinds of the main transformer & all motor fields is monitored
continuously, through the use of current transformer (CT).

Should an over current occur on any of the monitoring transformers, the main circuit breaker (MCB)
will open immediately. The potential transformer (PT) is used for monitoring the supply voltage.
When the supply is too high or too low, the MCB is opened. To enable the driver to immediately
discover any faults in the locomotive and, if possible, the reset from the cab, a computerized fault
indicating system (FIS) has been incorporated. This system consists of a microprocessor which
supervises all running conditions. Together with a display panel in each drivers cab this gives the
driver all the necessary information during fault conditions and also provides possibility to reset most
of the faults from the drivers cab through a push button.

Annexure 1.06
Functional description of the main circuit of Thyristor EMU
1. Power Circuits
2. The power circuits are shown in Fig.1.The symbols appearing in it are listed below together
with the location of the equipment.

III. Symbol Description Location

ABB Air-Blast circuit breaker Roof

AF1-3 Auxiliary fuses Main transformer
CMD1-2 Current-monitoring device Contactor case
D1-4 Main diodes Rectifier case
DX1-2 Di/Dt inductors Rectifier case
EAS Earthing switch Roof
EFR Earth fault relay Contactor case
ERF Electronic reference fuse Rectifier case
FRS Forward and reverse switch Contactor case
HFSK1-4 High-frequency surge-suppression capacitors. Rectifier case
LA Lighting arrestor Roof
M1-4 Traction motors Bogies
MC1-4 Motor contactors Contactor case
MOR1-2 Motor overload relays Contactor case
MT Main Transformer Underframe
P Pantograph Roof
POCT Primary-overload current transformer Roof

Indian Railways AC Traction Manual volume III [34]

POR Primary-overload relay Contactor case
SOCT Secondary-overload current transformer Rectifier case
SOR Secondary-overload relay Contactor case
SSF1-4 Surge-suppression fuses Rectifier case
SSK1-4 Surge-suppression capacitor Rectifier case
SSR1-2 Surge-suppression relays Rectifier case
SST1-2 Surge-suppression transformer Rectifier case
SSZ1-4 Surge-suppression resistors Rectifier case
SX1-4 Smoothing inductor Underframe
T1-4 Thyristors Rectifier case
WSR1-2 Wheel slip relays Contactor case
WSZ1-4 Wheel slip resistor Contactor case

3. Description of Circuit

The supply current is taken from the overhead conductor by the pantograph P, through the air-blast
circuit-breaker ABB and the H.T. bushing and cable, to the primary winding of the main transformer
MT. The return circuit to the running rails is via an insulated earth cable to the axle earth-brushes
fitted on each traction-motor axle-suspension. Also connected to the high-voltage end of the
transformer primary winding are a two pole earthing switch EAS and a lightning arrestor LA.

A primary-overload relay POR with its associated current transformer POCT protect the main
transformer. The main transformer has two equal secondary winding supplying two half controlled
asymmetrical bridges T1, T2, D1, D2 and T3, T4, D3, D4 the dc outputs of which are connected in
series. The rectifier bridges supply the four traction motors M1-M4 which are permanently
connected in series parallel configuration, with their fields and compoles arranged in the centre
(virtual earth position). The main smoothing inductor SX is divided into four sections, so that in the
event of a motor fault, a high impedance is in circuit and motor cut-out is simplified. The output
voltage of the rectifier is controlled to maintain a constant current in the armatures during
acceleration, the current being measured by current monitoring devices CMD1-2. Overload
protection is provided by the two current-monitoring devices and two motor-over load relays MOR1-
2.

A single twin-circuit linear reversing switch FRS is used. Motor isolation is provided by the motor
contactors MC1-4 and the motors can be cut out in pairs. Wheel slip detection is provided by
voltage-sensitive circuits comprising resistors WSZ1-4 and wheel slip relays WSR1-2.

The power circuit includes four surge-suppression circuits:

1. High frequency surge-suppression capacitors HFSK1-4 connected between each secondary

terminal and earth.
2. Resistor/capacitor snubber-circuits connected across each power device in the main
bridges.
3. Limiting inductors DX1-2 for rate-of-rise of current.
4. Main surge suppression networks SSF1-4, SSZ1-4,SSK1-4. These networks are connected
in pairs across each secondary winding; a failure of any component in these energizes one of the
surge-suppression relays SSR1-2

The main rectifier bridges are protected from overload by the secondary-overload-relay circuits
SOR, SOCT1-2

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [35]

 CHAPTER II

MAINTENANCE OF ROLLING STOCK GENERAL

II. Para No. Subject

30200 Shed Organization

30201 Duties of Shop Superintendent/Chief Traction Foreman (Maintenance)
30202 Duties of Electrical Foreman (Planning and Progress Office)
30203 Duties of Section Supervisors
30204 Distribution of Work Load in the Shed
30205 Technical Section
30206 Specification Updating Section
30207 Test and Trials
30208 Materials Management
30209 Demarcation of responsibility between Sr. DEE (RS)/DEE and AEEs
30210 Job Cards
30211 Shed Facilities
30212 Modification of Design for Rolling Stock
30213 Records and Registers to be maintained in Loco/EMU Sheds
30214 Unusual Occurrence Reports
30215 Periodical Review Information
30216 Daily Loco/EMU Position

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [37]

 CHAPTER II

MAINTENANCE OF ROLLING STOCK GENERAL

III. 30200 Shed Organization

1. At the head of an electric loco (or EMU) shed will be Senior Divisional Electrical
Engineer (Rolling Stock ) whose duties will be generally as defined in para 10108. He will be
assisted by one or more officers in lower ranks depending upon the work load.

2. The organization pattern in a loco shed will be generally as shown below :

Sr. DEE(RS)

DEE/AEE(RS)-I DEE/AEE(RS)-2 AEE/RS ACOS ACMT

(Maintenance) (Maintenance) (General) (Stores (Laboratory)
Depot)
IOH, AOH & Heavy Quality Assurance General
Repairs Inspections, Minor works.
Schedules
M2, M6 Light repairs Machine Shop
Millwright
E4, E5, E6 Testing and E7, E8,
OUT-TURN M4,M7
S1, S2, S3
Technical PPO
Matters Drawing
Office
Computer M1, M3, M5
Utilization E1, E2, E3

30201 Duties of Shop Superintendent/Chief Traction Foreman (Maintenance)

He being supervisor in charge of the loco shed directly under the control of DEE/ AEE (RS), as the
case may be, will be responsible for the maintenance of locos. His chief duties are:

1. To guide and instruct supervisors and men under him in the correct methods and schedules
laid down for maintenance and repairs.
2. To keep a close watch on maintenance so as to reduce the unscheduled withdrawal of locos
to the minimum and to watch the performance of equipment involved in frequent troubles.
3. To initiate appropriate steps for recommissioning locos out of service.
4. Execution of various approved modifications and to maintain locos and the loco shed in a
clean condition.

Indian Railways AC Traction Manual volume III [38]

5. To keep a watch on the availability of stores for maintenance and modifications and to
initiate appropriate steps for timely recoupment.
6. To ensure efficient maintenance of the shed plant and machinery and ancillary services.
7. To coordinate with TLC and TF(R) regarding withdrawal of locos for shed attention, POH
and nomination of relief locos from shed.
8. To coordinate with the Training School regarding relief of staff for training and refresher
courses.
9. He will be the stock holder of all equipments on locos, assemblies and sub-assemblies and
unit exchange spares.

30202 Duties of Electrical Foreman (Planning and Progress Office)

1. To maintain liaison with the operating wing and ensure timely availability of locos from the
shed.
2. To plan the scheduled and unscheduled repairs of locos to the shed as required, keeping in
view the shed capacity and proper utilization of inspection, lifting and heavy repair berths.
3. To issue job cards and to coordinate the working of the sections so as to ensure timely turn-
out of the locos after attention / repair.
4. To maintain necessary documents to enable scheduled attention to various locos and for
revision of maintenance practices and instructions.
5. To keep a watch on tests and trials and performance of modified equipment and
maintenance of requisite records in this connection.
6. To maintain the History Register, Equipment Cards, Modification Charts and other
prescribed records.
7. To coordinate with the workshops regarding release of locos for POH and special shop
repairs and to arrange for dispatch of requisite information and records to shops.
8. To maintain statistics of engine-kilometers, failure records etc.
9. To keep a record of wheel wear and to programme for tyre-turning.
10. Furnishing shed statistics to HQ office

30203 Duties of Section Supervisors

Each of the section mentioned in 30200 will be under a supervisor of appropriate rank who will be
directly responsible for the following:
1. He will scrutinize the job card for the loco received for inspection/unscheduled repairs,
carefully study the work to be carried out and based on his personal inspection, list out
additional items of work, if any, for approval as explained in para 30210.
2. He will allot the work to the staff under him with special instructions, if any.
3. He will ensure that the work is carried out within the time allotted and the loco released in
time.
4. The supervisor will maintain a record of work done by staff with the purpose of taking
corrective action in the event of reported malfunctioning of the equipment immediately after
overhaul/repair.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [39]

5. He is responsible for drawing, distributing and recording of all stores required by his section,
as well as any tools and testing instruments.
6. Before returning the job card in token of having completed the work, he will satisfy himself
that all work has been done satisfactorily. To ensure this he will make frequent checks while
the work is in progress.
7. He will ensure necessary co-ordination with other sections as well as with PPO.

IV. 30204 Distribution of Work Load in the Shed

Even though the classification of section in different Railways varies, the work load arrangement is
typically as under:

E1: a) To carry out preventive maintenance schedule inspections and overhauling

schedules on battery charger, rectifier blocks.
b) Trouble shooting and investigations of Unusual Occurrence Reports (UOR),
withdrawal and failures of Electric Locos/EMUs.
c) To oversee checking and complete testing of Elect. Locomotives nominated for
VIP/Superfast trains and special trains.
d) To oversee checking and complete testing of the nominated locos /EMUs by PPO.

E1 section shall have a Quality Assurance Group consisting of competent supervisors

and artisan staff who will carry out superchecking on nominated
scheduled/unscheduled locos.

E2: a) Test before and test after of all schedule inspection.

b) Electrical inspection and repairs (minor) of parts noticed defective during inspections
i.e. head lights, flasher lights, electrical equipments in BA panels, TFP, RPS, SL,
Programme switches, MP, EMC, DBR, SMGR, CGR, tap changer, cables, cable
sockets and cable connections.

E3: a) To carry out scheduled inspection, unscheduled repairs, modifications, overhauling of

traction motors.
b) Connection and disconnection of traction motors before lifting and after lowering.
c) To carry out scheduled inspection and unscheduled repairs, modifications and
overhauling schedule of auxiliary motors.
d) To disconnect and connect auxiliary motors while removing/refitting during
overhauling scheduled and unscheduled repairs.

E4: a) To carry out scheduled inspection, unscheduled repairs, modifications and

overhauling schedule on all delicate and precision electrical equipment like relays,
speedometers, ammeters, voltmeters and circuit breakers etc.
b) To disconnect and connect speedometer connection /DJ connections during
unscheduled repair.

E5: Major repairs and overhauling of EP and EM contactors, smoothing reacator,RPS,

flasher light, MP, TFP oil filtration, CGR,SMGR and tap changer (during IOH
schedule / unscheduled visits) and modifications.

E6: a) Removal and fitment of EMCs, EPCs, RPS, DBR during AOH schedule.

INDIAN RAILWAYS AC TRACTION MAN UAL VOLUME III [40]

 b) Removal and fitment of SL,SMGR, Tap changer during IOH schedule.
c) Overhauling of BA panel, head light, TK panel, SB panels, rotary switch board and
switches during AOH/IOH schedule.
d) Cleaning of cable junction boxes and cables during overhauling.
e) Overhauling of SMGR and GR during AOH schedule.

E7: Recabling work, partial or full

E8: Electronic labs and PCBs etc.

M1: a) Inspection and running repairs of mechanical parts, under frame, break gear, wheels
and axles,buffing gear, body doors and windows, locks, side glasses, look out glasses etc.
b) Special checks
c) Carry out pre-summer, pre-winter and pre-monsoon checks.

M2: AOH/IOH schedule work on i.e. centre pivot, side bearers, roof, buffing gear, cattle guard,
rail guard, side glasses, look out glasses, doors, windows and locks.

M3: Inspection, repairs and overhauling of pantograph.

M4: a) To supervise the work of machine shop.

b) To supervise proper functioning of Tool Room and its upkeep.
c) To supervise and execute the re-profiling of wheel sets of electric locomotives on the
pit wheel lathe and its preventive maintenance .

M5: a) To carry out scheduled inspection and overhauling schedules on all pneumatic
equipment except compressors and exhausters.
b) Testing of all pneumatic equipments on test bench after overhauling.
c) To carry out scheduled inspections,unschedule repairs, modifications and
overhauling of compressors, exhausters and auxiliary compressors.
d) Removal and fitment of compressors, exhausters and auxiliary compressors during
overhauling, scheduled/unscheduled visits.

M6: a) Mechanical disconnection and connection, lifting and lowering of locomotives.

b) Heavy repairs and overhauling of bogies and other mechanical components like
wheel sets, springs, axles boxes etc.
c) Traction motor assembly and dis-assembly.

M7: Remetalling of suspension bearings.

PPO: a) Receipt and dispatch of locomotives/EMUs for their scheduled and unscheduled
visits.
b) Planning of scheduled and unscheduled repairs of locomotives / EMUs.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [41]

 c) Monitoring the performance of development equipment.
d) Maintenance of history books, history cards of equipment fitted.
e) Keeping liaison with RSO regarding calling of locomotives/EMUs for scheduled/
unscheduled work.
f) To keep record of wheel wear and to programme reprofiling.
g) To scrutinize Electric Loco/EMUs log books on arrival of locomotives and issuing all
job cards to the section supervisor for proper attention to the defects and to ensure
that the work is done when the job cards are returned.

S1: All works pertaining to procurement of stores and liaison with HQ for timely procurement of
stores and upkeep of custody stores for not-stock items.

S2: Specification updating section.

S3: Tests and Trials sections.

G: a) Electric and mechanical millwright sections.

b) Maintenance of cranes and M&P itmes
c) General upkeep of shed.
d) Road Transport.

Technical Section

All technical correspondence of the shed i.e. outside and with in shed, updating and feeding of
technical data in computer etc.
Laboratory

Physical and chemical testing of all items including ultrasonic testing of axles and shafts.
Drawing office

All drawing work, preparation of office estimates etc.

Computer Section

Operation of computer collection of data and processing.

V. 30205 Technical Section

The chief responsibility will be :

i) Keeping track of every failure of components. The failure should be analyzed in detail on
the basis of which should emerge the analysis of the causes of failure, suggestions for
improvements, modifications etc.
ii) Documentation of all technical information.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [42]

 iii) Keeping a watch that the maintenance instructions issued to the shed staff are up-to-
date and ensuring that the instructions are explained to the concerned staff.

VI. 30206 Specification Updating Section

This section will be responsible with the drawing office, to update list of specifications and drawings
against which different items are to be ordered and for issuing stocking advices to Stores
Department. It should also keep records regarding consumable stores so as to pin-point any
abnormal consumption for effective investigation.

VII. 30207 Tests and Trials

The observations regarding tests and trials should be carefully documented for the benefit of
improving specifications or modifications to inspection schedules. The necessary documents should
be centralized and kept in the PPO.

VIII. 30208 Materials Management

1. This subject is dealt in detail in volume I. A few relevant items are being mentioned here.

A. The various components sub-assemblies and spare parts shall be purchased from the
original/approved supplier of equipment. Railway may however make out a compendium of
approved suppliers for each item/equipment, based on RDSOs/production units list. Any
variation from the same shall only be permitted personally by Chief Electrical Engineer.
B. For bringing in new suppliers in the compendium of approved suppliers, CEE may personally
authorise use of untried and untested equipment for field trials. Special care is needed while
approving any new make and type of brushes for traction motors.
C. Storage of Rubber Components.

Storage procedure in general for any type of rubber components are given below:-

i) Rubber components should be kept away from direct sun light preferably in dark place.
Direct sunlight causes much faster degradation of the rubber components.
ii) They should be stored in a cool place as far as practicable, preferably below 300 C.
iii) The humidity of the storage condition should not be such that condensation of moisture
takes place on the surface of the material.
iv) In the vicinity of these materials, any loose electrical connections should be avoided, as
these cause production of ozone which adversely affects rubber.
v) Rubber materials should be stored away from contact with certain materials particularly
those containing copper and manganese which act as poisoning agents, aiding their fast
degradation.
vi) Under no circumstances rubber materials should be stressed during storage. The portions
under stress undergo deformations with permanent set leading to degradation. The
materials should be stacked in such a way so that any super-imposed stresses are
substantially avoided.
vii) Any contact with grease or oil should be avoided as these cause swelling, softening and
deterioration of rubber materials.
viii) French chalk should liberally be applied on the surface of rubber materials.

Indian Railways AC Traction Manual volume III [43]

ix) Great care is to be exercised so that the material is used in the order of their receipt in the
stores. The rubber material whether under storage or in use continues to deteriorate. The
only difference is that under service condition, deterioration is much faster. Every moment of
storing is at the cost of useful life and prolonged storage of the material may render it
unserviceable due to progressive deterioration.

IX. 30209 Demarcation of Responsibility between Sr.DEE (RS), DEE and AEEs

The DEE / AEE (maintenance) will be responsible for day to day activities in the shed including
unscheduled attentions and scheduled inspections. He will be particularly responsible for induction
of any new type of stock in the shed and ensure that the maintenance schedule for such stock are
finalized in the shortest possible time.

The Sr.DEE will in addition concern himself with the broader aspects of work and forward planning
such as watch-out for organizational shortcomings, indenting and progressing the procurement of
forward delivery spares, maintaining a close watch on the functioning of the PPO and above all
exercising vigilant technical control over unusual occurrences, recurring failures and unscheduled
booking of locos to the shed and shall be in close liaison with Sr.DEE(OP).

X. 30210 Job Cards

For each loco/EMU received in a shed for scheduled or unscheduled attention, the PPO will issue a
job card in proforma 2.01 to each section incorporating the following:

a) The nature of inspection (IA, IB etc.) Refer to chapters III and IV.

b) Additional items of work to be carried out on the loco/EMU by the section, based on booked
defects, pre-inspection of the loco or planned modification.

c) The time by which the loco/EMU is required to be released.

Based on his own inspection, if the Section Chargeman finds that any items in addition to those
mentioned by PPO are required to be attended to, he will get such work approved by TF(M) and get
the additional items also entered in the job card by PPO. The job card will thus contain a complete
record of all work done on a loco during its visit to the shed. When the work is completed, the
Section Chargeman will sign the job card indicating the time of completion of the work and the
names of the workers. The loco/EMU should be offered by the PPO for final inspection by E1only
after job cards from all sections have received back duly signed by the respective Chargeman.

XI. 30211 Shed Facilities

Machinery and plant for Loco Sheds

The list of machinery and plant recommended for a loco shed to cater for inspection, maintenance,
overhaul and repairs including IOH of locomotives is indicated here under.
List 1 General Purpose Machine and Tools
A. Machine Section
1. Lathe 250 mm swing, 1500mm between centres 1
2. Lathe 150 mm swing, 1000mm between centres 1
3. Portable tool post grinder for 12mm to 100mm dia wheel 1
4. Radial drilling machine 1
5. Universal milling machine 900mm x 300mm table with index 1
6. Shaping machine, 600mm stroke 1
7. Do-all band saw 1

Indian Railways AC Traction Manual volume III [44]

8. Pillar drill (40mm hole in M.S.) 1
9. Power hacksaw to cut 150mm dia M.S. 1
10. Floor grinder 450mm dia wheels 1
11. Pipe threading machine 1
12. Pipe threading die sets 2
13. Pipe bending machine 1
14. Hand operated shearing machine 1
15. Marking table 1

Relay Room

1. Sensitive drill (20mm hole in M.S) 1

2. Watchmakers Lathe 1

Welding and White-metalling Section

1. Portable welding set 300A. dc. 1

2. Portable transformer welding plant 350A.ac. 1
3. Oxyacetylene welding and cutting set with 25 sets of
cylinders for oxygen and acetylene 1
4. Eutectic weld deposit torch set 1
5. Smiths hearth 1
6. Smiths anvil and swage blocks. 2
7. Centrifugal white metalling plant (shop made) 1
8. Electric Furnace for melting bearing metal 1

Painting Section

Spray guns portable compressor unit and reservoir with 2 spray guns 1
Tool Room

1. Portable electric tools : grinder, drills, Wrenches 3

2. Torque wrenches 5set
Compressed Air

Air compressor complete with air drier and filter after-cooler,

Reservoir, outlet valves 250cfm, 9kg/cm2
2
Vaccum cleaning, Water Pumps and Sanding.

1. Portable vaccum plant 2

2. Filter cleaning plant (shop made) 1
3. Pit dewatering portable electric pump 1
4. Booster pump for washing lines 2
5 sand drying and sieving plant 1
H. Other Electrical Equipment
1 Battery charger 2
2 Portable battery charger 1
3 Loading resistor for battery 1
4 Distilled water plant (Electrical ) 2
5 Oil centrifuging and filtering plant 1

INDIAN RAILWAY S AC TRACTION MANUAL VOLUME III [45]

6. Pneumatic crimping tool for power cables 1set
7. Hand crimping tool for control cables 2set
8. Panto assembly fixture (shop made) 1set

List 2 - Special Purpose Machines and Tools

A. Bogie wheel sets.

1. Pit type wheel lathe 1
2. 50 tonne hydraulic press 1
3. 10 tonne hydraulic press 1
4. Horizontal boring machine 1000mm x 1000mm table 1
5. Hack `s burners 2
6. Bogie squaring jig 1set
7. Wheel profiling set (tool room ) 1
8. Grease guns and lubricating equipment
(for each type of oil or grease ) 3set
9. Bearing extractor for transmission gears 1set
10. Lifting beam for locomotive body with stand 2
11. lifting tackle for bogie 1set
12. Spring testing equipment 1
13. Shock absorbers and snubbers testing rig 1
14. 25/30t hydraulic jacks for attending athermos bearing 5

B. Traction Motor and auxiliary machine Rewinding section

1. Pinion extractor 2
2. Pinion heating oil bath or induction heater 2
3 . Auto transformer rectifier unit 100V,150Adc 1
4. Commutator turning lathe 1
5. Mica undercutting and chamfering machine for armature 1
6. Armature banding lathe 1
7. Dynamic balancing machine for armature 1
8. Vacuum impregnating plant 1
9. Baking oven 200 degree C with trolley 2
10. Baking oven 40-60 degree C with trolley 2
11. Baking dynamometer with test bed 1
12. Contator and relay coil winding machine 2
13. Brazing tongs with transformer 1
14. Brazing extractor 2set
15. Hand operated shearing machine for insulation 1
16. Traction motor assembly fixture, for each type of motor 1set
17. Grease guns 2set
18. Commutator electric soldering irons. 6
19. Surge tester 1
20. Dynamic balancing machine for auxiliaries 1
21. Bearing Extractor and inserter for traction motor and auxiliary machineries 1
22. TIG Welding kit 1

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME III ( 46}

 List 3- Testing and Measuring Instruments and Panels

A Testing panels.
1. Test and calibration panel with meters for each type of relay. 1
2. Test and calibration panel with meters for speedometers 1
3. Test panel with meters for auxiliary machines 1
4. Loading dynamometer with test bed for auxiliaries 1
5. Test panel with meters for contactors, circuit breakers 1
6. Brake and pneumatic equipment test panel including air
compressor 500 litre per min. 15kg/cm2 1
B. Testing and Measuring Instruments
1. 2500v megger 2
2. 500v megger 6
3 Universal multimeter 6
4. Portable voltmeter dc 3
5. Portable voltmeter ac 3
6. Portable ammeter ac 3
7. Portable ammeter ac 3
8. Current transformer set 20 to 2000 A 2set
9. Set of shunts for dc ammeter 75mV 2000A 2set
10. Millivoltmeters 0-75mV 2
11. Vacuum tube volt meter 1
12. Cathode Ray Oscilloscope 10cm display double beam 1
13. High voltage tester 0-75kV 1
14. High voltage tester 0-15kV 1
15. Oil tester 0-50kV 1
16. Current injection set 2000A, 3Vdc 1
17. Silicon diode tester 3
18. Ductors 2
19. Contact pyrometer (0-5000 C ) 3
20. Ultrasonic crack detector 1
21. Zyglo ultraviolet light crack detector 1
22. Brinell hardness tester 1
23. Shore hardness tester 1
24. Spring balance 0-1 kg 2
25. Recording ammeter 2
26. Recording voltmeter 2
27. Spring balance 0-3 kg 2
28. Spring balance 0-5 kg 2
29. Spring tester 1
30. Battery voltmeters 2
31. Anemometer 2
32. Manometer 2
33. Vibration meter 1
34. Capacitance and inductance bridge 1
35. Clip-on ammeters 0-5-10-25-10 250A 2
36. Dial gauges, vernier caliper, micrometers and feeder gauges. 2
37. Revolution counter 3
38. KWh meter with accessories for mounting on loco 2
39. Electric coil tester 1
40. Electric timer 1
41. Portable relay testing kit 1

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III (47)

42. Commutator profile recorder 1
43. Stop watch 2
44. Illumination meter 1
45. Wheat Stone bridge 1
46. Distilled water tester 1
47. Stroboscope / tachometer 1
48. Gear teeth micrometer 1
49. Tan-delta measuring instrument 1
50. Dissolved Gas Analyser 1

List 4 Lifting, Handling and Transport equipment

A Lifting and Handling Equipment .

1. 45 tonne electric overhead travelling crane with 6 2 no.

tonne auxiliary hoist (50 tonne cranes for 132 tonne locomotives)
2. 25 tonne EOT crane with 6 tonne auxiliary hoist 1
3. 15 tonne EOT crane 1
4. 1.5 tonne monorail with electric hoist (in Stores Depot ) 2
5. Lifting tackles for transformer , traction motor armature, 1set
,loco underframe, roof sections, bogie, wheel set, loco,body etc.
6. 1 tonne monorail with chain pulley hoist 2
7. 2 tonne chain pulley hoist 3
8. capstan units 3 tonne 5
9. Tirfor 3 tonne 3
10. Hydraulic jack 50 tonne with traversing bases 1set
11. 50. Tonne screw jack with traversing bases 1set
12. 20 tonne high lift hydraulic jack with traversing bases 1set
13. Accommodation bogies

B. Transport facilities

1. 2 tonne fork lift battery truck 1

2. 1 tonne pallet battery truck 1
3. 1 tonne material hand trolley platform type ( rubber tyres ) 3
4. 1 tonne hand pallet trolley 3
5. 7.5 tonne trolley on rail ( for traction motors ) 2
6. 5 tonne truck 1
7. jeep with trailer 1
8. Departmental wagon for armature 1
9. Departmental wagon suitably modified for transportation of
wheels and bogies 2

C. Weighing Machine/ scales.

1. weighing machine 1 tonne (Stores Depot ) 1

2. weighing machine 50 kg ( stores Depot ) 1

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUME III (48)

 List 5 - Work Benches, Lockers etc.

1. Workmen's tables, battery charging benches, armature trestles.

2. Bench Vices .
3. Individual fitters tools.
4. Locks and keys for workmen.
5. Steel almirahs and stores racks.
6. Steel tables and chairs cardex boards, filing cabinets, index cards cabinets, typewriter,
calculating machines for PPO's office
7. Tables chairs for offices and supervisors, almirahs, filing racks, cabinets, typewriters, duplicator,
drawing office, and Ferro printing equipment.
8. Time office equipment, time clock, ticket filing racks, tables and chairs.
9. PCB testing kit.

30212 Modification of Designs for Rolling Stock

Railways should not adopt any new design or modify the existing approved designs except for trials,
without the prior approval of RDSO.

Procedure for Initiating and Progressing Modifications

1. One shed which has the bulk of the holdings of a particular class of loco / EMU will be
nominated by the RDSO, in consultation with the Railway, as the parent shed for that class of
loco /EMU.
2. Each Railway will continue to tackle operating and maintenance problems as hitherto, but will
also furnish complete particulars of all problems and failures on each class of loco /EMU to the
corresponding parent shed and RDSO together with the modifications evolved by it and further
suggestions, if any.
3. The nominated parent shed will then collate all the information in regard to each type of failure,
study the merits of the different improvements suggested from all angles and submit
recommendations to the CEE of the Railways, giving. full particulars of the most satisfactory
improvements / modifications after they have been actually tried out in service and found
feasible. When any defect is found to be intractable and expert investigation is necessary, a
comprehensive note on the subject should be prepared and submitted by the parent shed to the
Headquarters Office. CEE will arrange to forward the considered recommendations to RDSO.
4. The recommendations received from the parent Railway will be subjected to a further scrutiny
and analysis by the different wings of the RDSO after which final instructions regarding the
standard approved method of modification / improvement will be issued to all concerned, giving
an identification serial number to each with full details and drawings required for carrying it out.
5. On receipt of the instructions from RDSO, each user Railway will arrange to carry out the
modifications on priority on locomotives / EMUs until the work is completed in all locomotives/
EMUs. Progress of implementation of the modifications will be regularly sent to CEEs office by
each shed and CEEs office in turn will send a quarterly report of progress to RDSO.

30213 Records and Register to be Maintained in LOCO / EMU Sheds

Particulars of some of the basic records to be maintained by sheds are given below:

1 History Book - For each electric locomotive / motor coach, a History Book should be maintained in
the loco / EMU shed by the Planning and Progress Office, (PPO). The History Book should have
separate pages allotted for recording the items listed below in the proforma shown against each.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [49]

a) Pre-commissioning details:
i) Contract or order number against which received.
ii) Date of despatch/shipment.
iii) Date of receipt by the Railway.
iv) Date put into service.
v) Particulars of tests and trials carried out and reference to reports on these.
vi) Particulars and serial number of major equipment initially provided.
vii) Particulars of any major defects rectified or modifications carried out prior to commissioning.

b) Defects and failures during the Guarantee period:

-------------------------------------------------------------------------------------------------------------------------------------
Sl. Date Nature of Action taken Reference to reports
No. Defect to rectify sent to Manufacturers/
Production Unit/RDSO etc.
-------------------------------------------------------------------------------------------------------------------------------------
c) Statistical failures
-------------------------------------------------------------------------------------------------------------------------------------
Sl. Date Brief details Repercussions Action Reference
No. Of failure on traffic taken to detailed reports.
-------------------------------------------------------------------------------------------------------------------------------------
d) Non-statistical failures:

The same proforma should be followed as for (c).

e) Progressive record of kilometres earned:
-------------------------------------------------------------------------------------------------------------------------------------
Month and year Kilometres earned Cumulative Remarks
during the month kilometers earned
upto end of month
-------------------------------------------------------------------------------------------------------------------------------------
f) Availability for traffic
-------------------------------------------------------------------------------------------------------------------------------------
Month and year No. of hours Percentage Remarks
available for traffic. availability
-------------------------------------------------------------------------------------------------------------------------------------
g) Modifications (Electrical):
-------------------------------------------------------------------------------------------------------------------------------------
Sl. Description of modification Authority Date of completion on
No. This loco/motor coach.
-------------------------------------------------------------------------------------------------------------------------------------
h) Modifications (Mechanical):

This should be as maintained in the same proforma as for (g).

i) Inspections, Overhauls and Unscheduled Repairs.

-------------------------------------------------------------------------------------------------------------------------------------
Schedule Time in Time out Particulars of special
work
Carried out, if any
-------------------------------------------------------------------------------------------------------------------------------------
j) Changes in Main Equipments:
PPO should record particulars of replacement of complete units of main equipment such as Traction
Motors, Transformer, Rectifier, Pantograph etc., together with serial numbers of the original and
substituted items and reasons for replacement.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [50]
 k) Record of mechanical clearances with bearing on safety.

This History Book should be sent along with the loco/EMU to the workshop when the
loco/EMU is booked for POH for heavy repairs and should be received back with the loco/ EMU.
The workshop should enter details of work done and modifications, if any carried out.

2. Equipment Cards: In the case of major items such as traction motors, transformers,
rectifiers, circuit breakers, pantographs, tap-changers, auxiliary machines, bogies, wheels,
etc. Equipment Card should be maintained in the shed by the PPO so as to have for ready
reference the History of the equipment. Individual Cards should be maintained for each unit
of major equipment and the individual cards may be stored grouping them either equipment
wise or loco-wise as convenient. The equipment cards should contain details as shown
below:
EQUIPMENT CARD NO. .
Description of Equipment: Serial No.
Date of commissioning : Loco/Motor Coach
No. in which
initially installed
EQUIPMENT MOVEMENTS
_______________________________________________________________________________
Serial No. of Loco / Emu
Date In Out Reasons for movement
_______________________________________________________________________________
HISTORY OF OVERHAULS
_______________________________________________________________________________
Date removed for Date overhaul Particulars of work
Overhaul completed
_______________________________________________________________________________
HISTORY OF SPECIAL REPAIRS
_______________________________________________________________________________
Date removed for Date repairs Nature of repairs
Repairs completed
_______________________________________________________________________________

30214 Unusual Occurrence Reports

A report indicating failure, withdrawal and any other technical abnormality in locomotive
/EMU observed on line is called Unusual Occurrence Report (UOR). This should be made in each
case recording in full detail as to what has actually happened and what steps should be taken in
future to avoid recurrence.
While suitable proforma may be laid down by each Railway to suite local requirements, the
UORs should basically contain the following details:
i) Report of Drivers/Motorman detailing all his observations, together with remarks of TF (R)
and Officers incharge of operation.
ii) Observations made by Maintenance Organization i.e. Technical Investigation section,
Maintenance Foreman and AEE/DEE(RS). A sample proforma is appened (Proforma 2.02).

UORs should be serially numbered for each calendar year to identify the homing shed, class of loco
and serial number of the occurrence for the class of loco/EMU during the year e.g.
TATA/WAG4/3/90. A copy of all UORs should be forwarded to CEEs office periodically.

INDIAN RAILWAYS-AC TRACTION RAILWAYS-VOLUME-III [51]

30215 Periodical Review Information

Each homing shed should maintain requisite records and compile the following statistical
information for each month. While the report on availability and reliability of the locomotive should
be submitted to CEE every month, the report on the cost of repairs and maintenance should be
submitted quarterly.
1 Availability and Reliability
Locomotives
1. Average authorized stock (on allotment basis)
2. Average total number on line (on allotment basis)
3. Average number under or awaiting repairs (on allotment basis)
4. Average number effective (fit for use) (on allotment basis)
5. Actual number in good repair stored (on allotment basis)
5a. Average number available for use (on allotment basis)
6. Average number in use
7. Average number of engines on the line for operation
8 Percentage of total engine hours spent
9. Engine km per day per engine in use on individual services
10. Engine km per day per engine on line on individual services
11. Engine km per day per engine in use on all services
12. Engine km per day per engine in use on line (on allotment basis)
13. Engine failure

EMUs
1. Average authorized stock (on allotment basis)
2. Average total number on line (on allotment basis)
3. Average number under or awaiting, repairs (on allotment basis)
4. Average number effective (fit for use) (on allotment basis)
5. Actual number in good repair stored (on allotment basis)
5a. Average number available for use (on allotment basis)
6. Average number in use
7. Train km, passenger
8. Hours
9. Vehicle km (in units)
10. Train Usage
11. Vehicle used
12. Motor coach failures
13. Gross tonne km
14. Power used

II Cost of Repairs and Maintenance

1. Engine km
2. Cost of repairs and maintenance per Engine km
3. Cost of repairs and maintenance per EMU stock (in units)

30216 Daily Loco/EMU Position

1. The Daily Loco/EMU position at 00.00 Hr, will be put up to CEE next morning. Over the years
various railways have evolved their own proforma depending upon the local operating
conditions.
2. The proforma as used on SE Railway indicating the Daily Loco position is enclosed (2.03).
3. The proforma as used by Eastern Railway indicating the EMU position is also enclosed (2.04).
4. Railway may evolve their own proforma based on these proformae.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME 111 [52]

 Job Card
Electric Traction Rolling Stock Proforma 2.01
_______________________________________________________________________________
Job Homing Locomotive Location Head of Signature Working Date Date
Card Shed No. of Loco Allocation of P.P.O. Team No. of of
No. Foreman/ELC issue Receipt
_______________________________________________________________________________
Nature of work
to be done

_______________________________________________________________________________

Particulars of
work

_______________________________________________________________________________

Details of Approxi mate

materials used Expenditure

_______________________________________________________________________________
Name of Worker

Signature of Chargeman Signature of Elect.
Foreman

Signature of Worker

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [53]

 PROFORMA 2.02
UOR NO ............
....................................RAILWAY
UNUSUAL OCCURRENCE REPORT FOR ELECTRIC LOCOS/EMUs

Date..............

-------------------------------------------------------------------------------------------------------------------------------------

A. Driver's Report

1. Loco / Motor coach No.

2. Train No. and Time

3. Place of occurrence

4. Train Load
5. Catenary Voltage
6. Speed of train
7. Gradient at the place of occurrence
8. Weather conditions
9. Brief Description of occurrence

B. Observations of Operating Section'

C. Observations of Maintenance Staff / Technical Investigation Section.

D. History of Locomotive / Motor coach Involved

1. Last inspection date:

2. Commissioning / IOH date:
3. Any special repair carried out on this loco / EMU:
4. Kilometers earned after last IOH:

E. Remarks of Sr. DEE / DEE (RS)

1. Findings regarding causes of failure or damage:

2. Responsibility of staff:
3. Recommendations for modifications or improvement to equipment or maintenance schedule or
operating instructions:
4. Action taken for rectification:
..........................
Sr.DEE / DEE (RS)

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [54]

 PROFORMA 2.04

DAILY POSITION OF EMU COACHES

DATE

Availability HWH SDAH Punctuality HWH SDAH

i) No. of units in service i) Overall

ii) No. of units under repair ii) Progressive

iii) No. of M/Cs sent to KPA

iv) No. of T/Cs sent to KPA

v) % ineffective M/C

vi) % ineffective T/C

vii) No. of M/C's with TM isolation & reasons.

CTLC/TLC's Signature

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [58]

 CHAPTER III

MAINTENANCE AND OVERHAUL SCHEDULES OF LOCOMOTIVES

Para No. Subject

30300 Maintenance and overhaul Schedules of Locomotives

30301 Alterations in Maintenance Schedules

30302 Scheduled Inspections

30303 Technical Instructions

30304 Engine Fitness Certificate

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [59]

CHAPTER III

MAINTENANCE AND OVERHAUL SCHEDULES OF LOCOMOTIVES

30300 Maintenance and Overhaul Schedules of Locomotives

Indian Railways have gained considerable experience with the maintenance of electric locomotives
since 1960. Based upon the safety requirements, various checks have been evaluated and already
standardized. Also, based upon investigations into failures instructions (SMIs) are issued by RDSO.
Even for new type of locomotives, standard equipment like pantographs, circuit breakers etc.,
continue to be used and established maintenance practices for such equipments will, therefore, be
applicable.

The scope of maintenance work to be followed in each maintenance schedule is arrived at, based
upon the following:-

i) Maintenance Instructions supplied by locomotive manufacturer for a new type of rolling

stock. Copies of these manuals will be made available for reference by maintenance staff.

ii) Maintenance Instructions that are evolved on zonal railways for standardized equipments.

iii) Specific instructions already laid down regarding safety / fire prevention requirements etc. of
the rolling stock.
iv) Experience on the system taking into account environmental conditions in which electric
locomotives are expected to perform satisfactorily like temperature, humidity, dust, etc.

On the above lines, maintenance schedules for electric rolling stock of different classes and types
already in service have reached an optimum level. However, there may be necessity for marginal
changes as dictated by further service experience.

As far as new types of electric locomotives and their sub-assemblies that may be introduced from
time to time, the principles enumerated above are to be followed for arriving at optimum scope of
work consistent with periodicity of prescribed schedules.

30301 Alterations in Maintenance Schedules

Presently individual railways might have made minor alterations in the schedules based upon their
own experience. Considering the wide variations in operating and duty cycles and environments as
experienced in different systems, this would be considered logical. However, the recent trend is to
enlarge the field of operation of electric locomotives. Thus today electric locomotives of one system
are running in other systems. Thus alterations in schedules based upon local experience would
have to give way to standardization of schedules so that the locomotives of one system would
perform satisfactorily when called upon to operate in other systems.

In the light of experience and improvements based upon trials of modifications, it may become
advantageous either to reduce the scope of maintenance work or the periodicity already prescribed
and standardized. The following procedure should be adopted for effecting such changes.

1) Those which are connected with safety requirements, a comprehensive proposal indicating
the actual experience of the railways, the benefits that are likely to accrue due to proposed changes
and the particular reasons for suggesting the change will be sent to RDSO with the approval of the
Chief

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME II PART II [60

]
Electrical Engineer. Such modifications to the maintenance requirements shall only be implemented
after RDSO's approval.

ii) Proposals other than item (i) above: A similar procedure must be adopted excepting that the Chief
Electrical Engineer may authorise provisionally the introduction of the change subject to post-facto
approval from RDSO. In case RDSO convey an opinion to the contrary, the original schedule shall
be brought back. The Railways can however continue to pursue the matter with RDSO and if the
latter agrees finally, adopt the change to the extent agreed upon.

30302 Scheduled Inspections

The maintenance and overhaul schedules to be followed for AC electric locos are as under:-

Nature of Inspection/overhaul Place where to be carried out

i) Trip Inspection, IT Outstation shed or homing loco shed as

convenient.
ii) Monthly Inspection, IA + 5 days Homing or nominated Electric Loco
Shed
iii) Two-monthly Inspection, IB + 5days. Homing Electric Loco Shed
iv) Four monthly Inspection, IC + 10 days Homing Electric Loco Shed
v) Annual overhaul, AOH + 15 days. Homing Electric Loco Shed
vi) Intermediate overhaul, IOH 300,000 km Homing Electric Loco Shed or
Nominated after POH or first commissioning or 3 years Workshop.
whichever is earlier + 1 month.
vii) Periodical overhaul (POH) 600,000 km after Workshop nominated for the purpose
commi- ssioning or last POH or 6 years whichever
is earlier + 3 month.

Detailed Instructions for IT, IA, IB, IC, AOH and IOH and POH will be issued by CEE for each type
and each series of locomotives keeping in view inspection schedules issued by RDSO. The scope
of work is broadly covered in Annexure-3.0l.

Inspections as detailed above may need revision based on experience accrued on new types of
locomotives. For example with WAG 6A locos the schedules are monthly inspections, 6 monthly
inspections, annual inspections and 3 year schedule.

30303 Technical Instructions

A set of the technical instructions relevant to the work of each section should be made available so
that they may carry out their work correctly. These can be classified under the following heads: -

i) Inspection Books

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [61]

ii) Inspection Charts

iii) Trouble-shooting Charts

iv) Technical Charts

i) Inspection Books: These give the scope of work of the various scheduled inspections viz. IT, IA,
IB, IC etc. itemizing the works and the order in which they are to be carried out, arranged section-
wise. The responsibility of each section supervisor is defined.

ii) Inspection Charts: These charts are prepared for each component individually. These cover a
comprehensive list of all the points to be checked, the observations to be made, clearances to be
ensured, specifying the conditions under which such verification should be made and the measuring
equipment to be used for the purpose.

iii) Trouble-shooting Charts :Clear instructions should be issued in the form of trouble-shooting
charts for each type of defect, which detail the checks to be made and the order in which they are to
be made. Before the locomotive is given back to service, a competent supervisor should satisfy
himself regarding the correctness of the investigations and the rectifications made. In trouble
shooting, the investigating team quite often discovers a pattern of failure on the basis of which
modifications and improvements to designs may have to be initiated.

iv) Technical Charts: These cover full details of all repairs, major adjustments and refitting of
equipment which are to be carried out. Where such repairs are not possible, the item will have to be
replaced by a new component. In the technical charts the detailed description of the material, the
tools to be used and the procedure to be followed and the defects to be checked after completion of
work are detailed.

v) The CEE's office will be responsible for ensuring that (a) the instructions received from RDSO are
forwarded to the Loco sheds and (b) the superseded instructions are cancelled, withdrawn and
destroyed, preserving one copy only for future reference. Instructions received from RDSO require
constant review and a system of generating feedback information on the implementation of these
instructions will be followed. Any modifications required in RDSO's instructions should be carried out
only after approval from RDSO.

These instructions require constant review in the light of experience. If any modifications become
necessary, Sr. DEE (RS) may introduce changes provisionally with the approval of CEE. Such
changes should, however, be advised to RDSO for scrutiny and final incorporation in the documents
(see para 30301).

30304 Engine Fitness Certificate

Whenever a loco for passenger service is issued from a loco shed or outstation depot after
scheduled inspection or unscheduled repairs, an "Engine Fitness Certificate" will be issued, a
sample form for which is appended (proforma 3.01 Part A and 3.01 Part B).

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [62]

 Annexure - 3.01
INSPECTION OF ELECTRIC LOCOS
A. Trip Inspection (TI)

The trip inspection is mainly required for topping of oils, distilled water in batteries and
attention to various minor defects which have been recorded in the log book. In addition certain
checks are necessary mainly due to severe environmental conditions (hot, humid and dusty)
existing in the country.

1. Periodicity of trip inspection shall be as follows:

Type of service Periodicity

i) Passenger/Mail/Express Train locos Every 2500 km or one trip whichever is later.

ii) Freight locos 5000 km or 10 days whichever is earlier.

2. During trip inspection the Engine Examiner will ---

a) Carryout detailed checks in regard to any unusual occurrence reported by the drivers in the
loco log book.

b) Visually inspect the auxiliaries for satisfactory starting and operation.

c) Feel by hand the temperature of axle roller bearings.

d) Visually inspect mechanical components like springs, equiliser pin, dampers etc. and the
brake rigging to detect any abnormality.

e) Check the controls and indication and alarm circuits for correct functioning.

3. Specific items to be attended in TI are--

a) General roof inspection: Check the roof generally for any foreign materials such as wire
pieces; clean the insulators and check visually for cracks or chips; Check for abnormalities
such as flashovers;

b) Pantographs: Check for copper deposition, grooving of strips and proper lubrication; visually
check springs and articulation and also test raising and lowering;

c) Air Blast Circuit Breakers / Vacuum Circuit Breaker: Check for satisfactory operation.

d) Return Current Shunt: Check the shunt connections between the body / bogie frame /axle
boxes, traction motor/axle are intact, tighten if necessary.

e) Bogies: Remove foreign matter and dirt picked up on run. Visually inspect for loose,
defective or missing parts.

f) Battery: Check and record battery voltage; top up cells as required.

g) Auxiliaries: Check all auxiliaries for correct operation;

h) Oil level: Check and top up oil in suspension bearing, exhausters, compressors, auxiliary
compressors and gear cases and record in the log book.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME III [67]

4. Wherever time and facilities are available, the passenger locomotives should immediately be
washed.
5. Test the locomotive on HT and LT and record observations on the test proforma.

B. IA, IB, IC, AOH Inspections.

The following tests should be carried out before and after inspection of a locomotive :
a) Preliminary tests with 25 kV supply on

i) Measure and record battery (BA) voltage.

ii) Measure and record Generator (GE) or battery charger voltage.

iii) Check time taken to build up compressed air pressure from 1 kg to 8 - 9 kg/ cm2.

iv) Check cut in and cut out pressure of compressor Regulator (RGCP).

v) Check blowing out of safety valves.

vi) Check vacuum obtainable with Driver Braking control Valve (MPF) on 'run' and quick release
positions.

vii) After building up vacuum, check for vacuum leakage for 5 mt.

viii) Check vacuum drop required for brakes to apply.

ix) Note pressure gauge reading when brakes are applied.

x) Check working of braking electro-valve VEF.

xi) Check working of blowers under 'direct' and 'automatic' starting conditions.

xii) Note and record air leakages for one minute in main reservoirs and brake cylinders.

xiii) Test headlights.

xiv) Test working of cab heaters and fans.

b) Preliminary tests with 25 kV supply off --

i) Measure and record time required for raising and lowering both the pantographs.

ii) Measure and record time taken for various time-delay relays.

iii) Test functioning of Auxiliary Circuits, Earth Relay (QOA) by creating an earth fault.

iv) Test functioning of Power circuit Earth Relay (QOP) by creating an earth fault.

v) Check functioning of all lights.

vi) Check wind-screen wipers and horns.

c) Test under High Tension before and after inspection successively from cab 2 and cab 1.
i) Raising of pantographs.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME III (69)

ii) Working of Auxiliary Compressor motor (MCPA), Arno and Generator (GE), particularly
observing behaviour during starting and for abnormal noise.

iii) Working of main compressor, charging time of main reservoir from 0 to 10 kg/cm2 and from
8. 5
to 10 kg/cm2 with one compressor working. Record rate of leakage in reservoir and brake pipe and
brake and feed pipe pressure.
iv) Check up proper functioning of autodrain, HS4, HB5 , RS, D1, emergency valve and air flow

indicator.

v) Record rate of vacuum leakage and vacuum on test plate and dummy.

vi) Check up all brake cylinders for leakage from exhaust port and record brake cylinder
pressure.

vii) Working of both exhausters for various positions of exhausters isolating switch and driver
braking
valve.

viii) Working of blowers particularly watching for abnormal noise.

ix) Observation of contactors for abnormal sound and sparking.

x) Observe deviation of main ammeters taking two traction notches in forward and reverse
directions.

xi) Test differential (QD), progression and regression relays.

xii) Test electro-valve VEF.

xiii) Measure and record depression in loco with all blowers functioning.

d) Low tension test before and after inspection -

i) Testing of master controller for notch by notch progression and regression and total time for
regression.

ii) Test VER

iii) Test working of sanders

iv) Test working of Exhauster isolating lever (ZPV)

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [70]

2.4 Clean the cable trenches. Examine for any damage to cable, lugs and repair it. Provide
proper cable sheathing and cleats. Measure and record insulation resistance of all HT and LT
cables. Tighten all
the terminal connections.

2.5 Dismantle bogie, brake riggings and clean the bogie in washing tank. Check up for any crack
and weld it as per the instructions laid down by RDSO. Overhaul these equipment and replace all
worn out components. Ensure squareness of bogie frame. Overhaul axle box bearings and all
wheels should be repropfiled.

2.6 Overhaul all traction gears and check up their P and K values and record them.

2.7 All approved modifications which can be executed in the shed should be carried out.

3. On complication of IOH, the loco should be subjected to detailed HT and LT testing and
should also be given a short trial run before it is declared fit for traffic.

D. Periodical Overhaul (POH)

1. The nominated POH workshop should issue a programme for POH of locos at least six
months in advance giving the individual numbers of locos to be called in, each month. The homing
shed will then send to the workshop a list of the important points to be specially attended to during
POH and the list of modification to be carried out. This will enable the workshop to plan the POH
work and arrange for the procurement/ shop manufacture of components required.

2. The loco should be sent on its own power from the homing shed to the workshop under
escort and along with its History Book. A complete list of all deficiencies in the loco should be
handed over to the workshop representative who should jointly check the loco along with the shed
representative.

3. All electrical, mechanical and pneumatic equipment should be taken out of the locomotive
and overhauled during POH.All worn out rubber components and bearings should be replaced.

4. All panels should be removed from the locomotive and cleaned/overhauled. They should be
tested for their proper functioning.
5. All the dimensions of the under frame should be recorded. The deformation, if any, should
be set right.

6. Super structure and underframe should be thoroughly cleaned. Corroded and damaged
portion should be rehabilitated. All body joint gaskets should be replaced.

7. All axle and axle boxes should be overhauled and rediscing / retyring should be done. All
wheels should be reprofiled.
8. All reservoirs should be cleaned and tested for their safe working.

9. All approved modifications should invariably be carried out during POH. Deferment of any
item may be done only with the personal approval of CEE controlling the POH shops in concurrence
with the CEE controlling the homing shed and under advice to the homing shed. In addition to all the
items indicated against IOH renewal of liners, bushes, etc. should be done so as to ensure
clearances and tolerances mentioned in 'F' with adequate margin for wear in service till the next
POH.
10. In addition to complete LT and HT testing of the locos on completion of POH, individual
items should also be subjected to detailed tests after overhaul and repair. Detailed test schedules
should be laid down for each item, for mechanical as well as electrical tests, and standard
proformae should be available for recording the test results for each equipment. A typical list of tests
to be carried out on equipment is given below.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill (86)

a) Rotating Machines: Insulation resistance by megger, no load tests, full load tests (except for
traction motors) drop test of armatures, resistance measurement of field coils, temperature rise
measurement.

c) Transformers: For small transformers in control circuits, ratio test and insulation resistance
measurement.
For main transformer, testing of oil for BDV and acidity, insulation resistance measurement, ratio
test of regulating windings and auxiliary windings, induced high voltage tests if any repairs have
been carried out.

c) Relays: Measurement of resistance and insulation values for operating coils, pick-up and
drop-off values of voltage/current/ternperature, time delay where applicable, opening and closing of
contacts.

d) Contactors: Measurement of pick up and drop-off values for operating coils, check for
simultaneous closing of all phases where applicable, leakages from valves and cylinder in the case
of electro- pneumatic contactors.

e) Cables: Insulation and continuity test, high voltage tests for rewired panels.
f) Resistors, condensers and reactors: Measurement of insulation resistance and ohmic values
of resis- tance / reactance.
g) Air-blast circuit breaker: Insulation resistance of coil-windings and live parts, minimum pick
up voltage for operating coils, opening and closing time for primary and secondary contacts,
minimum pressure for locking in sequence of opening and closing of auxiliary contacts.

h) No-fuse breakers (MCBs) Tests for tripping at rated instantaneous trip value.

i) Tap-changer: Insulation resistance, BDV and acidity testing of oil, correct functioning with
minimum air pressure, correct progression and regression sequence.

j) Silicon Rectifiers: Forward voltage drop, inverse resistance, HV test for complete assembly,
voltage sharing between diodes, testing of cell-check device.

k) Compressors and exhausters: Volumetric efficiency and leakage tests.

l) Speedometers: Calibration by comparison with a standard meter.

m) Meters and Gauges: Calibration with sub-standard instruments.

11. On completion of POH, the loco should be taken over by a representative of the homing
shed after a joint inspection at the workshop. Details of work done and modifications carried out
should be entered in the History Book which should be returned along with the loco.

12 On completion of POH, the loco should be subjected to detailed HT and LT testing and
should be given a short trial run. Loco will be returned working on its own power, and if possible
working as a train, after POH to the Homing Railway.

E. Rebuilding and Recabling of Locomotive

1. During every alternate POH, depending upon the cable/pneumatic pipe condition, which will
be advised by Sr. DEE of the Shed, the locomotive will be recabled and repiped. Recabling and
replacement of air and vacuum pipe during the third POH will be an essential item if it could not be
replaced during 2nd POH. The workshop should therefore plan these works well in time.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME II PART II [87]

2. During every 4th POH, mechanical components and traction gear may need rehabilitation.
Some of the major components will also need replacement. POH shops should plan for such works.
Opportunity should be taken to upgrade the parts and use the state of art equipment during such
extensive repairs.

F. Mechanical Inspection of Locos

i) Locos provided with renewable steel tyres will have tyres as per Specifications IRS R15-64
- Oil quenched with tensile strength of 100-110 kg/mm2.

ii) Locos provided with solid wheel disc will conform to Specifications IRS M2-65 and IS 1030-
1962.

2. All springs should be checked up for any crack and damage. Free height and loaded height
should be recorded. Only matched tested springs should be provided in the locomotive bogies.

3. An important part of the maintenance of the locos is the checking, at prescribed intervals, of
important mechanical clearances and dimensions which have a bearing on safe and efficient
operation, to ensure that they are within the prescribed limits. Such measurements should be
recorded suitably either in registers or on printed cards and preserved so as to be readily available
for reference in the PPO at all times. The items and interval at which they are to be checked up are
indicated. Limits will be specified for each type of locomotives by the CEE based on the
manufacturers/RDSO recommendations.

Clearances

SNo.

Items to be checked Periodicity of check up

1 Clearance of spring plank from rail level IC, AOH, IOH, POH

2. Buffer height IA, IB, IC, AOH, IOH, POH

3. Coupler height 1105 (max.), 1030 (min.) IA, IB, IC, AOH, IOH, POH

4. Clearance between top of axle box and bogie frame IB, IC, AOH, IOH, POH

5. Clearance between bogie horn check and axle box horn face IB, IC, AOH, IOH, POH

6. Clearance between bottom of axle box and horn stay IB, IC, AOH, IOH, POH

7. Distance between two parallel beam of equaliser AOH, IOH, POH

8. Clearance between safety bracket and equaliser IC, AOH, IOH, POH

9. Clearance between spring seat face and equliser AOH, IOH, POH

10. Clearance between two equalisers on middle axle box IC, AOH, IOH, POH

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Il [ 88]

4. Wheels : Check the following.

S.No. Items to be inspected No. Periodicity Permissible clearance

Tolerance
------------------------------------------------------------------------------------------------------------------------------
1. Tyre profile to be IA, IB, IC 6mm for freight 4 mm
Root wear Y checked for passenger loco.
Flange wear X with
condemning
gauge
2. Flats on the running surface All inspection 50mm for locos having
speed less than 100 km/h.
40mm for locos having
speed of 100 km/h and
more.

3. A' proud metal at the edge -- do -- Less than 6mm.

4. 'B' thickness of the flange Condemming=40 mm

Standard "thick" and "wear adapted" profiles are shown in the Fig. 3.01 and Fig 3.02. The
condemning wheel profile is shown in the Fig. 3.03.

G. Bogies

1. Squaring of bogies.

Due to heavy mechanical stress and impacts suffered by bogies in service, some of them get out of
shape and distorted. During IOH and POH, it is essential to restore the bogies to their correct shape
and alignment. To check this, at every major shed and POH shop, a test rig with a substantial
foundation should be provided over which the bogie can be placed and the amount of distortion
which has taken, place accurately measured. By application of adequate pressure at appropriate
points either hydraulically or by other means, frame distortions should be corrected as required, so
as to ensure proper mechanical alignment of all parts assembled over the bogie.

2. Cracks on Co-Co bogies.

The bogie shall be thoroughly cleaned as per RDSO's recommendations. The extent of cracks shall
be located by visual inspection as well as with magnetic particle/dye-penetrant method. After
marking out the full extent of the cracks, arrest-holes of suitable size of minimum dia. 10 mm shall
be drilled at least 25 mm away from the vicinity of the cracks. The entire cracks shall be eliminated
by opening the affected section right upto the bottom. The removal of defective area shall be done
by grinding/arc gouging/chipping. The section thus opened out shall extend into the arrest holes and
shall be checked up with the help of dye-penetrant or magnetic particle technique to ensure freedom
from any other cracks. The welding shall be carried out as per the procedure laid down by RDSO
with the help of specified electrodes. It shall be also ensured that all modifications recommended by
RDSO are carried out during POH on the bogies.

H. Axle Roller Bearing

These bearings are used on electric locomotives using trimount Co-Co bogies. The assembly
consists of two cylindrical axle roller bearings capable of taking radial as well as axial thrust loads.
The bearing is composed of inner and outer race along with rollers and cages. The cages while
carrying no load keep the rolling elements axially apart and also prevent the latter from failing out
while handling. The outer ring is slide fit in the axle box housing while the Inner ring is an
interference fit on the axle journal forming part of the axle when in place. The rollers
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME III [90]
are plain, straight, solid cylinders and are flat on both ends. These bearings should be maintained
as per RDSO Maintenance Instructions No. MPMT-98/81, March 1981.

The riding properties of these locomotive fitted with Co-Co bogie have been further improved upon
by using axial resilient thrust unit on axle 1, 3, 4 and 6. Axle 2 and 5 are provided with float bearings
so as to permit negotiability over sharp curves and turn-outs. This arrangement involves changes in
bogie frames and axle boxes. Axle box roller bearings fitted with resilient thrust units should be
maintained as per RDSO's Maintenance Instructions No. MT. 04.004.

Proper service tools should be used for servicing and maintenance of axle roller bearing which are
also indicated in the Maintenance Instructions. Whenever bearings are removed for overhaul,
inspection, repairs replacement or lubrication, proper precautions should be taken to avoid ingress
of dust, metal contents, etc. Grease specified by RDSO should only be used.

I. Suspension roller bearing

In WAG-5 with Hitachi motor, axle suspension roller bearing have been used. In this arrangement,
taper roller bearings are used on either end of the suspension tube. The maintenance of these
bearings should be done as per approved instructions. While overhauling, various defects due to
stains, discolouration, spalling smearing, indentation, brinelling and electrical burns etc., should be
examined. Proper precaution should be taken to ensure that bearings are overhauled in dust-free
environment and all clearances should he maintained as given in the Maintenance Instructions.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [91]

II. Annexure 3.02

Dual Brake System on Electric Locomotives

WAG-5 and WAP- 1 & 3 locomotives manufactured at CLW are fitted with twin pipe dual brake
system. Railways have also converted some WAG-4 locomotive to twin pipe dual brake system.
Dual brake system is designed for hauling stock equipped with either graduated release type single
pipe or twin pipe air brakes or vacuum brakes.

The instructions contained herein are in supplement to GR and SR. Simple schematic diagram
explaining the principle of operation of working of dual brake system, vacuum brake system and
charging of main reservoir Is attached as Annexure 3.02 A, 3.02 B, 3.01 C.

1. Description of the brake system

The main features of the system as fitted on these locos are-

1.1 Self-lapping type independent brakes on the locomotive, i.e., the brakes on locos can be
applied and released in steps with pressure maintaining feature in all positions.

1.2 Braking of air braked passenger/freight trailing stock and at the same time proportional brake
application on locomotive through distributor valve.

1.3 Braking of air braked passenger/freight trailing stock fitted with graduated released type of
brake equipment, and at the same time proportional brake application on locomotive through
distributor valve.

1.4 Dynamic brake interlock to prevent simultaneously application of automatic air brakes and
dynamic brakes on loco. Automatic brake application of brakes on loco and trailing stock in case of
failure of dynamic brakes.

1.5 Multiple unit operations with locos fitted with similar type of brake system.

1.6 In an emergency, brake pipe and vacuum train pipe can be directly vented simultaneously by
the emergency brake valve provided in front of assistant driver's seat.

1.7 Loco brakes can be released independent of the train brakes.

1.8 Provision for freight/passenger change-over cocks to regulate locomotive air brake
application timings depending upon the type of stock to be operated by locomotive.

1.9 Provision for the driver to apply independent brakes on leading loco in MU operation in case
of parting between locomotives.

1.10 In case of very heavy leakage in the feed pipe or failure of feed pipe inter-coupling
equipment, twin pipe brake system on trailing stock can be worked as single pipe system by simply
isolating the feed pipe of trailing stock from locomotives.

1. 11 Power cut off during emergency brake application.

1. 12 Visual indication on driver's cab through air flow indicator device during train parting, alarm
chain pulling or Guard's emergency brake valve operation or loco parting while hauling air braked
stock.

1. 13 Audio/visual indication in driver's cab to indicate the failure of D-24B feed valve which feeds
air pressure for electrical controls.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [95]

2. Compressed air system: (Ref.. SKDP-2350 Alt. 4)

2.1 Compressed air delivered by the motor driven compressors is stored in the main reservoirs
after being cooled by after coolers. Three safety valves set at 11.5 kg/cm2 are provided to safeguard
the compressors against build up of air pressure to a very high value, in case of failure of check
valves. The compressors are controlled by electro-pneumatic governor,to cut in at 3.50.1 kg./cm2
and cut out at 100.1 kg/cm2 pressure. One more safety valve set to blow off at 10.50.1 kg/cm2 is
fitted between the second and the third main reservoir in case the pressure governor fails to
operate.
2.2 Compressed air at reduced pressure of 8 kg/cm2 is stored in the control reservoir. This air is
supplied for all electrical contactors. A pressure switch provided after the feed valve gives an audio
visual indication through a buzzer and an indication lamp in each cab, in case pressure in the
control reservoir falls below 6.00.1 kg/cm2 and cuts off the audio visual indication when the
pressure rises to 6.00.1 kg/cm2.
2.3 In release position of the A-9 automatic brake valve, main reservoir air flows to the regulating
portion of auto brake valve, where it is reduced to a predetermined pressure. The regulated air
pressure flows through the auto brake valve to the C-2 relay valve to charge the air brake pipe. The
air brake pipe pressure can be adjusted by adjusting the regulator of auto brake valve.

3. Independent brakes
3.1 Self-lapping SA-9 type independent air brake valve is provided in each cab for application
and release of air brakes on locomotive. The leakage in the brake cylinder is automatically
compensated and air pressure in the brake cylinders is automatically maintained between zero and
maximum value depending upon brake valve handle position.
3.2 Isolating cocks are provided in the air supply and delivery pipes of the independent brake
valve to isolate the defective or unused brake valve in the inoperative cab(s).

4. Vacuum system
4.1 Two exhausters, are provided to create vacuum in the vacuum system of the loco and the
vacuum trains pipe (VTP) for operating vacuum braked trailing stock. Normally one exhauster is run
to maintain vacuum in the system. Two exhausters can also be operated, if necessary.
4.2 Exhauster(s) create vacuum in the V.T.P. through VA-1-B control valve when A-9 (drivers
automatic brake valve) is placed in "release" position. The vacuum in the V.T.P. is limited by two
vacuum relief valves set at 60 cms max. with hose pipe on dummy. Exhausters are protected
againsts ingress of dirt and dust by GD/80-H type oil bath filters. Leakage of atmospheric air through
the idle exhauster is avoided by non-return valve. Vacuum relief valves in the exhauster line protect
the exhauster(s) against high vacuum when the VA-1-B control valve is the disconnected from train
pipe during brake application. The desired vacuum in the VTP during release position is controlled
by the HS-4 control air valve. In release position of the automatic brake valve A-9, VA-1-B control
valve is actuated by the air brake pipe pressure and the control valve piston is moved down to
connect the exhauster to the VTP.

5. Operation of brakes on trailing stock equipped with air brake equipment

5.1 In 'release' position of A-9 automatic brake valve, main reservoir air flows to the regulating
portion of automatic brake valve at a predetermined pressure, normally 5kg/cm2. The regulated air
pressure flows through MU-2B valve to the C-2 relay valve. This control pressure actuates C-2 relay
valve which in turn connects main reservoir to brake pipe and charges the brake pipe and the
connected system to the same pressure level through out the train. Any leakage in the train system
is automatically compensated by this relay valve.
5.2 When the brake valve handle is moved to minimum reduction position, reduction of pressure
in brake
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [96]
pipe by 0.2 to 0.5 kg/cm2 (3 to 8 PSI) is achieved and proportional application of brakes on loco and
trains takes place. In full service position of the automatic brake valve handle, the BP pressure is
reduced to 3.5 kg/cm2 .

5.3 The A-9 automatic brake valve handle when placed in emergency position, vents brake pipe
pressure at a very fast rate to atmosphere to initiate an emergency brake application. Regression of
power also takes place due to the actuation of H-5 relay air valve. Reduction in pressure in the
brake pipe actuates the distributor valve on the loco and trailing stock to apply brakes.
5.4 The C-3-W distributor valve provided in the brake circuit, is connected to the brake pipe and
responds to the variations of pressure in the brake pipe. It applies proportionate brake application
on loco- motive when train brakes are applied either through Automatic or Emergency brake valve.
The C- 3-W distributor has a built in Goods/Passenger changeover cock to regulate brake cylinder
pressure depending on whether it is hauling Passenger or freight train.

5.5 32 mm feed pipe through-out the train is charged from the first two main reservoirs, through
duplex check valve and feed valve set at 6.0 0.1 kg/cm2 and is used for filling auxiliary reservoirs
of the trailing stock initially as well as after the air from these reservoirs has been consumed during
braking. The main advantage of this additional pipe is to reduce the release and recharging time of
the train after brake application.

6. Operation of brakes on trailing stock equipped with vacuum brake equipment

6.1 In release position of the automatic brake valve handle, the brake pipe is charged to 5.0
kg/cm2 and vacuum in vacuum train pipe is created through VA-1-B control valve. When the brake
valve handle is moved from release position towards application position, the brake pipe pressure
and vacuum in VTP is reduced and maintained to a value depending on the handle movement.
6.2 The reduction in brake pipe pressure operates the VA-1-B control valve to admit
atmospheric air into the vacuum train pipe, to apply brakes on the vacuum braked trailing stock.
During application, the exhauster connection with the vacuum train pipe is cut off by the VA-1-B
control valve. After the- desired degree of brake application has taken place, depending upon the
extent of brake pipe pressure reduced the valve laps and maintains automatically the vacuum level
against normal vacuum train pipe leakage.

6.3 When the driver feels that it is not necessary to apply brake on a loco, during automatic
application the brake release pedal switch is pressed to release the loco brakes. The D-1 pilot air
valve is energised to cut off automatic air brakes on the loco while train brakes remain applied on
the trailing stock.
6.4 During train parting while hauling vacuum braked stock, the vacuum in the train pipe falls
suddenly. with a drop of vacuum by about 10 to 15 cm an unbalance in the VA-1-B control valve is
created allowing controlled air pressure to actuate HB-5 relay air valve to operate pressure switch
through double check valve for regression of power.

7. The operation of emergency brake

Valve D-1 provided in each cab, near the assistant driver's seat, directly connects the vacuum train
pipe and air brake pipe to atmosphere thereby applying brakes on loco and trailing stock at the
quickest possible rate. The circuit for auto regression of the loco power due to the actuation of H- 5
relay air valve is also automatically made. This relay valve also regresses power if the BP pressure
drops due to any reason.

8. Dynamic brakes
D-1 pilot air valve cuts off loco brakes.
8.1 While controlling train with dynamic brakes, if the dynamic brakes fails, brakes on the loco
and train will be applied automatically.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [97]
9. Air flow indicator

9.1 Air flow indicator, a relay valve, one pressure switch and two flow indicator gauges (one in
each cab) have been provided to give an indication of the air flow rate in the brake pipe of the train.
Any abnormal increase in air flow in the brake pipe because of train parting, loco parting, alarm
chain pulling, heavy leakage in brake pipe, guard van valve application or bursting of air brake pipe
hose would give visual indication to the driver by air flow gauge needle and by glowing of a bulb in
the cab. On getting the indication driver should apply brakes through A-9 automatic brake valve/D-1
air/ vacuum emergency valve depending upon the condition of the train and the emergency.

10. Multiple unit operation

10.1 When two or more locos are to be coupled together in multiple unit operation, the brake pipe,
the feed pipe, vacuum train pipe ( if vacuum braked stock to be operated), the main reservoir
equalising pipe and brake cylinder equalising pipe hoses must be coupled between the locos, and
the respective angle cocks shall be opened.

10.2 The compressors and exhausters of the trailing locos would also be working during multiple
operation. The automatic and independent brake valve handles in the trailing loco and on the
unused cab of the leading loco shall be kept in 'Release' position and the isolating cocks provided
near both brake valves should be closed.

10.3 MU-2-B valve provided to supply MR air to VA-1 release valve (11) and F-1 selector valve
should be kept in 'lead' in the leading loco and in 'Trail' position in the trailing locos. Isolating cock in
the brake pipe charging line should be kept in lead position (open) in leading loco and trail position
(close) in the trailing loco(s).

11. Gauges

There are five gauges in each driving cab. These gauges indicate BC, MR, FP, VTP, Air Flow, BP
pressures to the driver. Apart from these, three single Pressure gauges are provided. One single
pressure gauge is fitted near the panto reservoir. The second gauge is provided in the brake pipe
line to show the brake pipe pressure. One single pressure gauge is provided to indicate the
pressure in the control side of the VA-1-B control valve, which is regulated by HS-4 control valve.

12. General

12.1 It should be noted that whenever the vacuum setting is done- through the vacuum relief
valve, this should be done by seeing the single vacuum gauge fitted in driver's cab.

12.2 The first two main reservoirs are provided with auto drain valve and the condensate is
automatically drained off during the "cut out" and "cut-in" cycle of the compressor governor. All the
other three main reservoirs are provided with manual drain cocks to drain off periodically the
condensate collected in the reservoirs.

12.3 The main reservoir also supplies compressed air to auxiliaries such as wipers horns and
sanders. The MR equalising pipe is charged from the main reservoirs through a duplex check valve
set at 5.00. lkg/cm2.

12.4 The main reservoir also supplies compressed air to electrical auxiliaries such as
pantographs, tap changers, Board of gaduator etc. At the time of initial energisation of loco or when
there is insufficient pressure in pantograph reservoir to raise the pantograph, battery driven auxiliary
compressor is operated to build up pressure in the pantograph reservoir and auxiliary circuit to
energise the loco. The pantograph reservoir is protected against pressure leakage by a diaphragm
operated cock. One safety valve to cut out at 8.5 + 0. 1 kg/cm2 has been provided to safeguard the
baby compressor from excessive pressure.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [98]

 CHAPTER IV

MAINTENANCE AND OVERHAUL SCHEDULES OF EMUs

Para No Subject

30400 General

30401 Scheduled Inspections

30402 EMU Fitness Certificate

30403 Testing Air Brakes

30404 Maintenance of Vacuum Brakes

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME Ill [102]

CHAPTER IV

MAINTENANCE AND OVERHAUL SCHEDULES OF EMUs

II. 30400 General

Para 30300, 30301 and 30303 will be applicable to EMU mutatis-mutandis as well.

III. 30401 Scheduled Inspection

IV. The motorman, after overnight stabling of EMUs, while taking over shall ensure draining off
of the air reservoirs to expel accumulated water.

a) The Maintenance and Overhaul Schedules to be followed for AC EMUs will generally be as
under-

i) Daily Inspection

ii) Trip Inspection (IT)

iii) Monthly Inspection (IA)

iv) Quarterly Inspection (IB)

V) Half Yearly Inspection (IC)

Vi) Intermediate Overhaul (IOH)

vii) POH

b) The daily inspection is essentially an inspection to be carried out by the Running Section. It
may also be carried out in a shed if convenient or at an outstation when the unit is stabled overnight
away from the shed. IT, IA, IB, IC and IOH should be carried out in the homing shed for each EMU
whereas POH should be carried out at the workshop nominated for this purpose for each railway.
c) The details of work to be done during each schedule require periodical review in the light of
local conditions and operating experience with each type of EMU. The details given in Annexure
4.01 are for guidance only.

V. 30402 EMU Fitness Certificate

Instructions contained in Chapter Ill (Para 30304) for locos will apply mutatis-mutandis for EMU as
well. (Proforma 4.01).

VI. 30403 Testing of Air Brakes

A brief description of Electro-pneumatic brakes is given in the Annexure 4.02, Test procedure for the
air brakes is however given below:

1. Before an EMU train is issued for traffic from a shed after scheduled inspections, POH or
unscheduled repairs, a supervisor of the M5 section should test the air brakes of the complete train
formation. The brakes should be

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [103]

tested from the driving cabs at both ends of the train formation.
A list of items to be checked in the case of Westinghouse brakes of ICF EMUs is given below for
guidance. Detailed check lists on similar lines should be prepared for different types on EMUs and
units fitted with Knorr brakes. These should be in the form of printed forms. The completed forms
duly signed by the supervisor of M5 should be preserved in the PPO for a period of six months.
Check
i) that all inter-car hose connections are made and all coupling, isolating the drain cocks are in the
normal position.
ii) that MR pressure is maintained between 5.8 and 7 kg/cm2 and the compressors start and stop
respectively at these values of pressure.
iii) that when the Driver's control switch, EP brake switch and isolating valve switch are put on, the
green indicator light in the driving cab glows.
iv) that the brake pipe pressure builds upto 4.57 kg/cm2 in approx. 90 seconds.
v) that when the brake controller handle is moved from position I to position II step by step ( a
minimum of 6 steps should be used), the brake cylinder pressure builds upto the value proportional
to the handle position and is maintained at this value by the self-lapping mechanism. In position II
the pressure should be 3.5 kg/cm2 for cast iron brake blocks and 1.5 kg/cm2 and 2.0 kg/cm2 for
motor and trailer coaches respectively provided with composite brake blocks. When brakes are
applied the orange lamp should light-up to prove the application of brakes in all the bogies.
vi) that when the handle is moved back from position II to position I step-by-step ( a minimum of 6
steps should be used) the brake cylinder pressure is reduced to the value corresponding to the
handle position and is maintained at this value by the self-lapping mechanism.
vii) that when the handle is quickly moved from position I to position II, the brake cylinder pressure
will rise to the maximum set value.
viii) that on moving the controller handle from position II to position I, the brake cylinder pressure
drops to zero.
ix) that during EP application and release the brake pipe pressure is not affected.
x) that when controller handle is moved from position I to position Ill and then to IV, the brake pipe
pressure drops gradually with sound of escaping air, and brake cylinder pressure rises
correspondingly. When the controller handle is moved back to Ill, the drop in brake pipe pressure
and the rise in brake cylinder pressure should be arrested.
xi) that when controller handle is moved from position I (after allowing full BP pressure to build up)
quickly to 'Emergency' position V, brake pipe pressure is reduced rapidly and brake cylinder
pressure rises to slightly more than 3.9 kg/cm2 within 2.5 seconds.
xii) that with the brake controller in the driving cab in position II the brake cylinders on each bogie
are functioning and there is no leakage. Check also that the manual release valves have wires
attached to them to facilitate operation from the sides of the train.
30404 Maintenance of Vacuum Brakes
A brief description of vacuum brakes is given in the Annexure 4.03. Instructions regarding
maintenance of vacuum brakes are contained in TXR Manuals, the salient points of which are
summarized below:-
Periodical Examination of Vacuum Brake Gear:
1. All vacuum brake cylinders shall be lowered, examined, cleaned and necessary repairs and
renewals of rubber fittings effected, once in every 12 months. The code of the examining station
making such an examination, the date and words "EXD" shall be painted in white on the cylinder
thus : EXD-JTJ- 1 0- 1- 1 970.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [104]

2. In fitting up vacuum brake cylinders it is important to see that the lever of the brake shaft is
exactly parallel with the trunnions on which the cylinder swings so that no side or cross strains are
set up.
3. When putting a rolling ring on to a piston, care should be taken to ensure that the ring is not
twisted. Around the ring a seam line will be found, which should lie evenly and horizontally all-round
when in the groove. The correct alignment can be secured by pulling the ring slightly away from the
drum of the piston on the opposite sides with the thumb and finger of each hand. A good rolling ring
is one which when allowed to hang from the finger will hang straight. Whereas, if a ring twists when
being suspended it should be rejected. An air tight fit is made between the piston and cylinder by
the rolling ring.
4. (i) The stuffing box, gland and brass bush should be examined to ensure that they are intact
in all respects. Excessively worn gland will cause air leak below the piston and hence should be
renewed.
(ii) The gland is held in position by a brass ring having groove at top and bottom edges. When the
stuffing box is tightened the rubber gland is squeezed into the grooves. On creating vacuum, the
gland packing gets tightened, due to atmospheric pressure acting over the outside of it.
(iii) The brass bush must be examined for wear, as this part has the important function of
maintaining the piston rod steady in its movement. When the bush is worn excessively the travel of
the piston becomes unsteady and jerky.
5. The joint ring between the flanges of the vacuum chamber and cylinder should be in correct
position. To retain the joint ring in exact alignment while the cylinder is being lifted into position, clips
made out of split pins could be used.
6. While tightening up the joint, the nuts should be screwed up evenly all-round and not too tightly or
haphazardly.
Unequal tightening of the nuts may cause the cylinder being drawn out of shape. This should be
avoided. The correct procedure is to tighten up opposite nuts while assembling. On creating vacuum
the nuts should be tightened up finally.

7. The release valve has a flat valve head which normally remains seated cutting off all direct
communication between the body of the valve and the vacuum chamber or top of the piston. This
can be opened by pulling the release valve lever by hand. A defective seating washer or a
diaphragm washer will allow air to enter above the piston when vacuum is destroyed and the
vacuum cylinder will not function properly. Such defective washers should be changed.
8. Cleaning: When dismantling a cylinder for cleaning all rubber parts should be removed and kept
clear of oil or any other solvent likely to damage the rubber. French chalk may be used for cleaning
or dressing the rubber fittings, or the working surfaces of the cylinder and piston.
If it is found necessary to use a solvent to remove dirt from working surfaces of the metal parts all
traces of this solvent must be removed before replacing rubber parts, otherwise deterioration and
failure in service are liable to occur. These working surfaces are coated with a special red rust-
preventing varnish and the solvent must be of a nature which will not affect this varnish. Emery
paper or cloth should never be used to clean the piston and cylinder.

9. The piston travel should be limited to a maximum of 4" (100 mm) to ensure effective brake power.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME III [105]

 Annexure 4.01
1. Daily Inspection

During this inspection, the Engine Examiner should-

a) carry out detailed checks in regard to any unusual occurrence reported by Motormen in the log
book.

b) visually inspect the auxiliaries for satisfactory starting and operation.

c) feel by hand that the temperature of axle bearings is normal,

d) visually inspect mechanical components like traction bars, pendular suspension, springs,
dampers etc. and the brake rigging to detect any abnormality; and

e ) check the controls and indication and alarm circuits for correct functioning.

Every unit should be checked under the supervision of a Train Examiner (Traction), generally during
night stabling. Similar inspection (in addition to attention to the unscheduled repairs) should also be
carried out in a unit called to the shed for unscheduled attention, before it is declared fit for traffic.
The important items to be checked are

i) Tap all wheels to detect for loose tyre and tyre cracks. Visually inspect all wheels for defects such
as cracked tyres, flats etc. and also bogies and running gear for any abnormalities.

ii) Feel all axle boxes by hand immediately after stabling. Check axle box covers.

iii) Check axle guide helical springs for breakage.

iv) Check brake blocks. Renew badly worn or cracked blocks. Adjust slack adjusters, if required, to
obtain clearance of 12 mm between brake blocks and wheels. Look for broken or damaged parts
of brake rigging. Check the application of the brakes. )

(v)Check bolster helical springs, visually.

vi) Check look-out glasses and head code glasses. Clean look-out glasses.

vii) Cushions to be checked and badly damaged cushions to be replaced

viii)Test check passenger alarm chain for operation from at least 2 coaches in a train.

ix) Visually check the pantographs for any defect.

x) Check oil-level of air compressors and suspension bearings, top up if required.

xi) Check operation of automatic drain valve of main reservoirs. Drain all other reservoirs.

xii) Test the horns at both ends.

xiii) Check for noticeable air leakages in compressed air system.

xiv)Check inter-unit air hose couplings.

xv) Test wind screen wipers (in rainy season),
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [106]
xvi) Test brake controller at each driving position for correct operation. Particularly observe the
brake-pipe pressure.

xvii)Test deadman's device in each driving cab

xviii) Test pantograph raising and lowering push buttons in each driving cab.

xix) Check Master Controller in each driving cab.

xx)Test auxiliary compressor.

xxi)Check battery voltage and trickle charge current.

xxii)Test signal bells.

xxiii) Clean the compartments and cushions. Clean driving cabs.

xxiv) Test headlights, flasher lights and tail lights including. emergency lights.

xxv) Check that all the safety straps are in position

2. Trip Inspection
The chief object of this inspection is to renew the worn-out brake blocks if necessary usually at
Intervals varying from 5 to 8 days particular attention being paid to differential rate of wear between
motor coaches and trailer coaches.

The periodicity of this inspection will depend upon a number of factors such as daily kilometreage,
proportion of 'fast' and'slow' trains, quality of brake blocks etc. The periodicity should be decided by
each Zonal Railway depending upon its actual operating requirements. It is essential to ensure
renewal of brake blocks before they reach condemning thickness.

3. In addition to replacing brake blocks and the items listed against Daily inspection, carry out
the following checks:

i)Visually inspect the bogie frame for cracks or other damages.

ii) Check helical springs of axle guide for breakage.

iii) Check axle guide for excessive oil leakage

iv) Check tightness of axle guide oil filling cap.

v) Check axle guide safety strap.

vi) Inspect axle suspension bearings of traction motors and check oil levels, particularly check
pressure and tightness of drain plug and filler cap. Tighten bolts.

vii) Check gear-box for lubricant level and tighten bolts.

viii) Adjust brake pull rod, rigging and slack adjusters.

ix) Inspect brake rigging components thoroughly particularly bushes, pins, split-pins and cotters.

X) Check centre pivot.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUN'IE III [107]
xi)Inspect 'Schaku' couplers for cracks, deformation and damage.

xii)Inspect buffers and lubricate buffer plungers.

xiii)Lubricate screw couplers.

xiv)Check all doors and windows, door handles, foot-steps, window safety bars and hand rails.

xv) Check that protective screen for look-out glasses, where provided, is properly secured.

xvi)Clean driving cab window panes and swab clean cushions.

xvii)Inspect pantographs for flash-marks, wear of strips and cleanliness of Insulators. Lubricate
articulation joints, bearing joints and pans.
xviii) Check compressor crank case breather pipe.

xix) Check oil level of auxiliary compressor and top up, if required.

xx) Check operation of EP contactors and reversers by manual operation of the control magnet
valves.

xxi)Check transformer oil level and top-up if required. Check transformer for oil leakages.

xxii)Check colour of silica gel and replace if required.

xxiii) Open inspection covers and make a quick inspection of traction motors for flash-marks, broken
brushes, damaged pig-tails or other damages.

xxiv) Check that the auxiliary machines are running without any unusual noise.

xxv) Make a quick examination of all electro-magnetic contactors and relays.

xxvi) Make a quick visual examination of air-blast circuit breaker and test its operation.

xxvii) Battery: Clean vent holes of filler caps, check intercell and main connection, record specific
gravity and voltage of pilot cells, top up with distilled water if required and smear cell connections
and terminals lightly with petroleum jelly after cleaning.

xxviii) Check and attend to all defects of lights and fans.

xxix) Clean underframe equipment particularly at locations where fire is possible due to
accumulation of oily matter; also clean filters, as required.

xxx) Check the correct operation of RGCP.

xxxi) Check self lap feature of the EP brakes.

3. Monthly Inspection (IA)

In addition to the items listed against Daily and Trip inspections, the main items to be attended to
during Monthly Inspections are -

i) Measure tyre (root wear and flange wear) and record. (Refer to Annexure 3.01 item F) and
reprofile if required and ensure that variation of diameters are within permissible limits.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [108]

ii) Check axle boxes for leakage of grease, specially from back dust-guard and for any cracks or
other damages.

iii)Inspect reversible gear-box of speedometer.

iv)Check suspension. bearing housing fixing bolts for tightness.

v)Check gear,-case securing bolts for tightness.

vi)Check motor coach friction damper liners and pads.

vii)Check shock-absorbers for oil leakages.

viii)Check centre-pivot bottom cover with its fixing bolts and nuts.

ix)Inspect side-bearers for excessive oil leakage.

x)Inspect buffers for cracks and damages and tightness of fixing bolts.

xi)Check cattle guard for security of fastening, deformation and clearance from rail level.

xii)Check all seats, luggage carriers, strap hangers and door locks.

xiii)Check for. leakages from roof (particularly prior to and during rainy season).

xiv)Check that hand-brake are functioning effectively.

xv)Gauge and change if necessary, pantograph strips and clean all roof insulators.

xvi)Inspect and clean suction strainer and centrifugal dirt collectors.

xvii)Overhaul and test reducing valves and check that correct brake pipe pressure of 4.57 kg /cm2 is
built up.

xviii)Check complete compressed air system for leakage.

xix)Test EP, Auto and Emergency application from each driving position and brake cylinder
pressure in each coach. Check Guard's Emergency valves in driving cabs.

xx)Remove the arc chutes and inspect all EP contactors for flash-marks, contact wear, contact wipe
etc. Check for air leakage at control valves. Lubricate cylinders.

xxi)Check pressure in control air reservoir.

xxii)Check operation of all pneumatic governors.

xxiii) Check reversers for operation, finger pressure, wear of contacts, functioning of auxiliary
contacts and for air leakage at magnet valves.

xxiv)Inspect silicon rectifier cubicles and clean cubicles with dry compressed air.

xxv) Check cell-check device.

xxvi)Check traction motors for condition of commutators, arcing horns, brush holders, wear of,
carbon brushes and condition of earth-return brushes. Renew brushes, if required.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [109]
xxvii)Examine all other DC motors also as above.

xxviii) Lubricate the bearings of auxiliary motors.

xxix) Clean air intake filters for traction motors and compressors.

xxx) Check tightness of all main cable connections.

xxxi) Check the contacts and auxiliary contacts of circuit breakers.

xxxii) Check for functioning of all indication circuits and lamps;

xxxiii) Check voltage stabilizer.

xxxiv) Check all lights and fans individually and test emergency lights.

xxxv) Check the speedometers.

xxxvi) Wash coaches internally and externally by hand scrubbing.

xxxvii) Check head light focussing.

Train formation should finally be checked by El and Ml sections before release for traffic.

4. Quarterly Inspection (IB)

Items given below are required to be attended to in addition to the items listed against Daily, Trip
and Monthly Inspections
i) Check all axles with ultrasonic flaw detector.

ii) Check distance between wheel faces using prescribed gauge.

iii) Check axle guide oil level,

iv) Check condition of axle guide spring lower rubber pads.

v) .Check condition of speedometer reversible gear box.

vi) Traction motor suspension bearing lubrication pads to be checked.

vii) Measure and record radial and lateral clearances of suspension bearings.

viii) Inspect traction motor nose suspension bolts

ix) Inspect bogie frames, swing links and bolsters carefully, particularly welded, rivetted and bolted
joints.

x) Check friction damper spring assembly.

xi) Check compressed height of swing bolster springs.

xii) Inspect draw-gear rubber pads.

xiii) Uncouple 'Schaku' couplers and inspect the assembly. Lubricate the couplers as prescribed.
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [110]
xiv) Measure and record buffer heights.

xv) Body panels to be checked for rust, corrosion and damage.

xvi) Check passenger alarm device in each coach.

xvii) Clean the suction strainers of auxiliary air compressor.

xviii) Inspect all brake cylinders; tighten foundation nuts.

xix) For all EP contactors check air gap between main contacts, auxiliary contacts and spring
pressure of auxiliary contacts. Clean all insulating surfaces. Check magnet valve stem with
condemning gauge.

xx) Check reverser and changeover switch "WCO,

xxi) In silicon rectifier cubicles, slide out each rectifier tray and clean the cooling fins. Clean all air
ducts, check power connections, check capacitor for oil leakage and inspect HRC fuses, particularly
terminal connections.

xxii) Open and inspect Master Controllers. Wipe dry all insulating surfaces and check contacts.

xxiii) Clean supporting insulators and check tightness of connections of transition resistances.

xxiv) Clean traction motor brush-holder insulator and check earth-return brush-gear. Check junction.
box connections for tightness. .

xxv) Check main compressor foundation bolts for tightness.

xxvi) In all electromagnetic contactors check the air gap between contacts, conditions of flexible
shunts, knuckle spring pressure and hinge pins.

xxvii) Inspect all push button switch contacts and terminal connections.

xxviii) Check all knife switches.

xxix) Check current limit relay LT supply continuity.

xxx) Inspect voltage stabilizer transformer.

xxxi) Clean headlight reflector.

xxxii) Inspect commutator and carbon brushes of all fans. Renew carbon brushes if required.

xxxiii) Examine axle boxes. If required change the grease. (This item is normally required to be done
. during every third IB).

5. Half Yearly Inspection (IC)

In addition to the items listed against the earlier inspections, the important items to be attended are

i) Check pantographs for upward pressure.

ii) Renew oil in compressor crankcase and change the oil filter element assembly. Check oil
pressure

iii) Decarbonize the valve assembly.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [111]
iv) Renew crank-case oil of auxiliary compressor.

v) Safety valves in compressed air system including brake cylinder safety valves to be tested.

vi) Check the suspension arrangement-of all under-slung equipment.

vii) In the brake controller, check self-lapping mechanism for correct functioning, regrease fulcrum
pins and rollers and examine moving and fixed contacts.

viii) Clean and regrease pilot valve in Master Controller.

ix) Test and adjust operating pressure of all pneumatic governors.

x) Check the condition of cones and rollers of all EP contactors, measure knuckling springs tension,
renew Gaco washers and inspect flexible shunts. Check tightness of power connections.

xi) Attend to reverser and changeover contactor WCO as above.

xii) Test oil sample from conservator, reactor tank and transformer tank of main transformer for
dielectric strength and filter the oil if BDV is below 40 kV for one minute.

xiii) Disconnect all inter-vehicular couplers and examine male and female pins.

xiv) In the main rectifier cubicle clean all insulators and examine for cracks. Check individual diodes
for tightness with a torque wrench.
xv) Examine Master Controller, lubricate interlocking mechanism and notching cam roller, check
Contact gap, contact pressure and cam to roller gaps.

xvi) Check traction motor brush spring pressures. Lubricate armature bearings.

xvii) In MG set check bearings for grease leakage and lubricate bearings.

xviii) Overhaul and test all EP brake valves replacing all rubber component on a complete unit basis.

6. Intermediate Overhaul (IOH)

The following items should be attended to in addition. to the iterns listed against earlier inspections.

i) Reversing gear-box for speedometer to be overhauled and speedometer to be tested on test

bench.

ii) Check 'Schaku' couplers for wear and damage and lubricate.

iii) Overhaul servomotor of pantograph and check all adjustments,

iv) Overhaul and test pantograph EP valves.

v) Remove main and auxiliary compressors and overhaul on bench. Test volumetric efficiency.

vi) Overhaul and test brake cylinder.

vii) Overhaul the motors of all AC and DC auxiliaries.

viii) Remove air blast circuit breaker, overhaul and test on bench.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [112]

ix) Check the setting of all relays and test their operation manually.

x) Overhaul all coach fans.

xi) Remove battery set to battery room, examine carefully and subject the set to two cycles of
charge
and discharge. Take capacity test at normal rate of discharge.

xii) Doors, windows and seats to be checked individually and all defects attended to. Upper-class
cushions to be repaired and badly damaged cushions to be replaced.

7. Periodical Overhaul (POH)

The POH of EMUs should be carried out in the nominated workshop. The work content and
procedure to be followed should be on the same lines as for locos (Item D of Annexure-3.01 of
Chapter 3).

8. Mechanical Safety Checks

The Train Examiner of EMU coaches will generally follow the manual and guides of TXR as
modified from time to time for application to EMU coaches. The principal clearances as mentioned
in (Item F of Annexure-3.01 of Chapter 3) should be checked.

9. Rebuilding and Recabling of EMUs

Activities as mentioned in (Item E(1) of Annexure-3. 01 of Chapter 3) above may be carried out on
EMUs during every 4th POH and activities mentioned in (Item E(2) of Annexure-3.01 of Chapter 3)
may be carried out during every 8th POH.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [113]

 Annexure 4.02
ELECTRO-PNEUMATIC BRAKES

1. All BG EMU stock have been provided with 'self-lapping electro-pneumatic combined with
automatic' compressed air brakes. Two makes of equipment are in use viz. Westinghouse and
Knorr-Bremese. Though the details of equipment differ appreciably, both systems are quite similar
in principle. The description given below pertains mainly to the Westinghouse equipment provided in
ICF-built EMUs.

2. Electro-pneumatic braking is normally employed for service stops. The 'automatic brakes' are
used under the following circumstances:-

(a) For automatic application of brakes on both halves of a train in the event of a parting.

(b) For application by the Guard in an emergency.

(c) For automatic application due to operation of the dead-man's device.

(d) For service stops by the Driver in the event of failure of control supply for EP brakes.

3. When Driver makes an emergency application both EP and Auto brakes apply,

4. The main components of the equipment are as under-

(a) A main reservoir system consisting of a compressor in each motor coach feeding into main
reservoirs on motor coaches and supplementary reservoirs on trailer coaches interconnected from
end to end of the train by a main reservoir pipe with flexible couplings at ends of coaches. The main
reservoir is maintained at a pressure of 5.8 to 7.00 kg/cm2 by means of pressure governors
controlling each compressor. All the compressors in a train are synchronized to start and stop
together.

(b) A 'brake pipe' from end to end of the train with flexible inter-connections between coaches. The
pressure in this pipe is maintained at 4.57 kg/cm2 to keep the automatic brakes released.

(c) A 'brake unit' in each coach consisting of the control valves for control of EP and auto brakes.

(d) The brake cylinders on each bogie with automatic slack-adjusters and associated brake rigging.
Usually the number of brake cylinders is four per bogie on motor coaches and two per bogie on
trailer coaches.

(e) A brake controller in each driving cab. The controller in the driving cab in use being made
operative by means of an 'Isolating valve switch' operated by the Driver's key.
(f) A brake application relay in each driving cab, the one in the operative cab responding to the
operation of the brake controller to control the supply to the brake control train wires carried along
with the other control wires In the inter-vehicular couplers.
(g) Five train wires, viz. EP supply wire, brake application wire, brake holding wire, brake indication
wire and EP return wire.
(h) A warning system to indicate to the Driver if EP brakes have applied and to warn him if a failure
takes place.
(i) A pilot valve and emergency valve to operate the brakes if the deadman's device is released,

(j) Isolating cocks, pressure gauges and control switches.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [114]

(k) Release valves for manual release of brakes in individual bogies.

5. Each coach has an 'EP brake unit' which houses the control valves for both EP and auto-brakes.
The 'pipe- bracket' arrangement is used where by the valves are bolted on to a casting which has
the requisite inter connections between valves by means of cored passages in the casting itself, the
only external pipe connections being from the main reservoir and brake pipes and to the brake
cylinder and atmosphere.
6) The brake controller handle has five positions as under-
(a) I .. .. .. Release and Running.
(b) II ........... Full service EP.
(c) III ............. Lap(for auto application)
(d) IV ................ Service automatic
(e) V ................. Emergency.
Lower brake cylinder pressures with self-lapping feature as explained later are obtainable for
intermediate positions of the handle between positions I and II, the actual brake cylinder pressure
being dependent upon the degree of handle movement away from position I.

7. Fig 4.01 is a block diagram explaining the functioning of the EP brakes. When an EP application
is to be made, the controller handle is moved from position I towards position II. First the holding
train wire is energized which energizes the. holding magnet valves throughout the train, thus
closing, the exhaust, from the brake cylinders. The application valves are then energized via the
application train wire. This causes compressed air to flow to the brake cylinder from the main
reservoir pipe, the rate of flow being controlled by a choke (not shown in the figure). If the
application valve remains energized, the pressure in the brake cylinder 2 builds upto 3.5 kg/cm2,
any rise of pressure beyond this value being prevented by the 'limiting valve.

8. Between positions I and II the self-lapping mechanism controls the brake cylinder pressure. Fig
4.02 shows the self-lapping mechanism schematically. Movement of the controller handle towards II
compresses a spring in a small control cylinder, the amount of compression depending upon the
degree of handle movement. This spring acts on a piston at the back of which air pressure form the
brake cylinders of the leading bogie is applied. When the brake cylinder pressure exceeds the value
corresponding to the controller handle position, the mechanism de- energizes the application train-
wire, thus limiting the brake cylinder pressure to the value corresponding to the handle position. If
the brake-cylinder pressure drops on account of leakage etc. the application wire is re-energized. If
the handle is moved backwards, the holding wire is de-energized till the brake cylinder pressure
drops to the required value. The self-lapping mechanism thus automatically controls the brake
cylinder pressure at a definite value corresponding to the handle position and enables graduated
application and release. In. position II and V the application and holding circuits are energized by
'positive acting' contacts bypassing the self-lapping mechanism, the pressure then being limited by
the limiting valve as explained earlier.

9 Two indication lamps are provided on the Driver's desk-a green lamp to indicate that EP brake
control supply is available and an orange lamp which lights up when brake application -is made if
pressure has built up in all the bogies, which is detected by a pressure switch, the pressure
switches in all the coaches being connected in series. The extinguishing of the green lamp indicates
total failures of EP brakes necessitating use of the automatic brakes to control the train. Failure of
the orange lamps to light up when brakes are applied indicates partial failure of the EP brakes. The
Driver has then to be very vigilant and should be prepared to control, the train, if required, by using
auto brakes.

10. Fig 4.03 is a block diagram explaining the function of the automatic brakes. When the brake
controller in the driving cab is in position I and the controller is put into operation by putting on the
'Isolating valve switch', compressed air is fed to the brake pipe from the MR pipe via a reducing
valve in the brake controller which ensures that the pressure in the brake pipe is built up and
remains steady at 4.57 kg/cm2.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [115]
The vital component in the automatic brake system is the 'triple valve' which forms a part of the EP
brake unit in each coach. Its functions are -

(a) When pressure in the brake pipe is 4.57 kg/cm2, it opens the brake cylinder to atmosphere thus
releasing the brakes and at the same time connects the brake pipe to an Auxiliary Reservoir in each
coach storing compressed air at a pressure of 4.57 kg/cm2 in the Auxiliary reservoir.

(b) When pressure in the brake pipe is reduced either voluntarily by the Driver or the Guard or due
to parting of train or operation of the deadman's device etc., it closes the exhaust from the brake
cylinder and connects the auxiliary reservoir to the brake cylinders, allowing the stored air in the
reservoir to flow into the brake cylinders. The volume of the auxiliary reservoir is so chosen that the
maximum pressure in the brake cylinders is limited to 3.5 kg/CM2. The triple valve also has a 'lap'
position whereby it is possible to control the brake cylinder pressure to values below 3.5 kg/cm2 by
holding the brake pipe pressure at intermediate values making use of position III on the brake
controller.

(c) When the brake pipe is recharged by moving the controller to position I, the triple valve returns to
the position indicated in (a), thus releasing the brakes and storing air in the auxiliary reservoir in
readiness for the next application.
Not shown in Fig 4.03 is a 'triple valve stabilizing valve' which ensures that the triple valve does not
react to small pressure pulsations.

11. In position V (i.e., 'emergency') of the brake controller, both EP and auto brakes apply together.
Rapid application of the automatic brakes is obtained by quick venting of the brake pipe to
atmosphere. A safety valve in the brake unit on each coach prevents excessive pressure in the
brake cylinders. This valve is normally set at 3. 9 kg/CM2.

12. Release of the deadman's device by the Driver results in quick venting of the brake pipe to
atmosphere via an 'emergency valve' resulting in full auto application.

13. A valve is provided in each driving cab to enable the Guard to vent the brake pipe to
atmosphere and thus cause brake application. A gauge is provided close to this valve to indicate the
brake pipe pressure to the Guard.

14. A pressure switch usually called the 'control governor' connected to the brake pipe prevents
application of power to the traction motors till the brakes are kept ready . This control governor
opens and cuts off traction control supply if the brake pipe pressure is reduced.

15. A 'duplex' pressure gauge is, provided in the driving cab to indicate to the Driver the pressure in
the main reservoir and brake pipes. Another duplex gauge indicate to him the pressure in the brake
cylinders of the two leading bogies.

16. Isolating cocks are provided to isolate a defective brake unit form the MR and brake pipes and
also to Isolate brake cylinders in individual bogies.

17. The brake cylinders are equipped with automatic slack-adjusters to take up the slack in the
brake rigging with wear of brake blocks, thus ensuring fairly constant piston stroke and obviating the
need for manual adjustment of the brake-rigging between visits of the units to the shed. This is an
essential feature of brake equipment for suburban services, when the brake block wear is quite high
on account of frequent application of brakes.

18. The Knorr system is quite similar to the equipment described above . In this system , however,
the automatic brakes become operative automatically on failure of the EP system. With this
arrangement the brake controller has only three positions viz., 'release', 'full service application' and
'emergency'.

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME Ill [116]

 Annexure 4.03

VACUUM BRAKES

1. Vacuum brakes are provided in some EMU (MG). A description of the brake equipment together
with some details on general maintenance of vacuum brakes in goods and passenger vehicles is
therefore included here, Fig 4.04 give the schematic diagram of the system as adopted in MG
EMUs.

2. When vacuum is created in the train pipe, the ball valve establishes communication between the
chamber above the piston and portion of cylinder below the piston. With equal vacuum above and
below the piston, the piston comes down" by gravity and the brakes are released. When vacuum in
the train pipe is reduced by admission of air, the ball valve closes and the pressure of air below the
piston moves it up, the piston movement being assisted by the rolling ring. The amount by which the
vacuum is reduced in the train pipe determines the braking force.

3. When a cylinder has to be manually released the 'release valve' is operated to establish
communication between the chamber and the portion of cylinder below the piston. With equal
vacuum on both sides of the piston, the piston comes down by gravity and the brakes get released.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [118]

 Proforma 4.01
(Refer para 30402)
RAILWAY
E.M.U. CAR SHED

Note:- Test before and after Inspection, Overhaul of BG AC EMU.

Coach No......................................Date .....................................Time of starting of work ..
Time of completion of work...
-------------------------------------------------------------------------------------------------------------------------------------
SL. Parts to be Specific points require attention Any
abnormality
No inspected
noticed
-------------------------------------------------------------------------------------------------------------------------------------
1. Checking 1. Check negative Binding and ensure tightness
2. Check up battery voltage. Normal value-110v.
3. Check up battery voltage with auxiliary compressor
Working normal value 90-100V.

2. Battery 1. Check up charging voltage without load.

Charger & Normal value 110 115 Volts.
2. Check up charging voltage with load.
Normal value-110-115 volts.
3. Check up the charging current 5 to 8 A.

3. Auxiliary 1. Check up time taken to build up 6.3 kg/cm2

compressor pressure .
Normal time 12mnts.
2. Check up blowing pressure of safety valve
Normal value 8kg/cm2
3. Governor (GRCPA):
(a) Check up cut in pressure
Normal value 5.3kg/cm2.
(b) Check up cut out pressure
Normal value -6.4kg/cm2

4. Main 1. Check up time taken to build up 7kg/cm2 pressure

compressor Normal time 9 mnts.
2. Check up blowing pressure of safety valve
Normal Value 8.0 kg/cm2 .
3. Governor (GRCP):
(a) Check up cut in pressure
Normal value 6kg/cm2.
(b) Check up cut out pressure
Normal value-7kg/cm2.

5. Brake Pipe 1. Check up time taken for initial building of 5kg/cm2 pressure.
2. Check up time taken for rebuilding up of 5kg/cm2 pressure.

6. Pressure 1. Check up cut in pressure

Switch for ABB Normal value 5.2 kg/cm2.
(Gov. ABB) 2. Check up cut out pressure
Normal value-4.5kg/cm2

INDIAN RAILWAYS-AC TRACTION MANUAL-VOLUME III [119]

-------------------------------------------------------------------------------------------------------------------------------------
SL. Parts to be Specific points require attention Any abnormality
No inspected noticed
-------------------------------------------------------------------------------------------------------------------------------------
7. Control Governor 1. Check up cut in pressure
Normal value 4.2kg/cm2
2. Check up cut out pressure
Normal value 3.2kg/cm2
8. Pressure Switch 1. Check up cut in pressure
for Equipment Normal value 4.2kg/cm2
Reservoir 2. Check up cut out pressure
Normal value 3.3 kg/cm2
9. Check leakage in 1. MR Pipe leakage with E.P. Unit(BP Isolate)
Air pneumatic Normal value 0.1kg/cm2 per 5 mnts.
Pipe line. 2. BP Pipe leakage with auto unit.
Normal value 0.1kg/cm2 per 5 mnts.
3. MR Pipe line with B.P. Pipe line
Normal value 0.1kg/cm2 per 5mnts.
4. MR Pipe line, B.P. Pipe and B.C. applied with full E.P.
Normal value 0.8kg/cm2 per 5 mnts.
10. Check up Air 1. Main reservoir gauge,
Pressure gauge Normal value 7.0kg/cm2
Readings to check 2. Control pressure (B.P. pressure) gauge
Functioning of Normal value- 5.0 kg/cm2
gauges 3. Equipment reservoir pressure gauge
Normal value 4.8 kg/cm2
4. Emergency reservoir gauge
Normal value 6.3kg/cm2
11. Check up Air 1. Check up Air pressure for cast iron brake
pressure of brake blocks( B.C. pressure)
blocks Normal value 3.5kg/cm2
Normal value 1.5kg/cm2 and 2.0 kg/cm2 for motor
and trailer
Coaches respectively with composite brake blocks.
12. Pantograph 1. Check up raising time 6-10 sec.
2. Check up lowering time 3-11 sec.
13. Check up working of :-
(i) Wind screen wipers 1. Driving Cab
(ii) Horns 1. Driving Cab
(iii) Alarm Bell 1. Motor Coach B
2. Trailer A
3. Trailer D
(iv) Signal Bell 1. Driving Cab

INDIAN RAILWAYS-AC TRACTION MANUAL VOLUME III [120]

-------------------------------------------------------------------------------------------------------------------------------------
SL. Parts to be Specific points require attention Any abnormality
No inspected noticed
-------------------------------------------------------------------------------------------------------------------------------------
14. Check up function
of Lights and Fans:
(i) Head Lights 1. Driving Cab
(ii) Tail Lights 1. Driving Cab
(iii) Head Code 1. Driving Cab
Lights
(iv) Compartment 1. Motor Coach B
Light Normal 2. Trailer A
and Emergency 3. Trailer D
and Fans in
(v) Cab Lights 1. Motor Coach B
and Fans
(vi) L.T. Compartment 1. Motor Coach B
and Equipment
Compartment Lights
15. Sequence and
Inter lock tests:
(A) On power 1. Trip NFABB and see if ABB trips.
2. Open reverser bos and earth on reverser terminal with the
special insulated test rod and see if RFN sets and ABB
trips see for the flag indication.
3. Press panto lower switch and see ABB trips first (ON L.T.)
(B) L.T. test 1. Close E.A.S.
(i) Operate silicon (a) Only one bridge see if blue lamp glows
Rectifier Trip (b) Two bridge see if CBAR picks up and indicating lamp glows.
Switches 2. Create leakage in equipment reservoir and
see if M-1 to M-4 trips
3. Manually operate OLP, OL5 ,OL6 , FERA2, BIR
relays and see if ABB trips.
4. Manually operate TSS and see if ABB trips
5. Manually operate (a) OL1, OL2 and see if M-1 and M-2 trips
(b) OL3, OL4 and see if M-3 and M-4 trips.
6. Manually operate AOVR and see if progression is
affected
during full power
7. Manually operate CLR 1 and CLR2 and see if
progression is affected
16. Check functioning
of relays and trip
switches

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [121]

-------------------------------------------------------------------------------------------------------------------------------------
SL. Parts to be Specific points require attention Any abnormality
No inspected noticed
-------------------------------------------------------------------------------------------------------------------------------------

17. Final check up after

inspection 1. Visually examine roof equipment
Panto
ABB
Other Equipment
2. Visually examine underframe
3. Check up brake application and proper release of brake
4. Check motor cut out switches to see whether all the traction
motors
are Cut in .
5. Check indication bulbs
-------------------------------------------------------------------------------------------------------------------------------------
-----
Name of worker______________________ Signature of worker________________Section
Supervisors Remark
and
Signature______________
Dated______________
Dated____________________
PPO Supervisors
Remarks and

Signature_________________

Dated____________________

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [122]

 CHAPTER V
OPERATION OF ROLLING STOCK

30500 Divisional Organization

Senior Divisional Electrical Engineer /Divisional Engineer (Operations) assisted by junior officer /
officers is responsible for operation of Electric locomotives and Multiple Units in a division.

30501 Duties of Chief Traction Foreman-Running (CTFR)

In addition to overseeing work of the ATFR, he will

1. exercise overall day-to- day control over staff incharge of electric loco operation and outstation
maintenance;

2. ensure day to day availability of electrical running staff for train services and exercise control over
the booking of such running staff ;

3. arrange supply of uniforms, rule books consumable stores and tools to the running staff;

4. arrange periodical vision tests of running staff as prescribed and maintain records for the same;

5. maintain 'Road Knowledge Register' for running staff and ensure that no person is booked to
work a train until he has thoroughly learnt the road and has signed a certificate that he is fully
acquainted with the road;

6. investigate and report cases of time lost on loco account whenever reported by the Traffic
Controller; depute Driving Inspector whenever required to investigate and collect more details as
required

7. educate staff under his charge on safety rules and test their knowledge of such rules;

8. arrange relief of running staff as required for refresher courses and other training schemes;

9. ensure upkeep of running rooms so as to ensure that staff get adequate rest in the running rooms
and are satisfied with the same this may involve liaison with other departments;

10. arrange for outstation inspection of locomotives in accordance with the instructions laid down;
also carry out minor repairs at outstation depots to the extent feasible;

11. arrange drawal, distribution and accountal of stores and tools required for outstation
maintenance of electric locos and ensure that the prescribed tools, equipment and log books are
available in good condition on the locos;

12. exercise control and maintain liaison, with operating department over terminal detention in the
yards viz. turn-out of locomotives in time for working trains and timely availability of the staff;

13. investigate and report irregularities and signal defects noticed in train working and reported by
running staff;

INDIAN RAILWAYS, - AC TRACTION MANUAL - VOLUME Ill [125]

14. ensure that the Combined Driver's and Guard's Report are received back after return of the crew
to HQ.;

15. scrutinize forms submitted by driving staff to the Statistical Branch;

16. arrange adequate representation in minor joint inquiries in regard to accidents, detentions etc.

17. accompany relief trains in case of accidents involving electric rolling stock and supervise relief
operations at site;
18. ensure that the speedometer charts are regularly sent to loco Inspector (TELOC) sitting at
Divisional headquarters-100% for passenger locos and 25% for goods loco, and take appropriate
action in regard to the irregularities. (A suitable cell may be set up for this purpose). After removal
the charts may be preserved at least for a week;

19. arrange to ensure filling of dry sand in sand boxes of locos and EMUs and availability of dry and
clean sand as per RDSO specifications at all places nominated by Sr. DEE/DEE(OP).

30502 Duties of Assistant Traction Foreman - Running (ATFR)

ATFR will

1. ensure that the staff reporting for duty are sober and not under the influence of alcoholic drinks.
All incoming staff will be subjected to breath-analysis before being allowed to perform the duty.

2 ensure that all running staff Posses the valid competency certificates.

3. display of temporary speed restrictions in prominent manner at the booking offices.

4 notify the driver regarding existence of Short Neutral Section to avoid raising of both pantographs.

5.arrange relief for running staff whenever asked for by the Traction Loco Controller (TLC) to avoid
running staff performing more than the prescribed hours of duty at a stretch.

6.ensure that the outgoing locos / EMUs are provided with full complement of tools, emergency
telephones, fire extinguishers and other essential consumable stores.

7.ensure filling of sand in sand-boxes of locos and EMUs and availability of dry and clean sand at all
outstations and booking points.

8. investigate and report cases of time lost on loco account whenever reported by the Traffic
Controller; depute Driving Inspector whenever required to investigate and collect more details as
required.

9. arrange inspection of incoming and outgoing locomotives at the "bhar' coordination with the
maintenance staff that booked repairs are carried out.

10. report to TLC the details of locos to be attended to at outstation sheds and the defects which
require attention at shed; the cases of unusual occurrences should also be reported.
11. prepare position of issue and return of Combined Driver's and Guard's report in the proforma at
Annexure 5.01

12. ensure that the staff are availing adequate rest at headquarters and outstations.

INDIAN RAILWAYS- AC TRACTION MANUAL VOLUME Ill [126]

13.- ensure proper upkeep of "sign ON" and "sign OFF" register and see that every running staff
reporting for duty in his office signs in this register.
14. supervise call boy and Box Porter and instruct them suitably for calling the crew and sending the
boxes respectively.

30503 Loco Control Organization

Personnel manning the TLC Organization should be adequately trained. In addition they should be
sent for refresher courses to the Training Schools and Sheds periodically as specified to keep
themselves familiar with the current problems on locos so as to be able to guide loco crew
effectively.

30504 Duties of Assistant Traction Loco Controller (ATLC) & Traction Loco Controller (TLC)

ATLC / TLC will

1. maintain a list of passenger fit locos and watch the running of passenger Trains, report after
necessary investigation all cases of time lost on loco account as well as time made up by drivers;

2. plan in consultation with the PPO of the shed and move, the locos to the shed for scheduled
inspections and unscheduled repairs and obtain forecast of locos likely to be made fit by the sheds
and plan the movement of such locos for clearing traffic, in coordination with the Traffic Controller;

3. watch the detention to electric locos as well as, electrical running staff in yards and, Sections and
take remedial action in coordination with the traffic Controller;
4. maintain liaison with contiguous divisions in respect of "balancing" of crews;

5. watch train operation in order to avoid excessive waiting duty for running staff and take remedial
action as required in coordination with the Traffic Controller;

6. guide staff in trouble shooting if they are stuck up on line;

7. send back to the homing shed of foreign Railway loco due to scheduled inspection;

8. study cases of running staff performing more than prescribed hours of duty at a stretch and take
necessary remedial action to avoid recurrence;
9 .Prepare the locomotive charts.

30505 Duties of Chief Loco Controller (CTLC)

In addition to overseeing the work of ATLC/TLC he will

1. check of loco link charts, booking records and control charts and report all cases of avoidable
detentions to electric locomotives in yards and sections;

2. update the list of speed restrictions and advise different crew booking points on the division:

3. organize suitable relief loco in consultation with Section Controller in case of loco disablement;

4. scrutinize daily loco operating statistics;

5. organize trials of electric locomotives;

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [127]

6 .arrange escorting staff for trains carrying VIPs and other important trains as per procedures
specified by the Railway.

30506 Duties of Driving Inspectors

The Driving Inspectors will report to CTFR and their main duties will be as given in subsequent
paragraphs.

30507 Duties of Junior Driving Inspector (JDI)/Senior Driving Inspector (SDI)

He will

1 plan out in advance that train drivers and other running staff put under their charge 'learn the road'
and become fully familiar with all the signals and layout of the track, en route and in yards; test the
running staff for their knowledge of road as detailed in para 30615 and arrange for issue of
Competency Certificate to them;

2. train running staff in the correct methods of trouble-shooting, correct manner of operation of
electric locomotives, inspection of locomotives in accordance with the prescribed rules;

3. maintain records in respect of running staff allotted to his charge indicating the training imparted,
refresher and promotional courses gone through, knowledge of safety rules, knowledge of trouble-
shooting procedures etc.; watch running staff of poor calibre with a view to improve them and in
exceptional cases when a person fails to make the grade, submit report to TFR;

4. make himself fully aware of the competence of each of the crew under his control. He should also
be familiar with their habits, like drinking etc., traits, state of health and other personal problems. It is
the responsibility of driving inspector to ensure that he has counselled all the crew under his control
at least once a month. For this purpose he will maintain a proper calendar /diary;

5. keep high morale of the driving crews and keep on reporting about the same to superiors;

6. conduct enquiries into accidents, detention cases, disciplinary cases, etc., as directed by his
supervisors;

7. carry out any other duties assigned by Sr. DEE/DEE/AEE(OP).

30508 Duties of Senior Loco Inspector (SLI)

In addition to the duties assigned by Sr. DEE/DEE/AEE (OP), he will

1. carry out trials and checks on speed, signal visibility, riding quality of locomotives; test staff of
other departments as prescribed for their knowledge of rules applicable to operation of Electric
Locomotives and report to SR. DEE/DEE/AEE (OP), if any irregularities are noticed;

2. inspect locomotives particularly in regard to safety items and take necessary action to get the
defects attended by the home or outstation shed.

A nominated loco Inspector designated as Senior Loco Inspector (TELOC) will collect and scrutinize
the speedometer charts regularly- 100% for passenger locos and 25% for goods locos and bring
irregularities to the notice of Sr. DEE/DEE/AEE/(OP) for appropriate corrective action.

The assigned SLI shall keep a watch on duty hours of the Running Staff and report the matter to Sr.
DEE/ DEE/AEE (OP) for taking suitable corrective measures.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [128]

30509 Vision Test Register

1. All running staff are required to be periodically examined to ascertain their fitness in A-1 medical
category and other special prescribed tests, if any. Running staff who are below 45 years of age are
required to be examined once in 3 years and those who are over 45 years are required to be
examined. once a year. At the headquarters station of the running staff, a register as per proforma
placed below should be maintained to record particulars of periodical medical examination:

VISION TEST REGISTER

(Category of staff i.e. Driver /Asstt Driver /Motorman)
------------------------------------------------------------------------------------------------------------------------
SNo. Name Date of Date of Medical Certifi- Next Whether
Birth examination categorty ficate No. Due passed with
Date spectacles
------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7 8
-------------------------------------------------------------------------------------------------------------------------
2. Separate registers will be maintained for each category of running staff. No member of the
running staff should be allowed to become overdue vision test, and any person who is overdue
vision test should not be booked out on running duties. If during the periodical medical examination
a person is declared unfit for A- 1 medical category he should be forthwith withdrawn from running
duties.

3. On transfer from another section, particulars of last medical examination should be obtained and
entered in the Vision Test Register before the employee is booked out for running duties, including
road learning.

30510 Running Staff Passed Fit with Spectacles

1. A list of Drivers, Assistant Drivers, Shunters and Motormen who have been declared fit for A-1
category with glasses should be prepared with the names of staff of each category arranged
separately and in alphabetical order. This list should be exhibited prominently in the booking office
for each category of staff, who are likely to be booked from his station. The TFR should ensure that
this list is complete and updated in all respects. For this purpose he should make 100 percent cross
check of all the names in the list with details entered in the Vision Test Register at least once in six
months.

2. Each member of the running staff who is declared fit for A-1 category with glasses must
constantly use, glasses on duty and in addition should carry a spare pair of spectacles with them
always when on duty. During Inspections, check should be exercised by officers and supervisors to
ensure compliance.

3. Running staff passed fit with spectacles are also required to sign a 'Spectacle Register' on
reporting for duty in token of being in possession of two pairs of spectacles.

30511 Rules Applicable to Running Staff

The General Rules and the Subsidiary Rules issued by the Zonal Railways prescribe the duties of
train crew. Running staff will also be abided by all the rules given in Operating Manual of Zonal
Railways about their call, booking and liability for duty, etc.

30512 Acknowledgment of Circulars etc.

In addition to thorough familiarity with the General and Subsidiary. Rules, Manual of AC Traction,
Accident Manual, Working Time Table (in particular the permanent speed restrictions), Operating
Manual for various types of electric locomotives and departmental circulars issued from time to time,
every member of the, running staff shall, when signing on duty, study circulars, notices, instructions,
copies of the Gazette etc. displayed on the
INDIAN RAILWAYS - AC TRACTION MANUAI - VOLUME Ill [129]
notice board or in the registers provided for the purpose. They shall particularly acquaint themselves
with details of temporary speed restrictions imposed in the section in which they have to work,
details of caution orders and advice of defective signals. If any person has not understood any of
the instructions, he may seek clarification from the ATFR on duty.

30513 Availability of Dry Sand

All electric locos and EMUs are fitted with sanding equipments to improve adhesion and prevent
wheel-slipping when starting under difficult conditions e.g. up-gradients or when rails are wet.
Sanding is effected by means of electro-pneumatic valves to sand the front axles of each bogie in
the direction of motion, the control being achieved by a pedal switch in each cab. Means are
provided to adjust the height of the sanding nozzles. In modern locos automatic sanding takes place
on the onset of incipient slipping.

The sand to be used should not cake in the sand box and should be dry, free from clay, loam, mica
and other foreign materials. A detailed specification for the sand has been issued by RDSO.
Facilities should be available in all loco sheds and such outstation depots as considered necessary
for ensuring an adequate supply of screened and dry sand. Special care is also required during
inspections to ensure the water-tightness of sand box covers.

30514 Seasonal Precautions

1. A few essential precautions required to be taken prior to the commencement of the monsoon,
pre-summer season and pre-winter season are listed below. Local instructions may be issued to
supplement these lists as required.

2. The pre-monsoon precautions

a) Test the water-tightness of loco/EMU body including roof by means of a high pressure water jet
and seal all leakage points. (It must be ensured that the loco / EMU is well away from live OHE to
prevent the water jet coming into contact with live wires).

b) After the first rain the loco /EMU should be Inspected thoroughly to detect and attend to leakage
points. Special attention should be paid to the following water leakage points -

i) Body joints
ii) Joints of the mounting bases of the roof equipment.
iii) Joints of marker lights.
iv) Joints of look-out glasses and side glasses.

v) Door gaskets.

vi) Sand-box joints.

vii) Roof gaskets.

viii) Head light gaskets

c) The wind-screen wipers should be tested and attended to.

d) Roof joints with super-structure-roof gasket should be in good fettle.

e) Joints of side body filter with super structure.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [130]

f) Ensure cleanliness of roof gutter.

g) Proper functioning of sanders should be ensured.

3. The pre-summer precautions :

a) Clean all filters and check depression with a water manometer to ensure that the cleaning has
been thoroughly done.

b) The loco interior should be thoroughly cleaned of any accumulation of oil and dust.

c) Axle boxes should be thoroughly examined.

d) Drivers must he alerted to feel the axle boxes as often as possible.

e) Fans in the driver's cabs should be attended to.

f) Relay covers are properly provided and sealed to avoid ingress of dust.

4. The pre-winter precautions :

a) Heaters : It should be ensured that all the four cab, heaters are in working order

b) Window Shutters : The window shutter sealing gaskets should be checked and made air tight.

c) Doors : Ensure that cab doors and corridor doors locking handles are in working order. The door
sealing gaskets should be held tight in the position.

d) Cab Ventilators : Ventilator cover sealing should be perfect.

e) TFP : Main power transformer and Tap changer breather silica- gel condition should be checked
and replaced if necessary. Oil levels in TFP & GR to be checked and oil tested for DE.

f)Oil Baths : Main compressor and exhausters oil baths should be checked and oil replaced, if
necessary.

g) Sanders :Sand boxes should be checked : wet sand removed and dry sand filled.

h) Traction Motors : TM inspection cover sealing gaskets should be checked to ensure that there is
no air leakage

i) Pantograph : The servomotor of pantographs should be drained off and regrease . Roof and panto
insulators should be applied with a coat of silicone grease

j) SMGR : Tap changer servomotor cylinders should be cleaned and regrease.

k) Battery : Terminals should be checked for sulphation, cleaned and petroleum jelly applied on the
terminals.

l) Brake cylinder : Adjustment should be carried out and regreasing done.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [131]

OPERATION OF LOCOMOTIVES

30601 Trailing Loads Assigned to Various Locomotives.

1. The trailing loads assigned to various types and classes of locomotives will be governed by the
Load Chart issued by RDSO. (refer Annexure 1.03). These loads are worked out taking the
theoretical site condition and the track geometry specified in the drawings. Actual site condition and
the track geometry may differ. The ruling gradient of the section may differ from the declared grade
and the section may have curves, the radius of which may be different from the radius taken in the
calculation of the assigned load. Further, partial brake binding , capability of an average driver
combined with adverse weather condition may affect the actual load that can he hauled by a
locomotive in a particular section. Therefore, before the loads of a particular class of locomotive are
fixed for various sections, the actual trials with specified loads on these section should be carried
out. The trial would ensure the ability of the locomotive to start and haul the nominated load on the
ruling gradient.

2. For multiple operation, separate trials should be carried out with 2,3 or 4 locos in multiples as
required in actual operation. These need not be exact multiples of loads with a single loco, since the
sharing of loads by the locos may not be equal due to various manufacturing tolerances, varying
wheel diameters etc.

3. The nominated loads both for single and multiple operation should be determined for each
section, loco class- wise and tabulated.

4. Loads for each section with multiple operation should be given in the table as mentioned above
and also when the motors or pairs of motors have been cut out.

5 The loads will be fixed section wise for each class of locomotive by CEE in consultation with COM.

30602 Time Tabling and Loco Link Diagrams

To achieve maximum utilization of locomotives, loco link diagrams should be prepared in such a
manner that the locomotives are kept on the run for the maximum number of hours each day with
the minimum detentions at terminal stations. This work has to be done by close co-ordination
between Sr DOM/DOM and Sr DEE(OP)/ DEE(OP).

30603 Assessment of Operating Staff for Electric Locos.

1. For mail, express and passenger services running staff links are prepared based on the time
table and keeping in view the prescribed minimum rest to be given at out-stations and headquarters
station. This will give the bare number of sets of running staff required. Each set will consist of one
grade A Driver and one Assistant Driver. For Rajdhani/Shatabdi Expresses or other high speed
trains the assessment of crew will be modified suitably since the function of Asstt. Driver are
performed by a Co-driver booked to assist the train driver.

2. Requirement of running staff for goods services is arrived at on the basis of the "turn-round"
method. The turn-round of a Driver is "signing on time" to "signing off time" and includes waiting
duty at both ends.

- The average turn -round time 'T' hours for a Driver is equal to average time from signing on
at the starting station till commencement of journey plus average journey time plus average time
from arrival at destination to signing off.

- If there are N trains to be run per day, the total Driver hours per day will be equal to Tx N
hours

INDIAN RAILWAYS -AC TRACTION MANUAL -VOLUME III (135)

At an average of 104 hours of duty for 14 days per driver, the number of drivers required will be TxN
divided by 104/14.

Each set of staff to operate goods train will consist of a grade B or C Driver and one Assistant
Driver.

3. The detailed procedure for assessing the Running Staff requirement has been given in Operating
Manual of Zonal Railways . Running Staff requirement and its review shall, therefore, be carried out
as per instructions laid down in that Manual.
a) leave reserves in the appropriate category as per prescribed percentages ;
b) special and non-scheduled trains ;
c) loco shed working ;
d) overlapping crew at out stations;
e) relief crew en route ;
f) trainee reserve in the prescribed category ;
g) other special duties.

30604 Duties of Electric Loco Drivers

In addition to the duties laid down for Drivers in Chapter IV Of General and Subsidiary Rules,
Drivers shall be responsible for the following:

1. On taking over, a driver must study the log book and inspect the locomotive / EMU as laid
down in the Operating Manual of the particular class of loco. If he finds any abnormality, he shall
work in accordance with the instructions laid down in the Operating Manual.
2. When looking out he shall pay particular attention to the state of OHE of his own line & lines
in proximity.

3. While examining the under-gear or attending to any part of the under-gear he shall keep the
brake of the train (or in the case of a light engine the locomotive brakes) fully 'ON'.

4. Before examining or carrying out any work on equipment in the high tension compartment,
he must lower the pantograph and earth the locomotive in accordance with prescribed instructions.

5. The driver shall not permit any un-authorised person to travel in any cab or corridor of the
locomotive. Apart from the engine crew, only authorized supervisors of the traction branch and
those specifically authorize in writing by Sr. DEE/(OP), DEE(OP) shall be allowed to travel in any of
the cabs of the electric loco. When working the train, the Driver shall not enter into discussions or
conversation with persons travelling in the cab.

6. The Driver shall ensure cleanliness of the locomotive. He may make use of Asstt. Driver.
7. The Railways may issue special instructions locally for the checks to be performed by the drivers/
assistant
drivers on the locomotives when the halt at a station exceeds 10 minutes. This will depend upon the
nature of the section and severity of the service.

8. In the event of any abnormality on the run, he shall carryout the instructions in the Operating
Manual of the locomotive. He shall also keep a detailed record of unusual occurrences or
abnormalities experienced and submit

INDIAN RAILWAYS AC TRACTION MANUAL-VOLUME III [136]

report in the prescribed proforma to the TFR. If he is unable to localize and repair any fault on line,
he shall make use of the emergency telephone to seek the advice of TLC.
9. The Driver / motorman shall keep a special watch on the pantograph of his own train as well as
passing electric trains and report any abnormality as soon as possible to TPC/TLC. If he notices any
serious defect in the pantographs which are likely to cause damage to OHE, he shall stop the train
forthwith and convey details to the TPC/TLC on duty.

10. He will report any speed restriction if put near the Neutral Section which is likely to result in
stalling of train in the dead zone.

11. Before signing 'off' duty, the Driver shall submit reports as prescribed by local instructions
including any abnormality in signals, speed restrictions and trains along with the unusual
occurrences observed in the locomotive during trips worked by him to ATFR.
12. He will report for duty with a neat appearance in proper uniform.

13. He will perform any other duty assigned to him from time to time by ATFR.

14. The driver shall exchange signals enroute with assistant driver, station staff and guard of the
train as specified in GR & SR.
30605 Duties of Assistant Drivers

In addition to the duties laid down in Chapter IV of the General and Subsidiary Rules, the Assistant
Driver shall be responsible for the following:

1. Cleanliness of the locomotive.

2. During the run he shall examine the following items from time to time:

a) Battery / generator voltage.

b) Charging current
c) Transformer oil level and temperature.

d) oil level in compressors and exhausters.

e) Functioning of blowers and auxiliaries.

f) Target indicator of relays.

3. Assistant Driver shall assist the Driver to enable him to carry out instructions as detailed in para
30604 and sub-para 4 of 30634. He shall also watch out for any unusual smell or abnormalities.

4. He will report to duty with a neat appearance and proper uniform

5. He will perform any other duty assigned to him by the Driver and ATFR.

6. For Rajdhani /Shatabadi Express or similar high speed trains the functions of Asstt. Driver will be
performed by the Co-driver provided to assist the train driver.

7. He will assist the driver in attending any irregularities on line like ACP, HPD etc.,

8. He will ensure draining of cocks to expell moisture whenever the train stops for more than 15
minutes.

INDIAN RAILWAYS -AC TRACTION MANUAL -VOLUME III [137]

9. He will be responsible for maintaining a log of times and detentions enroute.

10. He will exchange signals with driver, station staff and guard of the train as per instructions laid
down in GR and SR.

30606 Checks by Driver on Taking Over

Every time a locomotive is taken over from a shed after scheduled inspection or repairs or from a
stabling line after maintenance or repair work has been carried out, it is the responsibility of the
Driver to check and ensure that the locomotive he has taken over is fit and safe in every respect for
service on the line. He shall operate it with due care taking personal interest in its upkeep. He shall
also make a note of the defects observed in operation and report them to the maintenance officials
for attention.

30607 Cleanliness of Loco

The Assistant Driver is responsible for the cleanliness of the driving desk, cab, look-out glasses and
glass windows during preparation before departure, changing of crew and inspection on arrival. The
maintenance staff who carry out the scheduled inspections are responsible for the cleanliness of HT
room, cubicles and corridors. The washing gang at the home shed is responsible for the cleanliness
of the roof and body sides during every washing schedule. In particular care should be taken to
keep the interior of the loco quite clean. Oil drippings should be cleaned out and leaky valves
attended to at the earliest possible opportunity to eliminate fire hazards.

30608 Unauthorised Persons in the Loco

No person shall be permitted to enter any locomotive or to handle any apparatus contained therein
unless he has been authorised to do so by the Sr. DEE/DEE/(OP).

Only Drivers certified for electric locos must be allowed to drive the locomotives. The Driver must
not allow any one to enter any of the driving compartments, other than those who are authorised to
do so under the rules or hold a permit issued by Sr DEE/DEE/(OP).

Normally not more than three persons other than running staff will be permitted to travel in the cab.

A Driver who is off duty is not permitted to enter or travel in any of the driving compartment unless
authorized by TLC and that too for travel towards headquarters after being relieved en-route. This
will be permitted only in the non driving cab/cabs.

30609 Interference with Equipment.

Drivers and Assistant Drivers will not tamper with the measuring instruments, speed recorder and
protective relays.
Relays or other sealed equipment should not be opened or wedged except as authorized in the
trouble shooting manual. If a driver opens a relay or breaks the seal of any equipment, full
particulars should be noted in the loco log book. Particular care is also necessary while putting back
metallic covers of relays to avoid inadvertent shorting of live terminals.

30610 Checks on the Run by the Driver

On the run, the Driver shall be primarily concerned with keeping a sharp look-out for signals and
watching the road. However, he should, from time to time, keep an eye on the vacuum and pressure
gauges, the voltmeters and ammeters as well as the speedometer and notch indicator, to assure
himself that everything is in order.

Apart from keeping a close watch of signals ahead, and signals from the Guard, the Assistant Driver
shall keep a special watch on the battery voltage and the battery current. In addition as often as
possible, he shall check the working of the blowers and keep a watch on the transformer and tap
changer oil level.
INDIAN RAILWAYS - AC TRACTION MANUAL -VOLUME III [138 ]
The Assistant Driver should not normally leave the driving cab to inspect the equipment in the
corridors when the train is approaching a station or at locations where speed restrictions exist.

30611 Change of Locomotive Crew at Stations

The relieving Driver should make a general inspection of the underframe, drain the main reservoir
and feel by hand the axle boxes and motor bearings to make sure they are not hot, before entering
the cab. The relieved Driver shall acquaint the relieving Driver about any abnormalities noticed
during the preceding run. The relieving Driver shall note and initial the entries in the log book. The
relieving Assistant Drivers should take over the loco tools.

30612 Service Troubles on Line

Every locomotive Driver is expected to be fully trained to deal with troubles which may be
experienced while a locomotive is on the run. Drivers should keep themselves fully conversant with
fault finding procedures so that they are able to identify the fault, isolate it, give first aid attention to
the equipment to keep the locomotive functioning, until it arrives at the next station. The Driver may
consult the Operating Manual for the type of loco where necessary to refresh his memory.
Should a locomotive fail completely and the Driver is unable to start it on his own, he should seek
the help and guidance of the Traction loco Controller by plugging the portable telephone set to the
nearest emergency telephone socket within 20 minutes.

30613 Entering Equipment Compartment

If the Driver or Assistant Driver has to enter the equipment compartment of a loco he should take
care to see that the cab doors and drop windows on both sides are closed before opening the
corridor door, to prevent dusty air being drawn into the equipment compartment.

30614 Driver's Duty when Stabling a Loco

When stabling a loco in the loco shed or a stabling line, the Driver assisted by the Assistant Driver
shall carry out the following operations:
1. Drain all reservoirs.

2. Ensure that the emergency reservoir is charged to the specified pressure and then close the
isolating cock of the emergency reservoir.

3. Trip the circuit breaker.

4. Lower the pantograph and check that it is fully lowered.

5. Open the battery main switch.

6. Put on the hand brake.

7. Close all doors and windows.

8. Enter in the loco log book the kilometre reading, particulars of the last trip, of any defects or
abnormalities to be attended to, any unusual occurrences during the previous trips and any other
particulars required in accordance with local instructions.

9. Hand over the log book and keys of the loco in the TFR/ ATFR's office before signing off.

When a locomotive is stabled on a pit line, the Driver shall also carry out under-gear and roof
Inspection in

INDIAN RAILWAYS - AC TRACTION MANUAL -VOLUME III [139]

accordance with detailed instructions in the Operating Manual for the type of loco and make
necessary remarks in the log book.

30615 Knowledge of Road

1. Every Driver (as well as Assistant Driver, and Shunter) shall have a good knowledge of the
section before he is allowed to work a train in the section. He shall be fully conversant with the
maximum permissible speeds, gradients and land marks on the section, the block and non-block
stations on the section, type and location of each individual signal and the line referred to by each
signal, the speed restrictions to be observed and neutral sections. For learning road as mentioned
above, he should be allowed a period of training at the end of which he shall be orally tested by the
Driving Inspector. He should also sign a declaration stating that he is fully conversant with the road.
The declaration should be witnessed and countersigned by the Driving Inspector and scrutinized by
the officer concerned before issue of the Certificate of Competence.

2. When a Driver, Assistant Driver or Shunter has been absent from duty for a continuous period of
six months, he shall not be permitted to work a train until he has again learnt the road and his
Certificate of Competency revalidated after oral examination by the Driving Inspector and a fresh
declaration. The period of six months prescribed above may be reduced, if necessary, by local
instructions issued by Sr DEE(OP) /DEE((OP). These instructions shall be equally valid if the driver
did not have the opportunity to work on the section whatsoever be the reason. However, in extreme
emergency such a driver can be permitted to work the train with a pilot driver who is conversant with
the road.

3. Road Knowledge Registers shall be maintained for all sections on which running staff
headquartered at a particular shed are required to work trains. Separate registers should be opened
for each individual section and each category of staff. The register should be in the following
proforma:

ROAD KNOWLEDGE REGISTER

(Section ... to ....)
---------------------------------------------------------------------------------------------------------------------------------
SNo. Name of Driver/ Signature in Date of Signature Signature
Asstt Driver token of signature of the of TFR/
(or Motorman) possessing Driving ATFR
necessary inspector
road know-
ledge on
section concerned
------------------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6
------------------------------------------------------------------------------------------------------------------------------------

30616 Speed Restrictions

1. Drivers and Assistant Drivers must be fully conversant with permanent as well as temporary
speed restrictions. Permanent speed restrictions are indicated in the working time table.

2. Temporary speed restrictions will be made known to the running staff at their booking office as
under:

a) Every Driver should study 'Temporary Speed Restrictions" bulletin issued by the Division and
sign

INDIAN RAILWAYS - AC TRACTION MANUAL-VOLUME III [140]

2. Equipment

The following equipment depending upon the type of locos will be issued to the Driver on taking
over a loco or may form part of loco equipments -

i) Loco Keys - BL Key, Panto Selection Key and, Reverser key

ii)Portable Telephone

iii) Hand brush

iv) Loco log book

30620 Loco Log book

1. A separate log book is required to be maintained for each individual loco. It will be issued to the
Driver along with the tools of. the loco and will be returned by him to the Running office when
signing off or handed over to the relieving Driver. The Log Book will have machine numbered pages.

2. For each trip the Driver should enter the following particulars -

i) Date

ii)Train Number

iii) From.................To. ................

iv) Load of train (in terms of vehicles)

V) Driver's and Asstt. Driver's name

Vi)Brief description of unusual occurrence and failures, if any.

vii) Kilometre reading at the end of trip.

viii)Energy meter reading to be recorded if meters are provided,

ix) Quantities of oil and lubricants added during inspections.

3. The details of repair carried out should be entered to by the PPO of the shed or the TFR/ ATFR
before the loco leaves the shed.

4. Running and Shed supervisors will also enter in the log book particulars of any item to be
specially watched by the Driver.

5. At '0' hours on the last day of each month the corresponding kilometre reading should be entered
in the log book by the Driver if the loco is in service and by the shed/ depot supervisor if the loco is
under repairs or is stabled.

6. Every time a loco is taken for the scheduled inspection, the type of inspection and the date on
which it is done should be entered in the log book by the PPO. PPO will similarly enter details of
unscheduled withdrawals of the loco for repairs, as well as particulars of modifications carried out.

7. Completed loco log books should be serially numbered for each loco and preserved in the
Planning and Progress Office for a period of one year.

INDIAN RAILWAYS -AC TRACTION MANUAL -VOLUME III [143]

8. Officers and supervisors of the Rolling Stock section, during their cab inspections, will also record
their observations regarding performance of the loco in the log book.

30621 Driving Crew's Pocket Books

Every Driver and Assistant Driver will be provided with a pocket book to be carried by him while on
duty to enable Inspectors and Officers to record their observations regarding his working as noticed
by them during their cab inspections. This book should have machine numbered pages. All entries
should be in ink. Erasers or alteration of the entries made or tearing off of pages will be viewed as
serious misconduct by the crew.
30622 Detailed Preparation of Locomotives
The operations listed for a particular type of locomotive should be carried out in the sequence
indicated, every time a locomotive is taken over from a shed or from a stabling line. These
operations should be carried out from the driving cab. The preparation schedule presently adopted
is detailed below.

1. Preliminary Check: Make sure that the loco is stabled on a wired track. Check the air reservoir
drain cocks, and close if found open. In locos meant for multiple operation, check tightness of
electrical couplers, air hose pipes and vacuum hose pipes and if standing on a pit he should carry
out under gear examination.

2. Energization of Control Circuit : Check the relay targets and condition of fuse-free breakers
(MCBs).

Check the following:

i) Battery voltage

ii) After unlocking the lever box for auxiliary switches, see that the indication lamps for air blast
circuit breaker (red), battery charging generator (green), tap changer (blue) reverser (yellow),
rectifier (white) and for wheel slip (red) are glowing and the tap changer notch indicator is in position
'0'. In some locos a push button is required to be pressed to check rectifier and wheel slip lamps. In
some locos the pilot lamps have been replaced by LEDs. The driver should ensure that the
corresponding LEDs are glowing.

iii) That all fuses are in position on the fuse rack and/or all fuse-free breakers are switched 'ON' and
spare fuses are in good condition.

iv)That the earthing switch for control circuits is in 'ON ' position.

v)That the oil level of tap changer and transformer motor is normal.

vi)That the auxiliary isolating switches motor cut out switches and earth fault shunting switches are
normal.

vii) That the drain cocks for air blast circuit breaker and pantographs are closed.

viii)That the isolating switch/isolating handle for tap-changer operation is normal.

ix) That the earth-fault isolating switches for traction circuit and auxiliaries circuit and their relays are
in normal position and the switch for pressure relay for main circuit breaker is normal. If an isolating
switch is not in the normal position, check the locomotive log book for any remarks in this respect
and report to the shed /depot.

x) Notice if any relay target shows red indication? lf so reset relay till white indication appears and
report to shed / depot.

xi)That the isolating switches for rectifier block are normal.

INDIAN RAILWAYS - AC TRACTION MANUAL -VOLUME III [144]
xii) That the position of Master Controller, Driver's Vacuum Brake handle, Independent Brake Valve
handle and Asst. driver's brake valve handle are normal in rear cab.

xiii) That the oil levels in compressor(s) and exhausters are normal.

3. Examination of Loco Log Book: When a Driver takes over a loco he shall checked entries in
the log-book before starting the train, and take note of remarks made during the last run and repairs
carried out, and , whether he is required to keep a special watch.
4. Traction Motor Cut Out : If the log book shows that any traction motor has been isolated
during the previous with, the Driver shall check the position of the isolating switch for that motor. If
no mention of repairs has been made, the matter shall be brought to the noticed of the shed
supervisor. In regards to restrictions regarding working a loco with motor / motors cut out,
instructions given in the Operating Manual for the particular type of loco shall be followed .
5. Compressed Air Supply: If the air pressure in the main reservoir is not sufficient, the battery
operated compressor should be used to build up the required pressure in the auxiliary reservoir.
Once the pantograph is raised, the circuit breaker should be closed.

6. Closing of the Circuit Breaker: On closing the air blast circuit breaker, the auxiliary machines
should start and the indication lamps or the corresponding LED for air blast circuit breaker (red)
and battery charger generator (green) will be off. The main compressor should now be switched on
to charge the air reservoirs.

7. Starting of the Exhausters: With the Driver's vacuum brake valve on running/release
position, switch on the exhauster and check if 53 cm vacuum is built up when the hose pipe is
connected to a disc with 8 mm , (5/16") hole.

8. Brake Test:
a) Hand Brake: Apply the hand brake hard and check if the brake blocks are effectively gripping the
right side wheels of the two front axles. Release the hand brakes and check that the brake blocks
are free.

b) Air Brake: Apply the Independent air brakes of the loco and ascertain whether the application of
the brake is effective on all the wheels. This should be ensured by physical examination of the
effective gripping of the brake blocks on the wheel tread. Check if the maximum brake cylinder
pressure as indicated on the gauge is 3.5 kg/cm2 .Release the air brake and check that the brakes
are released on all the wheels.

C) Vacuum Brake/Air Brake: The tests should be carried out after coupling with the train as per
instructions laid down for the purpose (para 30623 and para 30625).

9. Blowers and Traction Test:

(i) Switch on the traction motor blowers and check their working and apply independent loco brakes.

(ii)Set the reverser in forward position and ensure that yellow lamp goes off.

iii) If the white lamp or the corresponding LED for rectifier is extinguished indicating that there is no
fault on the rectifier system, notch forward by one notch and check if traction motor ammeter needle
moves from zero and ensure that tap changer lamp (blue) is extinguished.
(iv)Switch off master controller and repeat test for the other running direction.

(V)The blowers may now be switched off and air brakes be released after repeating the test for
reverse direction.

INDIAN RAILWAYS -AC TRACTION MANUAL -VOLUME III [145]

10. PantographTest :Check raising and lowering of the front and rear pantographs one after
another, making use of the selector switch. Finally keep the rear pantograph raised for normal
operation.

11. Quick Inspection of Mechanical and other parts

Check the following:

i) Operation of sanders and level of sand in sand boxes.
ii)Working of marker and headlights and flasher lights in both the cabs.
iii)Buffers and couplers
iv) Speed Recorder/Speedometer transmitter.
v) Springs, dampers and other underframe mechanical parts and make sure there is no
abnormality.

vi) Oil level in gear cases, suspension bearings and pivot.

12 The testing of the locomotive shall be carried out from both cabs. He shall also ensure isolation
of isolating cocks of the brake of rear cab before moving the locomotive.

Note:
1. When taking over a loco on which no repair or maintenance work has been carried out,
inspections in the sub-para 11 above may be omitted if time does not permit.

2. If the Driver notices some defect or abnormality likely to affect the working of the loco, he shall
bring it to the notice of the Engine Examiner on duty.

30623 Check of Vacuum Before Starting

1. Based on the gradient and other factors in the section in which electric locos have to work each
Zonal Railway should issue instructions regarding the minimum vacuum that should be indicated In
the loco and the Brake Van gauges. If the minimum prescribed vacuum is not obtained, the Driver
shall not start the train.

2. On attaching the locomotive to a train, if the vacuum stipulated cannot be created and maintained
by the exhausters, the train should be examined by the train examining staff and leakages should
be attended to so as to obtain the prescribed minimum vacuum before starting the train.

3. Other checks of the vacuum brakes as laid down in General and Subsidiary Rules and in the
Brake Power Rules of the Zonal Railway shall also be carried out.

30624 Minimum Brake Power

The running staff shall abide by all rules regarding the minimum brake power on the goods and
passenger trains, issued by the Railways. For the purpose of working out the percentage brake
power, the "piped" vehicle should be deemed to have inoperative cylinder/cylinders. An operative
cylinder is one in which the vacuum / pressure can be created / destroyed by control from the
engine and which moreover satisfy the stipulation that its piston should remain up for not less than
20 minutes after the vacuum / pressure is destroyed.

30625 Operation of Air Braked Stock

For operation of air braked stock guidelines appear in the Annexure 6.01 to this Chapter.

INDIAN RAILWAYS - AC TRACTION MANUAL -VOLUME III [146]

30626 Master Controller

1. The progression or regression from one traction notch to another (and similar progression or
regression during braking in the case of locos with regenerative or rheostatic braking) is controlled
by the Master Controller from each driving cab. The Master Controller has two 'stable' and two
'unstable' positions for traction notches as under:

0 (zero) ...... Stable position

- (minus) ....... Unstable position

N (neutral) ........ Stable position

+ (Plus) .......... Unstable position

First release the mechanical locking of the Master Controller by moving the Reverser Controller to
Forward or Reverse position. Then move the Master Controller to Neutral position. By moving the
controller momentarily to (+) and back to N, the tap changer would be notched by one step. Notch-
by-notch progression is effected by repeating this operation. In a similar manner notch-by- notch
regression is possible by moving the Master Controller to (-) and back to N.

2. A blue indicating lamp or the corresponding LED glows in the driving cab when the tap changer is
at "0". The position of the tap changer at any instant is indicated to the Driver by a Notch Indicator. It
takes a few seconds (the exact time interval varying for different types of locos) for the tap changer
to return from full 'on' to full 'off' position when the Master Controller is switched off. The blue lamp
re-lights when the tap changer has returned to ' 0'.

30627 Use of Pantographs

1. The rear pantograph of the loco (in the direction of motion ) should normally be used by the
Driver.The leading pantograph may be used only if the rear pantograph is defective or damaged or
specially instructed.

2. Loco should not be worked with both the pantographs raised.

3. For normal lowering of pantographs the Master Controller should be switched off and the circuit
breaker tripped before the panto-selector is moved to position '0'. In an emergency when the
locomotive is in motion, the pantograph may be lowered by using the panto-selector switch, even
without tripping the circuit breaker but after bringing Master controller to '0' position.

30628 Regenerative and Rheostat Braking

1. The regenerative / rheostat braking is also controlled by the Master Controller. For braking, the
Master Controller is moved in the opposite direction. The Master Controller positions corresponding
to such dynamic braking are -

(a) Stable positions

0 .............Common for traction and braking

P........... Preparation for braking.

N ........ Neutral

INDIAN RAILWAYS - AC TRACTION MANUAL -VOLUME III [147]

b) Unstable positions

+ (Plus) ... Notch-by-notch progression during braking.

- (Minus) ... Notch-by-notch regression during braking.

Notch-by-notch or continuous progression and regression are effected during braking, in the same
manner as during traction, but using the above mentioned positions of the Master Controller.

30629 Starting of a Train

1. The starting of a train is effected in two stages as under

Ist stage Initial starting

2nd stage Acceleration

When everything is ready for the train to start, set reverser handle for the forward direction, switch
on traction motor blower and progress the master controller notch by notch until the locomotive
starts and moves forward with the train. During this period, keep an eye on the traction motor
current to see that it is within permissible limits. Watch particularly for any signs of slipping of
wheels. At the first sign of slipping notch back and press the sanders pedal and notch forward once
again.

2. When accelerating from rest, the traction motors are liable to be overloaded. Notch-by-notch
progression of the tap-changers should be so controlled as not to exceed the overload (current and
time) ratings of the traction motors laid down for each type of loco. The permissible overload limits
are exhibited in each driving cab.

3. At the first available opportunity at the commencement of journey by a fresh crew, driver will test
the brake power of the train. The test should be repeated wherever the load composition is altered.

30630 Starting on an Up-gradient

When "attacking" an up-gradient, the Driver shall attain sufficiently high speed at the foot of the
gradient so as to enable him to negotiate the full length of the gradient without any stoppage en
route, ensuring at the same time that the maximum permissible speed for that section is not
exceeded. If for any reason, the train comes to a stop on an up-gradient, the train shall first be held
from rolling down by the application of the pneumatic brakes. While re-starting, the following
sequence of operations shall be carried out -
1. Apply the independent air brakes on loco.

2. Release the vacuum brakes by using both exhausters for about 3 minutes initially followed by the
normal running position of the vacuum brake valve for about 2 minutes.

.3. When the brakes are almost fully released the train will tend to roll back giving a slight jerk on the
loco. Just then notch forward 2 to 4 steps, simultaneously releasing the independent loco brakes (as
laid down in the Operating Manual for the type of loco) so that the locomotive starts hauling the
trailing load. Use sanders as required to improve adhesion.

4. Particular care should be taken to prevent sudden jerks due to excessive acceleration.

5. Continue notching forward as far as adhesion will permit and without exceeding the prescribed
limits of current, observing the precautions during initial starting (para 30629- sub para 2).

5. If the locomotive is not able to pull the load, the Driver shall apply independent air brakes
and make a fresh start. If this too fails he shall take appropriate steps as laid down in General Rules
and Subsidiary Rules.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [148]

30631 Speed control
Once the current drawn falls below the continuous rated current, speed may be regulated by
notching forward or backward so as to catch up with the "deserving notch" necessary to meet
service conditions, The aim should be to maintain the speed as close to, but never exceeding the
maximum permissible speed over each section. After the maximum voltage has been reached,
speed control can also he effected by using the field shunting controller.
Field Weakening Switch : After the maximum voltage for the motor has been attained, field
weakening may be effected if it is necessary to raise the speed further. This is done by operating
the 'Shunting Lever'. Care must be taken to see that sufficient time is allowed for train to accelerate
before going to the next step. The current ratings prescribed for each type of loco should not be
exceeded. Too fast a rate of field weakening could cause a flashover of traction motors and should
not, therefore, be attempted.

30632 Operation of the Reverser for Braking

Operation of the reverser to stop a train when the loco is in motion is strictly forbidden.
30633 Manual Control of the Tap Changer
1. Provision exists in all the locomotives for manual operation of the tap changer, should normal
electrical operation through the Master Controller fail. In some locomotives, manual control is
possible from the driving cab itself. In some others manual operation has to be done by the
Assistant Driver in the corridor in response to signals from the Driver. In some types of locos, in
addition to manual control through the Master Controller, separate electrical push-button control is
also provided.
2. The manual control located in the corridor should be used only to clear the block section and if
directed by TLC, the driver can go to the nearest loco changing point. The loco should be withdrawn
from service at the earliest opportunity.
30634 Slowing down and Stopping

Depending upon local conditions, Railways may issue local instructions indicating a given stopping
point identified by a board / OHE mast etc. in the event a particular signal ahead at danger. The
driver should follow these instructions. While slowing down and stopping the following guidelines
may be observed.

1. Before a scheduled stop or an unscheduled stop which can be anticipated by the Driver, coasting
should be resorted to the maximum extent possible, taking into account the gradient of the section.

2. Before application of brakes, the Master Controller should be in the "OFF" position and the tap-
changer should have returned to '0' notch as indicated by glowing of the blue pilot lamp or the
corresponding LED. In locomotives fitted with regenerative or rheostatic braking, the electrical
brakes should be made use of to the maximum extent possible.

However if the driver is negotiating the down gradient, he can apply loco brakes till he prepares for
regenerative/ rheostatic braking to keep his train under control, if necessary.

3. After a stop, the blowers for traction motors and transformer should continue to run for 15 minutes
especially after long runs with heavy trains to cool the motors.

4. The place and duration of stop permitting, the Driver or Assistant Driver shall check the following:

a) Axle box, traction motor and gear box bearing temperature (by feeling). In case the running staff
observes abnormal temperature, he will report the matter to TLC for suitable action. TLC will
arrange its checking through maintenance staff at the appropriate point.

b) Working of all blowers.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUEME III [149]
c) Oil level of main transformer and tap changer and temperature of main transformer whenever
possible.

The air reservoirs shall also be drained off to expel accumulated water.
30635 Locos in Multiple Operation
1. Some series of locomotives are designed for multiple operation of two, three or four locos. This
will be indicated in the Instruction Manual of each type of locomotive. The condition of the apparatus
on the leading and trailing locos, the electrical and pneumatic connections to be made between the
locos and all other details of preparation of the locos for multiple operation shall be in accordance
with detailed instructions for each type of loco. Similarly the driving and other instructions for the
individual types of locos as laid down should be followed.

2. Differences in wheel diameters of different locos in a multiple consists will be within the
tolerances specified and the consist will be treated as a single unit for operation purposes.

3. In case of failure and break down of a loco in a consist the entire consist should normally be
withdrawn from services.

4. One important check to be exercised by the Driver when operating locos in a multiple unit is to
verify that the pantographs of the rear locos respond to the lower/raise operation, when negotiating
sections where the pantographs are required to be lowered and subsequently raised.

5. Coupling of locos
a) All the hose pipes i.e. brake pipe (BP), feed pipe, Vacuum hose pipe, Main reservoir (MR)
equalizing pipe and brake cylinder (BC) equalizing hose pipes should be connected between the
locos and the angle cocks are fully opened. The angle cocks of outer ends of MR and BC equalizing
angle cocks are kept closed in addition to BP & FP angle cocks of front end.

b) The three electrical jumpers on one side only should be connected between the locos. The auto
brake valve handles (A9) and independent brake valve handles (SA9) should be kept at "Release"
position in all the cabs but the cut-out cocks must be kept open in driving cab only. The cocks in all
cabs in each loco must be kept closed. The isolating cock (A-8) should be kept in lead position
(open) in leading loco and trail position (closed) in all the trailing locos. The position of MU2B Valve
should be "Lead" on leading loco and "Trail" on all the trailing locos.

The compressors may be put in service as per requirement depending upon the number of wagons
of the train. Care should be taken to put at least one compressor in service in each of the trailing
locos.

6. Energizing of Multiple Units

The battery switch of all the locos should be put ON and the air pressure built up in emergency
reservoir of each loco. The pantograph of all the locos may be raised and circuit breaker should be
closed from leading loco. The compressors of all the locos should be started.

7. Precaution while changing driving cab

The changing of Cab means the changing of driving loco. Care should he taken to change the,
position of cut. Out cocks of A9 and SA9 Lead and Trail Cocks and MU2B valve while changing the
driving cab.

8. Loco Faults

It is possible that a fault may develop in any of the locos in Multiple Operation. It may be detected
with help of
INDIAN RAILWAYS AC TRACTION MANUAL -VOLUME III [150]
six pilot lamps and two additional lamps. A lamp in the ceiling of the Cab called "LSGRT" (group
loco lamp) glows only on the faulty loco. The other lamp provided on driving desk called "LSOL"
(other loco lamp) glows in good loco indicated that the fault is in other loco. When fault is diagnosed
on a particular loco, it is necessary that the train is stopped on a station and the remedial action is
taken on the faulty loco. In case the fault can not be removed and it is not possible to keep the faulty
loco in service, it should be made dead to run as a vehicle.

30636 Double Heading

1. Operation of a train with two locos in front ,both coupled together and to the train ,but
operated independently by separate crew is known as double-heading. The two locos can be of
different types.
2. Subject to compliance With all speed restrictions,the maximum speed of a double headed
train shall not exceed the lower of the maximum speeds of the two locos individually.
3. Each loco must be manned by a Driver and Assistant Driver who are qualified to work the
type of loco and have learned the road over which the train is working. The driver of the leading
loco, known as the "Train Driver" must be qualified to work the class of train and will be responsible
for working the train in accordance with rules.

4. It is the duty of the leading Driver to satisfy himself that the exhauster of the second loco, if
running, is suitably isolated from the train pipe and does not create vacuum in the train pipe. Except
in an emergency, the leading Driver only will apply the brakes. Under no circumstances may the
second Driver release the brakes on his loco or the train or apply the brakes independently on his
loco.
5. When starting power may be applied by both locos as required. The leading Driver who is in
charge of the train will notch up until the train moves. The rear Driver will assist as required.
6. While running, power may be applied as often as necessary but gradually by the rear Driver.
7 The rear Driver may switch off power using his discretion and with due regard to locality,
gradient etc. The rear Driver must frequently observe his vacuum gauge and be prepared to stop.
8. It is the duty of the train Driver to ascertain that the second Driver is acquainted with the
contents of all caution orders and special instructions etc. which he may receive while working the
train.
9. Instructions issued by local Railways regarding coordination amongst the two crews should
be followed.
10. All rules in regard to switching off power at neutral section, lowering of pantograph in the
event of emergency feeding etc. shall be observed. The Driver of the rear locomotive will be
signalled by the Driver in the leading locomotive to carry out these operations, as required, by
means of code whistles. The code to be used for such occasions shall be laid down under local
instructions.

30637 Banking

1. On a gradient sections, sometimes banking locos are used in the rear of the train to assist the
leading loco/ locos to negotiate the gradient. The banking locomotive, must be coupled to the train.

The vacuum hose/air brake pipes of the banking loco should be coupled to the last vehicle, but on
no account should the exhauster of the banking loco be run. In the event of banking air braked
trains, MUZ 8 valve of banking loco shall be kept in trail poistion. The Driver of the banking loco will
keep a watch on the vacuum gauge and take necessary action to assist the leading Driver when
brakes are applied.

2. All rules in regard to switching off power at neutral section, lowering of pantograph in the event of
emergency feeding etc. shall be observed. The Driver of the rear locomotive will be signalled by the
Driver in the leading locomotive to carry out these operations, as required, by means of code
whistles. The code to be used for such occasions shall be laid down under local instructions.

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3. When working a train up a gradient with the assistance of an electric banking loco, the following
procedure should be followed.
a) When the signal is lowered the leading Driver will give the prescribed code whistle. The
banking Driver will acknowledge the whistle and notch up quickly so as to obtain the maximum
permissible starting current, simultaneously releasing the loco brakes. The sanders should be used
to avoid wheel slipping.
b) The leading driver should take 2 to 3 notches, releasing the loco brakes simultaneously and
using the sanders as required.

c) The leading and banking Drivers should keep a watch on their respective ammeters and maintain
the current at the continuous rating.
d) If a "Stop" signal is encountered in the gradient section by the leading Driver, he should switch off
the Master Controller and bring the train to a stop applying the brakes to the extent required. He will
also use code whistle for the banking driver. This will increase current in the banking loco. The
banking loco driver should regress the Master Controller so as to maintain the current at the
continuous rated value till the train stops. On stopping, both the leading and banking Drivers should
apply independent air brakes to avoid rolling down.

e) When re-starting after a stop signal, the same procedure as in (a), (b) and (c) should be followed.

f) At the point where the rising gradient ends, the Banking Driver should switch 'off' the Master
Controller and stop pushing. A board is provided to indicate this point.

30638 Inability to Haul Goods Trains - Stalling

The most common causes for inability of electric locos to haul goods trains are as under :-
1. Inclement weather can result in poor adhesion. Some sections on Indian Railways during
autumn season in forest areas are subject to track being covered by semi-dry leaves which turn into
a wet paste by movement of wheels and is a serious cause for failure of adhesion.
2. Passage of salt laden trains with leaking wagons can also affect the adhesion.
3. The total trailing load exceeds the permissible load for the type of loco, either due to increased
number of wagons or due to the cumulative effect of excess loading of a number of individual
wagons.
4. The drag caused by brake-binding on rakes equipped with vacuum brakes which may be due to
one or more of the following causes.
a) Trains hauled by diesel locos sometimes have a high degree of vacuum. An electric loco
subsequently attached may not be able to create as much vaccum. Unless every cylinder is
manually released, some brake binding will occur.
b) Many forms of temporary expediencies are used to reduces leaks while forming a load. The load
may thus start initially with a good vacuum. The various methods used to prevent leakage may give
way on the run and the brakes may begin to bind.
c) Initially the brakes may be released fully by working both exhausters. If, however, there are leaks
in the train line, the vacuum is lost gradually as soon as normal single exhauster working is
resumed.
30639 Heavy Haul Trains
Such are the trains which can not be accommodated in the existing loops of the section. Railways
operating such trains will issue special instructions and the driving crews should be made familiar
with various problems anticipated to be countered with such operation. Some of these trains may
have locomotive/locomotives sandwiched in between.. Their operation too will call for special set of
instructions.

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30640 Neutral sections

It is essential to switch off power of locomotives when passing through a neutral section to prevent
the possibility of arcing at the OHE and possible damage to it. To ensure this following boards are
provided on the OHE masts (Refer Chapter II - Vol.I).
i) 500 m warning board - Be alert and ensure main reservoir pressure is at maximum limit. Close
direct switch for compressor if necessary.
ii) 250 m warning board - Master controller to be brought to zero and ensure that the glowing of
Blue lamp for tap changer. Get ready to open the circuit breaker.
iii) Open circuit breaker board - open circuit breaker before passing the board and ensure that
glowing of red lamp for circuit breaker. If the circuit breaker does not trip at "Open Circuit Board" the
panto must be lowered immediately.

2. After passing through the neutral section, the Driver should close the circuit breaker at the "close
circuit breaker" board and resume normal working thereafter.

3. As a normal rule the train should coast through a neutral section. However, if for some reason it
becomes necessary to stop the train in the vicinity of a neutral section, the Driver must try his best
to stop the locomotive after crossing the neutral section. Only in an emergency or to avert an
accident, may the locomotive be brought to rest within the neutral section. If a locomotive comes to
a stop within the neutral section and the train cannot restart, special arrangements will have to be
made to push or pull it by means of another locomotive.

4. Before tripping the circuit breaker at a neutral section, the main compressor should be worked
"direct" for some time to build up enough pressure in the reservoir, otherwise there is possibility that
the air-blast circuit breaker may fail to reclose after passing the neutral section due to low pressure.

5. If the speed of the train while approaching a neutral section is 30 km/h, the Master Controller
should not be switched off at the 250 m board. Power may be kept on till the circuit breaker is
tripped at the "open circuit" board.

6. Passing a Neutral Section with Multiple Loco Unit

The bipolar Switch BSLN provided in driving cab to open the circuit breaker and to lower the
pantograph of trailing locos, should be put on at 250 m warning board after putting master controller
to 0. The circuit breaker of leading loco may be opened at open CB board with the help of BLDJ.
After passing the Neutral Section the circuit breaker of leading loco should be closed first and then
BLSN should be put off. The pantos of trailing locos will make contact within 10 sec. circuit breakers
of trailing locos may now be closed and traction resumed.

7. Short Neutral Section

In such a section both the pantographs should not be raised under any condition.
30641 lowering Pantographs Under Emergency Feed
When power supply from one substation is interrupted and feed is extended from the adjacent
substations, it will be necessary for the Driver to lower the pantograph at least 2 or 3 spans before
arriving at the overlap span opposite the substation which is out of operation. Such an eventuality
may also arise when some portion of
OHE is defective. When any of such contingencies arise the Drivers are advised by a "Caution
Order" either at the starting point or through Station Masters enroute. Where this restriction is to be
observed emergency "lower pantograph" and raise pantograph" boards may be provided (Chapter
II - Vol. I).
30642 Unwired Tracks
1. In station and goods yards only certain tracks are equipped with OHE. Special sign-boards
are exhibited at

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points where unwired tracks take off from wired tracks. Drivers/Motormen should keep a careful
lookout for unwired tracks when entering or running through stations and goods yards. Should per
chance an electric train be signalled erroneously to enter an unwired track, the Driver should stop
short of the turnout and draw the attention of the cabin. Drivers should also report such cases with
details to the TLC immediately.

2. If in case a Driver notices that he is going on an unwired track and cannot stop, he should lower
the pantographs immediately. This will minimize damage to the pantographs.

30643 Coasting Down-gradients

1. Drivers are expected to be well conversant with the road and to make the best use of down-
gradients to effect maximum possible saving in energy consumption.
2. In level sections and particularly in suburban sections, coasting should be resorted to as much as
possible and brakes applied only when essential to control the speed or to stop the train. To help
Drivers "coasting boards" are fixed in some sections.
3. In undulating country, speed may be allowed to drop down when going up a short up-gradient.
After passing over the crest, the train will automatically pick up speed with power off on the other
side when going down-hill, so that it attains maximum permissible speed on the section when it
arrives at the foot of the next-up-gradient. This feature should receive special emphasis during
learning the road period.

4. When going down a long, steep gradient, brake shoes are liable to get very hot and in these
circumstances, brake power will be reduced. With the reduction of brake power, speed may rise to
dangerous levels. To prevent this possibility, Drivers are required to maintain the speed within the
limits prescribed and sometimes even to halt a train at certain points to prevent the possibility of a
run away speed and consequent serious accidents. Drivers are required to adhere strictly to
standing instructions issued by local authorities in this regard.

30644 Loco Running Light

Before starting a light loco the Driver should personally verify that the loco brake isolating valves are
closed in rear and open in the driving cab. When a loco is run light; the free ends of the vacuum
coupling hose pipe shall be secured firmly to the dummy and one of the exhausters may be kept
working. The driver should, however, satisfy himself that the air-brakes on the loco are effective. He
should normally stop the loco during light run by independent air-brake valve, but the Assistant
Driver may apply the brakes by operating emergency brake valve, if the situation warrants.

30645 Wheel Skidding

Wheel skidding in locomotive takes place whenever braking force exceeds the limit of adhesion.
The braking force could be higher due to incorrect setting of automatic brake valve, independent
brake valve and pressure limiting valve or due to malfunctioning of proportionate valve, distributor
valve and C2 relay valve. This can also however happen if the pressure gauges are not calibrated
properly.

Wheel skidding is also noticed under adverse adhesion conditions caused by oil and grease on rail
table, wet rails and falling of tree leaves and salt on the tracks. Poor brake power of the train can
also result in wheel skidding of the locomotive, in certain condition.

To avoid wheel skidding, it is necessary to maintain the brake equipment in perfect working order
and ensure setting of equipments at designed value. Locomotive brake should be applied
judiciously. In case the poor brake power of the train is observed by the Driver, he should advise
control for joint checking and corrective action as laid down in Operating Manual and ensure
pressing of PVEF switch while applying train brakes.

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Annexure 6.01
OPERATION OF AIR BRAKED STOCK
1.0 Operation

The running of air braked stock is subject to the following stipulations:

1. 1 Electric Loco used for hauling air braked stock have the provision of IRAVB-2 (twin pipe)
graduated release air brake system.
1.2 Before attaching locomotives to trains, the engine should be thoroughly tested to ensure that it is
free from any leakage and the valves are in working order.
The A-9 valve should be set at 5 0. 1 kg / cm2 and effectively sealed. The flow meter should be in
working order.
1.3 Procedure for Checking Capability of Locomotive Compressors for Charging/Releasing of Train
Brakes

N.B.: This test should be carried out on single locomotive if only one locomotive is used for hauling
the train or on the foremost loco of a consist of locomotives, unless otherwise stated.

1.3.1 Place the Driver's automatic brake valve handle in emergency position.

1.3.2 Start the locomotive compressors for building up of main reservoir pressure.

1.3.3 Allow the main reservoir pressure to build up to the maximum stipulated limits for the
particular type of locomotive.

1.3.4 Close the angle cock for the brake pipe, couple 7.5 mm diameter leak hole special test
coupling
fabricated to RDSO design with the brake pipe coupling of the locomotive. In case of MU
consist
coupling should be fitted on the rearmost locomotive of the consist.

1.3.5 Move the Driver automatic brake valve handle from emergency position to release position
to charge the brake pipe to 5 kg/cm2.

1.3.6 Open the angle cock for the brake pipe. The brake pipe pressure should fall from 5 kg/cm2.

1.3.7 Check the brake pipe pressure with the help of the gauge fitted in the locomotive, it should
not fall
below 4 kg/cm2 with in 60 second.

1.3.8 The test shall be carried out with the number of compressors considered adequate by the
driver for
operating the train.

1.3.9 Generally the number of compressors used shall be governed by the number of wagons
hauled and the leakage rate -
A general guide line is given here under -
-------------------------------------------------------------------------------------------------------------------------
No of wagon Less 50-80 80-90 90-100 More than
in train than 50 100
----------------------------------------------------------------------------------------------------------------------------
Compressed 2000 3000 4000 5000 6000
air require-
ments in
Litres/Min.
----------------------------------------------------------------------------------------------------------------------------
Each compressor on an Electric loco has a capacity of 1000/1500 litres/minute.

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1.4 Procedure for checking the leakage rate of the air brake system of the Locomotive with
Auxillaries in the circuit

1.4.1 Charge the system fully with MR pressure charged to 10 kg/c m2. Keep the brake in released
position.
a) There after with automatic brakes applied in full, shut down the compressors. The drop in MR,
FP
pressure should not be more than 0. 3 kg/cm2in 4 min.
b) With independent brake applied in full, shut down the compressors. The drop in MRFP and
brake pipe pressure should not be more than 0.3 kg/cm2 in 4 min.
c) With both independent and auto brake released, shut down the compressors. The drop in
MRFP and BP pressure should not be more than 0.3 kg/cm2 in 4 min.

1.5 Procedure for checking the leakage rate of the air brake system without Auxiliaries in the circuit

1.5.1 Charge the system fully with MR pressure charged to 10 kg/cm2 . Keep the brakes in released
position.

1.5.2 Shut down the compressors. Close the isolating cock of panto circuit line C-6 and BA panels
isolating cock C20 on the wind screen wipers and the horn circuit. The drop in pressure in any of the
circuits should not exceed 0.2 kg/cm2 in 4 min.

1.6 Procedure for checking the leakage in BP circuit

1.6.1 Charge the system fully Make 0.6 kg/c m2 reduction in BP by automatic brake valve. Close
isolating cock A 15 in BP control line (Lead/trial cock). The pressure drop in BP should not exceed
0.7 Kg/ c m2 in 5 minutes.

1.6.2 Charge the system fully. Make 0.6 kg/c m2 reduction in BP pressure by automatic brake valve.
Close isolating cock A-8 provided near the BP charging C-2 relay valve A-31 (locomotive nominated
for long haul operation have this provision). The pressure drop in BP shall not be more than 0.7 Kg/
cm2 in 5 minute.

1. 7 Procedure and checking to leakage in FP circuit

1.7.1 Charge the system fully with FP charged to 6 Kg / cm2 . Close isolating cock A-21 provided
before the feed valve A-52. The pressure drop in feed pipe should not exceed 0.7 kg/cm2 in 5
minute.
1. 8 Starting of Train

1.8.1 Blow off the angle cocks before coupling to expel dust etc.
1.8.2 Check the position of angle cocks of air hoses of the leading and trailing locomotives and of
the first wagon of the load.

1.8.3 Ensure that the brake pipe and the feed pipe connections are not mixed up either between two
locomotives or between the locomotive and the first wagon of the load.

1.8.4 Ensure that brakes of the train are fully released by TXR otherwise while starting skidding or
even breakage of coupling will occur. At non-TXR stations this job has to be done by the Driver.

1.8.5 Ensure that BP gauge in the loco is showing 5 + 0.1 kg/c m2 and FP gauge is showing 6 kg/c
m2 and then after ensuring the continuity of air pressure sign the brake power certificate jointly with
the TXR. Do not disturb the setting of A-9 valve under any circumstances.

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1.8.6 In the flow indicator gauge, set the red needle to coincide with the white needle after the
needle has established. Do not disturb the red needle thereafter, through-out the run.
1.8.7 Move one engine length to get a feel of the train. Thereafter start the train smoothly.
1.9 While on Run
1.9.1 As far as possible, the train should be stopped only by minimum application of brakes. In other
words, full service application or over reduction or emergency application should be used in genuine
emergency only, and not in normal circumstances, as otherwise heavy braking force will result in
skidding and excessive wear of wheels. After over reduction or emergency application, to have the
brakes fully released, wait for 3 to 4 minute.

1.9.2 If the train is running heavy, stop immediately and investigate the cause. Any delay in
investigation may cause skidding of wagon wheels or other damages.

1.9.3 CBC of loco and wagons can break due to high coupler force which can arise either while
stopping, starting or accelerating. To avoid breakage of couplers, therefore, instructions regarding
application of brakes given herein should be followed rigidly.

1.9.4 In case of heavy leakage or mal-functioning of distributor valve (if brake binding is noticed) pull
the quick release valve lever of the distributor valve of the wagon. In case brake binding problem is
repeated, the DV of the concerned wagon should be isolated by putting the isolating cock handle to
off position and the quick release valve of DV pulled till the brakes are fully released.

1.9.5 In case of disconnection of air hose enroute, attention be given by closing the angle cocks and
if necessary by replacing air hose by removing from either the front end of loco or rear end of the
brake van. After this is done and the air hoses are correctly coupled, the angle cocks should be
opened and the system fully charged, brakes released and the train started as mentioned in para
1.8.

1.9.6 The braking technique shall be as under:- Minimum application / release / minimum
application / release. A series of minimum application/ release operations should be done for
controlling the train.

1.9.7 After stop, even with minimum application wait for two minutes before restarting. Start only
after the white needle on the flow-meter coincides with red needle.

1.9.8 Report all problems and unusual events noticed on run in respect of air brake functioning and
wagon movement etc. to TXR concerned.

1.10 Brake Binding on run

1.10.1 lf during run the train comes to a halt and brake binding is observed, sound locomotive horn
with a whistle code prescribed for alarm chain pulling. This will give an indication to the Guard that
the train is held up due to brake binding and the Guard should take action as prescribed for him.

1.10.2 If the locomotive is fitted with an air-flow indicator locating the trouble is easier, Check as
follows-

If the white needle has moved up only slightly, it indicates leakage in the train brake pipe, source of
leakage should be traced. If the white needle moves by a big margin, it indicates heavy discharge of
air from the brake pipe. This could be due to an angle cock in front of a wagon being closed. It could
also be due to a disconnected brake pipe or a burst hose pipe.

1.10.3 If there is no flow indicator, look carefully at the brake pipe pressure gauge. Originally the
pressure should have been 5 kg /c m2 on the locomotive and minimum of 4. 8 kg /c m2 in the brake
van. If at the time of occurrence the pressure is less than the original value, this could. be due to
additional leakage in the train brake pipe or train

INDIAN RAILWAYS -AC TRACTION MANUAL VOLUME III [157]

parting. The driver shall therefore ensure that his full train is intact, otherwise take action as if train
parting has occurred.

1.10.4 If there is brake binding but no drop of BP pressure, it could be due to rear angle cock of a
wagon being closed.

1.10.5 Examine the train along with guard to find out the cause of brake binding. If the brake
binding is due to a closed angle cock, open the angle cock fully.

If any distributor valve is defective, isolate the same and release the brakes of that wagon and
record the same in the train journal as well as on the brake certificate.
If the leakage is due to a burst hose pipe (which is very rear), release the brakes in rear of the burst
pipe after closing the rear angle cock of the last unaffected wagon and clear the block section
cautiously at a slow speed with partial brake power.

After obtaining Guard's observations and taking corrective action, record on the journal and also
report the problem to the section controller indicating the wagon number affected.

1.10.6 In case, the leakage or cause of brake binding is not located, destroy the brake pipe
pressure completely through A9 close the angle cocks of the loco, release the brake of the complete
train and work the train as non-braked, cautiously at a slow speed to clear the block section.

1.11 Stopping of a Train

1.11.1 Braking technique to be observed should be as detailed in sub-para 1. 9.

1 11.2 Stopping of train should be smooth ( without jerks) which is to be done by releasing the
brakes just before final step. The handle of drivers brake valve should be put to release position
when the speed is about 5km/h prior to stopping.

1.11.3 When stopping at a station on a down grade, the dynamic brakes be kept in ON position and
should only be cut off after the application of independent brakes.

2.0 Action to be Taken in Case of Loco Failure with Air Braked Stock

1. During double headed operation, if the rear loco fails, the train is to be worked by the leading
loco and the block section cleared. If, the load cannot be cleared by one loco, assistance is to be
given by any other loco, preferably from rear, only for the purpose of clearing the block section. But
when the block section is being cleared by a loco equipped with vacuum brakes, the loco driver has
to be extra cautious to stop the train at the stop signal.
2. During double headed operation, if the leading loco fails, the train is to be stopped, isolation
cock A8 in the brake pipe charging line and MU2B in the trailing loco are to be put to normal position
in order to feed the BP pressure to the load and application of brakes from the rear loco and the
block section cleared in the same manner as explain in sub-para above.
3. In the event of non-availability of loco fitted with air brakes (either electric or diesel) the
brakes of the entire rake have to be released in the block section and an ordinary loco (vacuum
braked) attached to clear the block section. In this event, the train is to be worked at a restricted
speed of 15km/h as it shall be controlled only by the loco brakes. This load is to be received on the
main line. If it is not possible to receive the train on the main line, it should be received on the loop
line, provided the trailing end of the loop is set for the main line, so that in case of loss of control, the
train does not get derailed on the trap point or goes in to the sand hump.
4. In the event of failure of both the locos and non-availability of a loco fitted with air-brake the train
can be worked with an unmodified Diesel or electric loco, at a restricted speed of 15 km/h.

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CHAPTER VII
OPERATION OF EMUs

30700 Duties of Motor Man

1. Rules 30604, 30606, 30608 to 30616 and 30620 for Drivers in connection with operation of
loco will be equally
applicable to Motormen
2. Motorman will also be responsible for cleanliness of the EMU cabs .
30701 Motormans Personal Effects

Motormen of suburban trains should carry the following equipment while working trains :
1. Special keys for operation of the Master 1 set
Controller, reverser, controls switch etc.
2. Hand signal lamp (at night ) 1
3. Green and red flags 1 set
4. Working Time Table 1
5. A watch in good working order 1
6. Detonators 12
7. General and Subsidiary Rules AC Traction 1 copy each
Manual and Operating Manual for the type of EMU
8. Rough journal book 1
9. Screw driver, universal pliers and any other tools 1 set
prescribed under local instructions
10. Any other items in accordance with local instructions

30702 Check for Motorman on Taking Over

1. The Motorman taking over an EMU train will carry out checks as detailed below when

(a) a train is taken over from and EMU shed or stabling line after maintenance or inspection ;
(b) a train is taken over for its first trip of the day or after stabling at a station siding for more
than one hour.

INDIAN RAILWAYS AC TRACTION MANUAL VOL III [160]

2. The duties prescribed in the paras mentioned above for the Motorman will devolve on the
Shunters or Engine Turners when the train is worked by a Shunter or Engine Turner from the shed
or stabling line to the station platform and the Motorman takes over the train on the platform. The
joint brake test prescribed in para 30708 shall, however, be carried out only by the Motorman who
works the first trip.

3. Instructions given in this section are of a general nature applicable to all types of EMUs and
should be treated as complementary / supplementary to detailed instructions issued by respective
railways for each class of EMUs.

30703 Preliminary Checks

The Motorman should -
a) check that the entire train is on a wired track so that by inadvertent raising of the pantograph on
an unwired track, no damage is caused.
b) he is in possession of the correct set of keys for operation of the reverser, control switch,
pantograph selector switch and doors and
c) go through the defects register to acquaint himself with the defects noted earlier and the action
taken by the maintenance staff to set right such defects.

30704 Checks Before Starting Trains

1. In the entire train the Motorman will check the following :-

a) that the coaches are mechanically coupled properly and the electrical/pneumatic/vacuum
connections between coaches are correctly made;

b) that all the drain cocks are closed and pneumatic isolating cocks are in normal position

c) that the intermediate driving cabs not in use are properly locked;

d) at the ends of the train the pneumatic and vacuum (wherever applicable) pipes and electrical
couplers are correctly placed in the dummy sockets and dummy hooks respectively;

e) the headlights, tail lights, marker lights, head-codes and tag-boards are in order;

f) hand-brakes are released;

g) that fire extinguishers and alarm resetting rods are available.

2. In each motor coach he shall check that :-

a) none of the overload relays are in tripped position;

b) all fuses are in order and fuse-free breakers are "ON",

c) all traction motors are cut in for normal service;

d) the control cut-out and battery switches are "ON" and battery voltage is normal;

e) the cut-out switches for pneumatic governors are in normal position;

f) the transformer oil level is normal;

g) the main earth switch is "OFF" and interlock keys are in the proper position.
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3.In the leading driving cab i.e. the driving cab to be used for the first trip, check that

a) all fuses are in position and fuse free breakers are ",ON";

b) the deadman's device is functioning normally;

c) wiper, hooter, headlight (including emergency headlight) , head code light and tail light( including
emergency tail light) are functioning correctly;

d) the main reservoir and brake pipe pressures are normal;

e) all indicating instruments are normal.

4. In addition motorman will conduct checks for each type of EMU as required in the respective
Operating Manuals.

30705 Familiarity with automatic brake application

In EMUs provided with electro-pneumatic and automatic brakes, normally the braking system made
use of by the Motorman for service stops is the electro-pneumatic system. Though primarily meant
for use in emergency and for automatic application in the event of train parting, the automatic air
brakes are capable of graduated application for service stopping of EMU trains. This graduated
application of automatic brakes, however, requires some practice on the part of motormen. Once
during every trip they should, therefore, control the train and bring it to a stop making use of the
automatic brakes. In the event of failures of electro-pneumatic brakes it will be quite safe to keep the
units in service using the automatic brake system till the train can be conveniently withdrawn from
service.

30706 Dead Man's Handle

1. Since an Electrical Multiple Unit train is operated by a motorman alone, it is necessary to provide
means of applying the brakes and bringing the train to a stop in the event of the motorman getting
incapacitated in any manner. This is arranged by means of a dead man's device associated with the
master controller.. With the reversing key in the 'forward' or'reverse' position, the handle of the
master controller has to be kept continuously depressed by the motorman. If the pressure on the
handle is released on account of the motorman fainting or getting incapacitated in any manner,
power for the traction motors is cut off and the brakes are automatically applied.

2. Deadman's device should be tested before commencement of every trip. An EMU train should
not be considered fit for service if the dead man's device in any of the end driving cabs of a train
formation. is inoperative. In the event of the dead man's device becoming defective when a rake is
in service, it should be either promptly withdrawn from service or a Guard, Train Examiner or some
other person conversant with the operation of the brakes in an emergency should travel with the
motorman.

3. The dead man's device will be operative when the train is in motion only if the reversing key is in
'forward' or 'reverse' position. If the reversing key is returned to the off position when the train is in
motion, the dead man's device is rendered inoperative with consequent serious danger of accident
in the event of the Driver fainting or getting incapacitated in any other manner. Motormen are,
therefore, forbidden from moving the reversing key to the 'off' position when the train is in motion.

4. It is essential to impress upon Motormen (during their initial training and whenever they attend
refresher course), the importance of this rule. Frequent checks are also essential to ensure that the
rule is being strictly observed by motormen during their working. This is one of the primary
responsibilities of the Driving Inspectors. Officers and other senior supervisory staff should also,
during their cab, inspections specially check on the Motormen's observance of the rule. Any
disregard of, the rule should be dealt with severely and promptly.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME [162]

30707 Auxilliary Warning System (AWS)

This system ensures extra vigilance on part of the drivers and in case of driver becomes
momentarily inattentive it gives a warning bell and then applies the brakes automatically. Power is
cut out and brake operation also take place in case driver crosses a stop signal at danger. The
driving crew operating with the system should be made fully conversant with the same before being
put on loco /EMU, while working trains operating on sections fitted with such system.

30708 Joint Testing of Brakes by Guard and Motorman

1. Before an EMU train is brought on to a running line after inspection or maintenance in an EMU
shed or stabling line, the brakes of the train shall be jointly tested by the Motorman and the Guard to
ensure that the electro- pneumatic, automatic brakes and vacuum brakes (whichever is applicable)
are functioning normally and the brake pipe is continuous throughout the train.

2. This joint test shall be conducted in accordance with detailed local instructions laid down for the
purpose in the Operating Manual for the particular type of EMU.

3. As far as possible this joint test should be carried out before the EMU train leaves the shed or
stabling line. However, if specially authorized jointly by CEE and COM, the brake test may be taken
on the platform before commencement of the first trip.

30709 Duties of Guards of EMU Trains

In addition to the normal duties prescribed for them in General and Subsidiary Rules and other
instructions, Guards of EMU trains shall be responsible for the following :

a) Joint brake test with the Motorman as detailed in para 30708.

b) Switching on the lights and fans when required and making a general check at the
commencement of the trip that lights and fans are An good working order in the train.

c) Conveying information to the maintenance staff regarding failures and defects of lights and fans
in the compartments.

30710 Defects in EMU Trains

1. Motormen are expected to be fully trained to rectify minor defects and in the method of isolation
of faulty equipment. Detailed instructions on the method of trouble-shooting and rectification of
minor defects are ' contained in the Operating Manual of the respective type of EMU. Motormen are
expected to keep themselves fully acquainted with details of these instructions and to rectify such
defects themselves.

2. Defects such as failure of fans or lights, leakages in air pipes etc. will be attended to on arrival of
the units in the Car shed or Stabling Depots.

30711 Defects Noticed During Run with Special Reference to EMUs

1. In the event of defects which affect the punctual and safe running of trains and require early
attention by the maintenance staff, the Motorman will convey a message indicating the exact nature
of defect to the Traction loco Controller through the Station Master of the nearest station and will
abide by the instructions given by the TLC. Depending upon the nature of defects, the TLC will
decide whether the units are fit to be retained on line or should be withdrawn from service.

3. In the event of isolation of faulty traction motors, failure of auxiliaries etc., the maximum
speed and other restrictions subject to which the train may be worked are detailed in the Operating
Manual for each type of EMU.

INDIAN RAILWAYS --- AC TRACTIO N MANUAL VOLUME Ill [163]

The Motorman should abide by these instructions strictly.

30712 Turn-round Time at Terminal Stations

At terminal stations a minimum turn-round time of 6 minute should normally be allowed. This is
necessary since normally the brake pipe pressure should be reduced to zero or vacuum destroyed
in case of vacuum braked EMUs at the end of the trip and normal pressure / vacuum built up again
when the train starts in the opposite direction. In exceptional circumstances, justified by local
requirements , the CEE and COM jointly may permit a shorter turn-round time in which case it will
only be possible for a partial reduction in brake pipe pressure/ partial destruction of vacuum to be
effected at the end of the trip.

30713 Stabling of EMU Trains

1. When stabling an EMU train in the car shed or on a stabling line, the Motorman or Engine Turner
who has taken over the rake will carry out the following essential operations:
a) Switch off the lights and fans.
b) Trip the main circuit breakers and drop the pantographs.

c) Destroy the brake pipe pressure or vacuum (as applicable), isolate the brake controller and return
brake controllers to the release position

d) Apply the hand brakes fully in the driving cabs at both the ends.
e) Put off the main battery switch in the motor coaches.
f) Lock the equipment compartments; and driving cabs.
g) Any, other operations
k@;-f .... .. prescribed under local instructions.

2. When a rake is to be stabled, the Motorman should invariably be at the leading driving cab.
Backing an EMU rake to a siding with the motorman at the rear cab is strictly forbidden.

3. After stabling an EMU train or handing it over to the Engine Turner, the Motorman before going
off duty should convey to the supervisor-in-charge of the Car Shed or stabling line (or to the TLC)
any defects or abnormalities noticed during the previous trips requiring immediate attention.

30714 Coasting with Special Reference to EMU Operation

In order to keep down the energy consumption for operation of EMU trains, it is necessary to resort
to coasting to the maximum extent feasible. The running time between stations given in the Time
Table is after allowing for sufficient coasting. For guidance of Motorman, Coasting Board indicating
the point at which power may be cut off normally are fixed on the OHE masts facing the direction of
the train movement. When the distance between a pair of stations is long, sometimes power may
have to he applied in two spells. In such cases additional boards indicating at what point power has
to be switched on a second time and the point at which power may be switched off again are also
provided.

It is an important duty of a Motorman to observe the Coasting Boards to the maximum extent
feasible when the train is running on time. To make up time when a train is running late, the
Coasting Board may be disregarded and power kept on for a longer time, taking care not to exceed
the permissible speed of the section.

It must be reme mbered that if the "switch-off" Coasting Board is not observed when the train is
running to schedule, apart from waste of electrical energy, there will be greater wear and tear of
brake block. The location of the Coasting Board on each line should be decided by Sr. DEE / DEE
(RS) after taking actual trials. A register
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [164]
should be maintained in the Office of Sr. DEE / DEE (RS) as well as TFR showing the locations of
the Coasting Boards provided. These locations should also be advised to the ATFO (OHE) of the
section who should ensure that the Coasting Boards are not shifted for any reason by OHE staff. A
periodic check-that the boards are located correctly in accordance with the register should also be
carried out by the Driving Inspectors.

30715 Operation with Traction Motor(s) Cut Out

a) Normally an EMU should be operated with all the traction motors in position.

b) In case it is important to operate an EMU with motor(s) cutout as a long term measure, the EMU
should be operated at a restricted speed and coasting restricted and a revised time table should be
issued, if necessary.

c) For temporary cut out operation, motorman should inform the TLC and operate the train as
directed i.e. to clear the section or to haul to destination or to complete the link till the EMU touches
the maintenance shed. No EMU should normally leave the shed with any motor cut out.

30716 Working of Trains when Tracks are Flooded

1. The speed at which an EMU train may be worked with various heights of water from rail level
shall be laid down for each type of EMUs under local instructions and incorporated in the respective
Operating Manual.

2. It must also be ensured that in areas liable to flooding, special gauges (as laid down in para 716
of Indian Railways Permanent Way Manual) are provided to indicate when different types of EMU
stock and electric locos have to be stopped.

30717 Push pull Operation

Some of the suburban trains are equipped with a locomotive in the centre not at each end. The
operation of such train is similar to EMU operation and the maintenance of the locomotive should be
carried out in a loco shed and the various schedules as laid down should be followed.

30718 Long EMUs

a) At times it may be necessary to haul long EMU train say two or more of 8 coach or 9 coach trains
as one unit. In such an event Railways will issue local instructions in the matter.
b) It will be necessary to ensure that controls on each 8/9 coach trains are fed from the battery of
the leading motor coach of the same train.
c) CRS sanction may be required for such an operation.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [165]

CHAPTER VIII

COMMISSIONING OF NEW ELECTRIC LOCOMOTIVES AND EMUs

Para No . Subject
30800 Sanction of CRS

30801 Commissioning of New type of Rolling Stock

30802 Trial Runs on Open Line

30803 Commissioning of New Electric Rolling Stock Switching on 25 kV.

30804 Electric Multiple Units

30805 Additional Precautions Before Commencement of Commercial

Operation.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [166]

CHAPTER VIII

COMMISSIONING OF NEW ELECTRIC LOCOMOTIVES AND EMUs

30800 Sanction of CRS

Sanction is required from the CRS in respect of -

1 Introduction of electric traction on any railway or section of a railway.

2. Bringing into use any new type of electric locomotive or EMU or to operate any in service at
speeds higher than those already sanctioned. The term "New Type" includes:

a) any alteration made in the existing rolling stock which will have an effect on the riding
characteristics of the rolling stock. Generally, the points to be considered are axle load, unsprung
mass, primary and secondary suspension systems and load transfer arrangements between body
and bogies and bogies and wheel sets.

b) any alteration in the traction electrical system which is likely to interfere with signalling system.

30801 Commissioning of New type of Rolling Stock

When any new prototype loco/EMU are received for the first time from a manufacturer, the following
are required to be ensured for inducting the rolling stock into services safely:- .

First Stage: One time movement of the Rolling Stock

The new prototype needs to be certified fit for movement, based on an application made to the COM
of the Railway over which the loco is to be moved. The application is supported by -

a) Certificate from RDSO regarding its overall dimensions, axle loads, curve radius etc. for fitness to
move on IR tracks.

b) Certificate from manufacturer of the locomotive from site of unloading/ interface with the zonal
railway that the vehicle is fit to be moved.

c) A note on origin, destination, route and special conditions of speed, escort, etc. under which the
loco is to be moved.

The COM of the zonal railway issues a movement order authorizing the movement of the
locomotive, based on the application, and any other conditions which he may find essential to
stipulate.

Second Stage: Provisional running

a) RDSO at the first instance shall furnish Provisional Speed Certificate for the particular loco
type. In this certificate RDSO will indicate the maximum provisional speed of the rolling stock
permitted to run with a particular type of track, nature of curvature, type of bridges, axle load, length
of the rolling stock, ODC dimensions if any and type of traction installations. RDSO will also furnish
the infringements for which the loco is over dimensional and Board's condonation for the same is
required to be obtained.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [167]

b) On receipt of the Provisional Speed Certificate, an application is made by the Chief Engineer of
the concerned Railway to the concerned CRS for obtaining sanction. This is accompanied by Safety
Certificate issued by CEE, CE, CSTE and CME. This certificate details restriction imposed and
precautions to be observed for the movement of the loco. CRS in turn will then forward the
same to the Secretary (Works), Railway Board along with his recommendations. Engineering
Directorate at the Railway Board will finally communicate the sanction based on the safety
certificate issued by CEE, CE, CSTE, COPS and CME and comments of the concerned CRS for the
provisional running of the rolling stock.

Third Stage: Instrumented trials

RDSO will furnish the details of test and trials to be carried out on the rolling stock, generally,
consisting of the following..

a) Oscillation trials: The trials are carried out for assessing the speed potential, the riding quality and
stability at different speeds on straight and curved tracks of concerned sections. The parameters
which are generally measured on the oscillograph car are lateral forces, lateral and vertical
accelerations. Dynamic augment, bogie rotation and other parameters are derived. These trials are
repeated for leading and trailing bogies with new and worn out wheel diameters.

b) Braking Distance Trials: RDSO will conduct the braking distance trials with the loco hauling
prescribed loads at different speeds.

c) Tests regarding Interference with Signalling Circuits: The tests also will include measurements to
determine the interference to signal and telecommunication circuits..

d) Performance trials : RDSO will conduct the trials to assess the performance ratings of the
locomotives as per the extant instructions laid down.

Fourth Stage

Based upon the results of trials RDSO will issue a Final Speed Certificate indicating the maximum
speed for which the new stock is considered fit, mentioning therein special precautions to be
observed, if any. Based upon this certificate, the user Railway will issue a speed certificate signed
jointly by CE, CEE, CME and CSTE and send the same to concerned Commissioner of Railway
Safety (CRS).

Final Stage

Sanction of the Railway Board for commercial exploitation of the rolling stock is accorded.

30802 Trial Runs on Open Line

Subject to the condition that the operation of the particular new type of locomotive has already
received the sanction of the CRS, trial runs on the open line may be undertaken, taking all the usual
precautions. The Driver should be a senior and experienced man who has acquired the "feel" of the
type of locomotive in question, as he would be in a better position to give his reactions as to the
performance of the locomotive. Initially the locomotive should be run for short lengths at low speeds
and subject to various equipment continuing to operate satisfactorily, the length of run and the
speed may be progressively raised over a period of, a few days. Test in particular how the brakes
function under the normal and emergency conditions. At the conclusion of each trip a detailed
examination should be made of the equipment, particular attention being paid to the temperature
rise, lubrication, protective devices etc. Every new rolling stock after initial run for a period of 15 to
20 days will be called back to the home shed and will be given a thorough inspection of all under-
gear equipment with special attention to loosening of bolts. These bolts will be re-tightened and
secured before the rolling stock is put back into the system.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [168]

30803 Commissioning of New Electric Rolling Stock

1. Locomotives and EMUs do undergo, before dispatch, detailed tests and trials at manufacturing
units which include tests prescribed by RDSO. Nevertheless, it is necessary for officers and staff of
open line to check up the equipment thoroughly before they are put into commercial operation .

Sr. DEE/ DEE(RS) and the staff should make a detailed inspection of all parts of the rolling stock,
one equipment after another, keeping a full record of defects observed and action taken to rectify.
The inspection shall be broadly based on IC schedules. In any case, a report should be forwarded
for every loco or EMU tested, to manufacturers and to RDSO so that they may in turn improve the
design, revise the testing procedure and tighten up for final inspection. Such checks should also be
normally carried out before commissioning a loco / EMU after an IOH/ POH by the shed /
workshops.

2. Test certificates bound in book form issued by the Manufacturers / Production Units should be
available in duplicate. These should contain results of actual tests and measurements carried out on
the different components, duly countersigned by the Inspecting Officers. One copy should be
preserved for reference in the loco shed and one copy in CEE's office.

3. The manufacturer is also required to submit guarantee / warranty of the loco components / sub-
assemblies wherever applicable. Whenever a new type of equipment / sub-assembly is inducted
into the locomotive, operation and maintenance instructions shall be furnished by the manufacturer,
in advance, before dispatch of the locomotive.

30804 Electric Multiple Units

The contents of paras 30801 to 30803 apply equally to every electric multiple unit, except that, in
addition to the electrical equipment of the driving unit, the interconnecting pneumatic pipe
connections and the brake equipment in each coach should be subjected to detailed examination for
detection of leakage and. proper operation. Similarly the control cable connections between
coaches should be checked for proper sealing at the ends to make them weather-proof. The running
gear and brake equipment in all motor and trailer coaches should also be tested.

Insulation resistance of the through wiring in the coaches, and internal wiring for lights and fans
within the coaches should also be checked and recorded. Verify that the. different circuits are
provided with individual fuses and the fuses are of the correct rating. All tests and trials should be
conducted with the EMU without any passengers, except for the officials in-charge for testing ,
loading of the train may be done by sand box, etc .

30805 Additional Precautions Before Commencement of Commercial Operation

1. During trial runs, very close watch should be kept of the performance of new loco or EMU put into
normal service. For the first few runs , the Driving Inspector, together with. a few key personnel,
should accompany the loco or EMU and examine the equipment at frequent intervals and arrange
for rectification of any defects which may show up. A separate History Sheet should be maintained
for every electric locomotive or EMU.
2. The "trouble-shooting directory" should be got ready well in advance of introduction of a new type
of loco/ EMU and the running staff adequately trained in the trouble shooting methods and operation
of the type of loco/ EMU.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [169]

CHAPTER IX

SAFETY, BREAKDOWNS ANDDISASTER MANAGEMENT

Para No Subject

30900 General
30901 Knowledge of Rules
30902 Emergency Stores and Break Down Equipment
30903 Use of Hydraulic Re-railing Equipment of Electrified Tracks.
30904 Break Down Gangs
30905 Record of Staff Movements.
30906 Summoning of Emergency Staff
30907 Expeditious Clearing of Track
30908 Emergency Telephone
30909 Flasher Lights
30910 Access to the Roof of Electric Locos and EMUs.
30911 Precautions to be Followed While Dispatching Locomotives as
Vehicle.
30912 Hauling a Damaged Locomotive.
30913 Haulage of a Disabled EMU Train.
30914 Movement of Electric Trains Under Conditions of Flooded Tracks.
30915 Accidents Involving Electric Rolling Stock
30916 Look out for OHE Defects
30917 Pantograph Entanglement
30918 Protection of Train in Case of Loco Failure and/or OHE Supply
Failure.
30919 Parting of Trains
30920 Firefighting Appliances for Electric Rolling Stock.
30921 Fires in Electric Rolling Stock
30922 Technical Investigation of Fires
30923 Fire Accidents
30924 Electrical Safety
30925 Rehabilitation of Fire/Accident Damaged Rolling Stock

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [170]

CHAPTER IX

SAFETY, BREAKDOWNS AND DISASTER MANAGEMENT

30900 General

The safety precautions to be taken have been dealt with great length in various parts of the Manual
particularly in Chapters 2 to 7 dealing with Operation and Maintenance of Rolling Stock. The
compliance of these rules should be ensured.

Various instructions given under this Chapter are in addition and over and above to the ones
already mentioned elsewhere in this manual and other relevant manuals issued by the railway. .

Drivers/ Motormen should be fully trained to protect not only their train but also the trains running on
other tracks in case of any infringement suspected as laid down in General and Subsidiary rules.

30901 Knowledge of Rules

All officers and supervisors of the Rolling Stock section should be fully conversant with the "Rules
for Reporting Accidents" as given in the Accident Manual and other instructions in force for dealing
with accidents and breakdowns. The instructions given in the following paragraphs are to be treated
as supplementary instructions. They should not be taken as nullifying or contradicting the
instructions contained in other official manuals.

30902 Emergency Stores and Break Down Equipment

At electric loco sheds and EMU sheds and at selected stations in the electrical sections, tools and
equipment such as special lifting jacks, traversing jacks, etc. for dealing with accidents to electric
rolling stock will be maintained. Sr. DEE / DEE incharge of sheds will be responsible for proper
upkeep of such equipment. They should inspect the same periodically and ensure that the same are
kept in working order and maintained properly. The list of tools and equipment to be maintained
specially for dealing with breakdowns of electric rolling stock in use on the railways will be issued by
CEE.

30903 Use of Hydraulic Re-railing Equipment of Electrified Tracks

In case of electrified tracks whenever the restoration is to be carried out and infringements are
required to be removed which in most cases will be the Rolling stock i.e. locomotive, coaches and
wagons, it will be mandatory to use hydraulically operated jacks. The use of overhead crane will be
resorted to in case the hydraulic operated rerailing equipment, is unable to carry out restoration.
Use of overhead crane for restoration of services on electrified sections will only be permitted with
the personal approval of DRM.

30904 Break Down Gangs

It is essential that adequate number of selected, experienced staff of all categories should be
housed in railway quarters closed to loco sheds / EMU sheds, outstation depots and EMU stabling
lines etc. so that their services can be utilized for dealing with breakdowns and accidents whenever
required.

30905 Record of Staff Movements

Senior Supervisors of the Rolling Stock section should keep Traction Loco Controller advised of
their movements to enable him to contact them in the event of an emergency of any breakdown
involving electric rolling stock.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [171]

30906 Summoning of Emergency Staff

Addresses and telephone numbers of officers and staff of the Rolling Stock Section should be
available with TLC. Station Masters should also keep the residential addresses of staff residing
nearby especially those who have no residential telephones, so that they can be summoned when
required. Where special sirens are installed in railway colonies to summon emergency staff in the
event of breakdowns or accidents, a special code signal may be employed for such summoning.
The adequacy and proper observance of these instructions should be checked at least once in
every six months by sounding the alarm and recording the time taken for the key staff to turn up.

30907 Expeditious Clearing of Track

In the event of a failure of locomotive or EMU, the primary objective should be to clear the line as
quickly as possible so that the repercussions on traffic are minimal. The Driver should follow the
detailed instructions given in the respective trouble-shooting manuals. He should seek guidance
from TLC wherever necessary.

In such cases it may be necessary to disconnect / disengage and even cut out the drive due to
wheel sets getting jammed. For expeditious clearing of the track, the locomotive may have to be
driven at a reduced speed to be decided in consultation with the engineering staff.
If the Driver is unable to move the locomotive or EMU on its own power, he should ask for a relief
engine or assisting train as the case may be.

30908 Emergency Telephone

The driver of every locomotive shall carry with him a portable emergency telephone set, so that in
the event of a serious breakdown enroute in mid-section, he could contact the TPC/TLC from the
nearest emergency telephone circuit. To help the Driver arrow marks are painted on the faces of
OHE masts indicating the direction in which the nearest emergency telephone socket lies. Every
Driver shall be fully conversant with the method of plugging the portable telephone to its socket and
establishing communication with TPC/TLC.

In case telephone is not working the Driver will arrange to communicate the incident to the nearest
railway station either himself or through Guard or Asstt Driver. In busy suburban sections, motormen
of disabled EMU trains can send messages to the nearest station through the Motorman or Guard of
trains on adjacent track, which may be stopped by him for the purpose by showing hand signals. In
case telephone is not working the Driver will arrange to communicate the incident to the nearest
Railway Station either himself or through Guard or Asstt. Driver.
30909 Flasher Lights

These lights are provided on all locomotives and EMUs. As soon as the train stops due to
emergency application of brakes not initiated by the crew, the driver should assume that some
portion of his train has derailed and should put on the flasher light to warn the driving crews of the
oncoming trains on the opposite track. The operation of the flasher lights may be suspended only
after the crew have verified physically that the neighbouring track is not infringing. Similarly the crew
observing the flasher light should take immediate action to stop the train even with emergency
application of brakes if necessary and should only restart after the physical verification of the
infringement.
30910 Access to the Roof of Electric Locos and EMUs

On Line
a) Access to the roof of electric locos and EMUs is authorized only under the conditions that the
OHE has been made dead and earthed on both sides of the loco /EMU by the OHE staff in
accordance with procedure laid down. The power block will he taken by the OHE staff.

b)On locomotives a ladder is provided for gaining access to the roof. The ladder is normally kept
locked.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [172]

To remove the ladder from its locked position the Driver should operate the main isolating switch
and take out the key for unlocking the ladder. When the operations on the roof of the locomotive are
over the Driver should put back the ladder in its proper place. After locking the ladder he can
release the key for operating the main isolating switch.

c) When required, for climbing from rail level, portable ladders are provided in each EMU. These
ladders are fixed at a height at the ends of motor coaches. Though no special interlocking is
provided to prevent the ladders being used, the Motorman must ensure that the condition of para (a)
above is satisfied before going on to the roof.

d)After the Driver/Motorman has completed his work, he shall ensure that everything is in order and
advise the OHE staff to energize the line.

In Sheds

The supervisor incharge of maintenance gang shall ensure that OHE supply is switched OFF and
earthed before any staff is authorized to go on the roof of a locomotive/EMU. For this purpose, the
OHE shall be made dead and earthed by opening the controlling isolator(s) fitted with earthing
heels. He will ensure physical contacts of earthing wheel and provision of padlock in this condition.
Where the isolators are not provided with earthing heel, the line shall be earthed an both the ends of
the locomotive with the help of discharge rod. Having ensured this, he will allow the staff access to
the roof who in turn will follow the following procedure :

a) Each of the staff will collect padlock(s) with key(s) and will sign in a register maintained for this
purpose.

b) Handle(s) of the controlling isolator(s) already opened by the supervisor incharge will be further
secured by providing individual lock(s) by the staff. Keys of the locks will be retained by the staff till
such time the work is completed.

c)After completion of the work and when the last staff has removed his padlock(s) from the
isolator(s) and signed the register again; the concerned supervisor, after satisfying himself that all
staff, tools etc. and the earths provided have been removed, may re-energize the OHE.

30911 Precautions to be Followed While Despatching Locomotives as Vehicle

Electric locomotives should not be worked as dead vehicles unless an authorised railway
employees has taken all the measures detailed in the respective Operating Manuals. Essentially
these measures are lowering and isolating the pantographs, making all electrical equipment of the
loco dead, releasing the brakes of the loco and closing the corridor and cab doors. In such cases,
the loco must he attached as the first vehicle of the train next to the engine. Para 30912 may also
be referred in this regard.

30912 Hauling a Damaged Locomotive

1. If a damaged electric locomotive which is stabled on the open line or at a station is to be hauled
as a dead vehicle, it must be certified by the Driver or EXR and must be accompanied by competent
staff. In case of damage to the traction motor or transmission gear, the locomotive must be
examined by an engine examiner and certified as fit for movement. The speed at which the
damaged locomotive may be hauled in such cases should be as specified by the engine examiner.

2. On dead locomotive all the circuit breakers and battery knife switch shall be off and such other
steps to ensure that the dead locomotive cannot be started inadvertently.

3. Care shall be taken to ensure that traction motor reversers are physically placed and locked in
the neutral position. For long distance movement of dead electric locomotives, the traction motor
brushes shall be lifted and secured before the loco is dispatched.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [173]

4. The locomotive brakes shall be fully released. The brake pipe and main reservoir pressure shall
be fully discharged or the vacuum fully destroyed. The MU2B valve, if fitted, shall be lifted and
properly secured,

5. The dead locomotive shall be accompanied by a competent person not lower than an Asstt Driver
when attached to a passenger train and also when attached to the rear of a goods train. When
attached to the rear of a goods train, it will be the duty and responsibility of this person to apply the
hand brakes judiciously in case of run away occurring on a graded section.

6. The train driver shall be informed that he should work the train carefully as the dead locomotive
will have no brake power at any time. If the dead loco is to be hauled by a light engine, the speed
may be required to be limited on account of limited brake power available on the light loco. This will
be laid down by the CEE of the railway.

7. The Assistant Driver of a train to which a dead electric locomotive has been coupled should keep
frequently looking back to watch for any signal from the staff accompanying the dead locomotive.

30913 Haulage of a Disabled EMU Train

1. Instructions contained in Para30912 for haulage of damaged loco shall apply mutatis-mutandis
for movement of a disabled EMU as well.
2. An EMU train which cannot move on its own power but is otherwise fit to be moved, may be
hauled by another EMU train or a steam, electric or a diesel locomotive till it can be conveniently
side-tracked into a siding. Special adopters are provided to enable such emergency haulage of
EMU trains fitted with automatic couplers by means of locomotives. Drivers must be familiar with the
procedure for fitting such adopters. The speed at which a disabled EMU train may be hauled under
such conditions will be as laid down in local instructions.
3 The relevant General and Subsidiary Rules for moving disabled EMU trains should be rigidly
observed.

30914 Movement of Electric Trains under Conditions of Flooded Tracks

When the tracks are flooded, the restrictions regarding movement of electric locomotive and EMU
trains shall be in accordance with local instructions (see also para 30716).

The traction motor and associated parts including gear case, etc., are designed to permit propulsion
of rolling stock at 10 km/h through water upto a level of 200mm above rail level. Further, the traction
motors are made completely water-proof to a standing water depth of 760mrn above rail level.

30915 Accidents involving Electric Rolling Stock

The Traction Loco Controller should immediately inform the Officer-in-charge of operation of Electric
Rolling Stock in the event of any accidents involving Electric Rolling Stock. An Officer or Senior
Supervisor of the Electric Rolling Stock section should be invariably associated with restoration work
when derailment or other accidents to Electric hauled trains are involved. Before restoration
commences the shed supervisor shall make measurements/ checks jointly with the engineering staff
to help investigation into the cause of accident later. For this purpose proforma prescribed in the
Accident Manual or issued under the local orders of the railway should be used. Action shall be
taken to preserve the evidence as far as possible. The restoration work of locomotive and train shall
only be started after the TrD gives clearance.

The checks to be carried out are detailed in the Annexure 9.01

30916 Look out for OHE Defects

The engine crew of all trains shall keep a sharp look out and report any defects in OHE noticed by
them to the TPC from the nearest station. Such defects need not be confined to the line on which
train is moving but in the entire vicinity. They should give as detailed information as possible on the
nature of the breakdown, its location;
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [174)
whether the masts have been uprooted, whether both lines in a double track section have been
affected etc. The OHE defects as observed by the driver may be of any one of the following
classification.
1. Uprooting of or damage to OHE masts on account of cyclone, derailments etc,
2 Entanglement of pantographs with the OHE.
3.Snapping of OHE conductors.
4.Flash-over or other damage to insulators.
5.Faults on account of stray wires etc.
6.Theft of OHE conductors.

30917 Pantograph Entanglement

The officer or supervisor of the Electrical Department arriving first at site of a breakdown, particularly
those involving entanglement of pantographs with the OHE, should make a very careful note of all
relevant details pertaining to the break-down and also prepare a sketch indicating the particulars.
He will also arrange for preservation of such evidence as may be useful subsequently for
investigating the cause of the breakdown.

Items to be checked on the pantograph and OHE are indicated in the Annexures 9.02 and 9.03.

Maintenance Staff, after ensuring that OHE is dead, and earthed in association with OHE staff will
climb on the roof of the locomotive. They will remove the HPT links of the damaged pantograph and
earth it and will secure the pantograph with wire rope from the base frame of the pantograph in such
a manner that it does not come in contact with OHE during the run.

30918 Protection of Train in Case of Loco Failure and/or OHE Supply Failure

1. When overhead supply fails, the Driver shall endeavor to proceed on the momentum of the train
and see whether he can reach the next station otherwise he will stop the locomotive close an
emergency socket. To help the Driver, arrow marks are painted on the faces of OHE masts
indicating the direction in which the nearest emergency socket. lies. If power supply is not restored
within 5 minute after stopping the train, he should make use of his portable telephone to ascertain
from the TPC through the emergency telephone socket the time when the supply is expected to be
restored. If it is likely to be more than 15 minutes then the Driver should apply air and hand-brakes
on the loco and pin down brakes on 10 wagons immediately behind the loco in the case of goods
trains and all available hand brakes in the case of passenger trains.

If the Driver is unable to stop the train close to the emergency telephone socket, and is likely to take
more than 15 minute to ascertain the time of restoration of the over head power supply from TPC he
must first protect the train against rolling as indicated above and then contact the TPC.
The same instructions shall be observed in case of electric loco failure when it becomes necessary
to make the loco dead and call for assistance.
2. In addition, the precautions prescribed in General and Subsidiary Rules for protection of trains
when stopping out of course should be observed.

3. If after power is restored, the Driver experiences tripping again, he shall not energize the
locomotive until he has personally satisfied himself that there is no abnormality on his locomotive.

4. The locomotive will not be left unmanned in such an eventuality.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME III [175]

30919 Parting of Trains

1. Failure of inter-vehicle couplers can cause train partings. This can be due to sudden acceleration
or braking causing jerky motion of vehicles. Such jerks cause waves of alternate compression and
tension in inter-vehicle couplers passing down the train length and the weakest coupler is liable to
break.

2. Drivers will observe following precautions to avoid parting of trains:

a) When starting a train, tractive effort should be applied gradually to ensure that all the couplings
are fully tight.

b) Pick up speed notch by notch and start train smoothly.

c) Do not release brakes too fast after destroying vacuum by using double exhausters.

d) It is not enough to be guided solely by the vacuum gauge. Sufficient time (3 to 5 mt.) should be
allowed for full release of vacuum brakes.

e) Do not use loco independent air brakes to stop trains.

f)Ensure engine coupling is properly tightened / locked before starting a train.

3. When a parting occurs the driver (in the front portion) should not endeavour to stop the front
portion of the train, but should allow the portion to move forward to the extent possible to prevent
the possibility of the rear portion colliding with the front portion. The automatic brakes applied on
parting may not be effective equally on both the halves of the parted train.

30920 Firefighting Appliances for Electric Rolling Stock

1. Every electric locomotive should be provided either with 2 number of 4 kg capacity or 4 number of
1. 25 kg capacity halon type fire extinguishers to IS: 11108, one in each cab and remaining in each
corridor. The fire extinguishers shall be fixed on brackets at approved points in the cabs and
corridors. The ATFR on duty will be responsible for ensuring that the locos leave with the full
complement of fire extinguishers. Sufficient number of spare fire extinguishers should be available
with the ATF(R) to replace defective and damaged fire extinguishers.
In exceptional circumstances CEE may authorize change in complement and / or type of the fire
extinguishers.
2. On EMU, 2 number of 2.5kg. capacity Halon type fire extinguisher should be provided in each of
the cabins occupied by motorman and Guard and also one number of Halon type extinguisher of the
same capacity should be provided in each motor-coach of EMU. As in the case of other passenger
trains, the Operating Department will be responsible for custody of the fire extinguishers and their
issue to the Guard at the originating station of each EMU rake.
3. All the staff of electrical department connected with the running and operation of trains should be
duly trained for fire fighting and use of fire extinguishers within the locos and EMUs.
4. The staff should be trained in taking necessary precautions as enumerated in para 30921

30921 Fires in Electric Rolling Stock

Preventive Maintenance and Inspection

1. The presence of a large quantity of oil in the transformers and tap-changers of electric locos and
EMUs makes it possible for even minor fires to spread and assume serious proportion. Leakage of
oil from exhausters and compressors results in accumulation of oil on the loco flooring causing
spread of fires. An essential step in
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [176]
prevention of fires in locos is, therefore, to control the leakage of oil from exhausters, compressors
and pipe lines and to arrange periodic cleaning of the locos to remove accumulated oil. Always use
funnel of proper shape for tapping of oil to prevent spillage.

2. The arcing horns should be properly attended to during inspections. The arc-chute should be
properly secured and the securing arrangement periodically checked. The arc-chute should also be
cleaned during inspections.

3. In addition to periodic cleaning of the bogies and underframe to remove oily dust, it is also
important that rheostatic and regenerative braking, where provided, is kept in working order and
drivers trained to make use of these on graded sections, obviating the need for heavy mechanical
braking as far as possible thus preventing sparks from brake blocks.
4. Rating of fuses particularly of low voltage dc circuits are to be checked periodically to eliminate
the possibilities of the fire due to shot circuits/ overloads etc. Always ensure that the proper sizes
and types of fuses are used for replacement. Check calibration of MCBs during POH. Use MCBs
and fuses of only approved supplier as laid down by RDSO.

5. Ensure that all the Protective relays are in good working order and are properly calibrated. Do not
bypass any protection on the rolling stock.
6. A loose connection is a potential source of fire. Proper tightness of all the connections is,
therefore, to be ensured and this point is to be given particular attention during inspections.
Coaches commissioned after POH or new coaches after commissioning should be thoroughly
checked up for loose connection as during the first few days, loose connections will show up.
Ensure that all the connections secured with a nut and bolt are provided with a set of plain and
spring washers.

7. Insulation failures can result from surface flash overs due to presence of dirt and dust. It Is,
therefore, essential that proper cleaning of terminal connections, bus bars, insulators and equipment
is done during schedules as laid down to remove oil and dust.

8. Fires in control equipment cubicles are a problem and usually lead to considerable damage. A
particular difficulty is the detection of fire and, therefore, the fire is likely to get a good hold before it
is noticed. Ensure that proper maintenance of the equipments inside the cubicles is done and the
equipments are carefully looked at during inspection for any developing faults.

9. Batteries constitute some fire or explosion risk when they are being given a heavy charge. Heavy
charging can be either due to malfunction of the charging equipment or carelessness when charging
from the shop floor rectifier. It is therefore important to check that the ventilation provided in the
battery box is not choked. The staff should, therefore, be made aware of the danger of
overcharging.

10. Use only approved quality of cables and furnishing material for repairs. Proper care should
betaken while laying down the new cables so that no damage to the insulation is caused.

11. In order to monitor healthy condition of insulation of wiring and equipment, insulation resistance
should be measured periodically in sheds and during POH in shops, and records kept.

12. In the event of fire it is essential that the main circuit breaker is tripped and the battery fuses of
locomotives and EMUs are immediately removed to eliminate the continued feeding of the fault by
the battery.

30922 Technical Investigation into Fires

Every case of fire minor or major, irrespective of the location, whether in power, auxiliary or control
circuits, should be investigated very carefully, even though an inquiry in accordance with the
Accident Rules may not be called for. The causes as established by the investigation should be
analyzed by the Sr. DEE / DEE personally to identify areas requiring further investigation and to
tighten up preventive measures. A report on each case of fire should
INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [177]
also be furnished to CEE. The general guidelines to check up the items in locomotive in the event of
fire, is given Annexure 9.04

30923 Fire Accidents

1. Fires in trains, whether carrying passengers or not, resulting in loss of human life or injury to any
person or loss of or damage to railway property to the extent of or more than the value prescribed
are required to be treated as "accidents" and have to be inquired into in accordance with the "Rules
for Reporting and Inquiring into Accidents". Fires in other railway premises resulting in damage to
railway property of the prescribed value or over are also to be treated as "accidents". Fire accidents
involving loss of human life or injury to persons or damage to railway property estimated to cost
equal to or over a prescribed value have also to be reported as soon as possible on telephone to
the Railway Board by the General Manager through Operating (Safety) Branch. Procedure laid
down in the Finance Manual should be followed.

2. When electrical installations or electric rolling stock are involved or when there is possibility that
the fire was caused by electrical short circuit or due to defect or malfunctioning of electrical
equipment, a representative of the Electrical Department should invariably be a member of the
inquiry committee. Rules also require that a representative of the Security Department should be
associated with all inquiries into fire accidents. On arrival at the site of fire they will collect necessary
evidence and make out a joint report in consultation with the representative of the security
department.

3. The composition of the inquiry committees and the method of disposal of the report of the inquiry
committee will be as laid down in the "Rules for Reporting and Inquiring into Accidents" issued by
the Zonal Railways.

30924 Electrical Safety

Procedure for reporting of electrical accidents and action to be taken have also been laid down in
Vol. I of this manual. The various authorities to be informed in case of injury / death due to
accidental contact with live installations have also been indicated.

Following guidelines are specifically meant for Electrical Rolling Stock. These are to be observed
and in no way nullify or counter any of the instructions laid down elsewhere by the CEE in his
capacity as Electrical Inspector to the Government of India.

1. All Loco / EMUs sheds should ensure that the various interlocks provided on the high tension
compartments are effective and it is not possible to open HT compartment until the pantograph is in
lowered position and is fully earthed.

2. Drivers / Motormen should not enter the HT compartment unless the pantograph has been
lowered and fully earthed.

3. Drivers / Motormen should be fully trained in operations necessary to ensure electrical safety.

30925 Rehabilitation of Fire/Accident Damaged Rolling Stock

The items need to be checked up before the electric rolling stock is taken for rehabilitation for its
suitability is given is Annexure 9.05.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME [178]

Annexure 9.05

ITEMS TO BE CHECKED UP BEFORE TAKING UP SPECIAL REPAIR OF FIRE/ACCIDENT

DAMAGED LOCOMOTIVE

All the items given below need attention for a locomotive involved in a major accident, affecting the
under-frame. However, checking up of only under-frame and item 3 is necessary in case a major fire
damaged locomotive is taken for rehabilitation.

1. Electrical equipment
1.1 Condition of tap changer plate, oil level in the gauge glass.
1.2 25 kV condenser bushing for physical damage and oil leakage.
1.3 Fixing/foundation bolt of all equipment.
1.4 Visual inspection for any damage.
2. Mechanical equipment
2.1 Under-frame
(a) Visually inspect the underframe main sills for crack/local deformation/squareness.
(b) Measure height of couplers/buffers
(c) Measure important dimensions of the underframe and examine for any bend/twist. The typical
dimensions which are required to be recorded for WAG -5 class of locomotive are given in Fig. 9.02
(Sheet 1, 2).
(d) Measure camber by running a piano cord from end to end of the locomotive. If there is a
negative camber, the under-frame is likely to have under-gone a permanent set. It is normally not
possible to set right such deformation except when it is localised or is on a non-stress bearing
member.
(e) Any separation between underframe and shell.
(f_) Coupler, coupler pin, draft lugs (inside the coupler pocket) for crack/deformation.
(g) Holding arrangement of each equipment and shear checks, etc.
2.2 Bogie and Brake rigging

(a) Visually examine the bogie frame and brake rigging for any damage with special attention to
cracks.
(b) Measure all dimensions of bogie frame and examine for its deformation/squareness.
(c) Condition of the interfaces of the bogie frame with underframe.
(d) Condition of axle box roller bearing and horn liners.
(e) Bending of axle and traction motor shaft.
(f) Cracks/deformation of equaliser beam, spring and spring seats.
3. Miscellaneous
Visual inspection of all equipment of locomotive for any damage and deficiency.

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INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [184]
 CHAPTER X

Para No. Subject

31001 Annual Statements

31002 Monthly Statements

31003 Daily Position

31004 Shed-wise Performance

31005 Combined Driver's and Guard's Report.

31006 Nomination for Foreign Railway.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME III [186]

Utilization ( Territorial Basis) E Km/day in use
a) Goods ( Through)
b) Passenger
c) All services

7. Total Engine km/per day earned

(Average for the month)
a) Goods services
b) Passenger services

31005 Combined Driver's and Guard's Report

The only basis of the operating statistics which give the vital performance index of a particular type
of locomotive or the shed emanates from Combined Guard's and Driver's Report Part - I and Part -
II (attached). This report in addition to being an instrument of payment of wages, running and
overtime allowances to the crew, also becomes the basis of operating statistics. This goes to the
statistical office and gets coded in the coded sheet for operating statistics. It is therefore important
that the ATFRs should check very particularly all the details given in the joint report so that the
operating indices of the shed are not vitiated.

31006 Nomination for Foreign Railway

In addition, the locomotive nominated for foreign Railway shall be issued with Trip Card, a sample
proforma is attached. The trip card is also sent to the statistical office after the loco touches the
homing shed. This also helps to keep correct record of the performance of the locomotive.

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 CHAPTER XI

TECHNOLOGICAL ADVANCEMENTS

Para No. Subject

31101 Introduction

31102 Conversion Equipment

31103 Controls

31104 Drive

31105 Power Rating

31106 Other Developments on Hand

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 CHAPTER XI
TECHNOLOGICAL ADVANCEMENTS
31101 Introduction

Some of the recent technological innovations introduced by Foreign Railways are discussed
below. Advantages offered by these innovations in respect of operating performance and
maintainability have also be indicated. With a view to use developed technology of 3- phase drives
system on Indian Railways, import of 3- phase drive system locomotives with technology transfer
for subsequent indigenous manufacturer is on hand.

31102 Conversion Equipment

1. With the availability of thyristor of higher power handling capability use of tap changer is
being eleminated making the equipment entirely static. This will not only reduced attention required
but also enhance reliability. Other very important benefit achieved by the thyristors is the capability
they offer to control individually the supply to each motor permitting full utilization of the adhesion
existing between the wheels and the rails.
2. Indian Railways have imported 12 locomotives from Japan and 6 from Sweeden with this
technology (WAG6 series). Earlier a few experimental thyristors units were also fitted in existing
locomotives, some of them with indigenous know how . Indian Railways have also imported 25
sets of thyristor control traction equipment for fitment on 25kV ac MG EMUs from UK. These are
being fitted on 25kV ac MG EMU coaches at ICF, Madras. Seven such thyristor controlled EMU
rakes are presently in operation on MG Section of Southern Railway.

31103 Controls

With the advent of solid state devices in general, and microprocessors in particular, more
and more sophistication has become possible. Other things remaining the same, with stepless
control and consequent non-pulsating torque offered by such controls, higher average tractive effort
can be achieved. The solid state control is fast acting and methods are now available to detect
incipient slip and take corrective action before the slippage becomes uncontrollable and curative
action is called for by reducing the tractive effort applied. Thus the locomotives can be made to
develop tractive efforts to very high levels of adhesion co-efficient.

31104 Drive
1. One of the severe restrictions imposed on the capability of electric locomotive is the dc series
motors. These motors have limitations on their use because of windings on the rotor and assembly
of commutators, making it vulnerable against centrifugal forces and requirements of satisfactory
commutation. The 3-phase asynchronous motor with a bar rotor does not have the surface speed
limitations. The useful portion of its speed torque characteristics is only near its synchronous speed
.This useful portion can be spread over a wide range by varying the synchronous speed through
frequency control.

2. With the advent of Gate Turn Off (GTO) thyristor problems associated with conversion of dc into
multiphase ac system have been eliminated and use of 3-phase synchronous/ asynchronous motor
has become feasible. Variable Voltage and Variable Frequency (VVVF) control has been
developed and use of induction motors as traction drives has been tried successfully on the different
railway systems. With induction machines a maximum surface speed of 100 m/s is achievable and
an rpm level of 4500 has been accepted in the railways systems in Europe. This considerably
increases the output power of the traction motor for the same size. This state of art technology has
yet to arrive in our country.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME III [193]

 3. Typical power circuit along with brief details of locomotive fitted with asynchronous motors is
shown in Fig. 11. 0 1.

31105 Power Rating

1. Necessity for increasing the throughput resulted in the design of BOX "N" wagons. With these
wagons, a trailing load of 4700 t has been optimized. Further improvements are under consideration
which may result in a maximum trailing load of 5100 t on the existing loop lengths. Also efforts are
on hand to increase the maximum speed of these stock to 100 km/h. For trailing loads of 4700t, a
6000 HP locomotive with 45 t starting effort was taken as an optimum. Once the trailing load is
increased to 5100 t and the speed potential to 100 km/h, the horsepower requirements further go up
to 8000 with a starting tractive effort of 50 t. Indian Railways will require a 8000 HP loco to meet the
increasing throughputs of freight traffic.

31106 Other Developments on Hand

1. Indigenous development of multiplexing and locotrol for use on long passenger and heavy-hauled
goods trains.

2. Indigenous development of on board power factor correction equipment for improving power
factor of locomotive.

3. Indigenous development of fault diagnostics for locomotive

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME, III [194]

 ANNEXURE 11.01
ELECTRIC LOCOMOTIVES WITH 3-PHASE DRIVES
1. Introduction

Till electronics came into the field of traction recently, the best suited drive for traction application
was the dc series motor because of its inherent characteristics to give high torque at low speeds
and vice-versa. The dc series motor was the best solution found for meeting the actual service as
well as control requirements. On a fixed frequency, the asynchronous motor has a characteristic
which is not well suited for traction application. However, this motor is of rugged construction when
compared to a dc motor and requires much lower inputs for maintenance. Therefore its choice as a
traction motor will always be preferred if control of the motor to suit the service requirements is
possible. With the development of GTO thyristors, power electronics and micro processor control,
controlling of any drive to suit specific requirements has become quite easy. In the circumstances,
adoption of 3- phase induction motor for traction application has been tried for the past 10 years and
has now become commercially viable proposition. The control is being achieved through variable
voltage and variable frequency briefly referred to as VVVF. Originally thyristors were used with
commutation requirements for cut off. With the advent of GTO, the control has been made much
simpler and more efficient thus use of 3-phase asynchronous motors for traction could also become
financially viable.

A locomotive With 3-phase asynchronous motor drive has the following advantages

- higher power capability due to high power/weight ratio,

- regeneration capability over a wide speed range,
- lesser maintenance,
- unity power factor at pantograph,
- higher adhesion.

2. Principle of control of 3-phase drives.

The speed/torque characteristic of an induction motor supplied from a 3-phase voltage source of
fixed frequency f is of the form shown in Fig. 11. 02.

It may be seen that at low speed, the torque is small and the stator current is high. The zone
normally usable lies at the extreme from the point of maximum torque, in the vicinity of synchronous
speed. For traction applications a high TE is necessary for starting and accelerating the train.
Therefore, when constant torque is required, it is necessary to obtain whole series of characteristics
curves such as shown in Fig. 11.03. This calls for change in synchronous speeds and therefore
variable frequency.

3. Control scheme for induction motors :

The control of the ac induction motor drive in traction application is achieved in 3 stages.

1) Constant torque mode : The torque developed by a motor is proportional to the product of the
magnetic flux in the air gap and the rotor current. The applied voltage is proportional to the
synchronous frequency and the magnetic flux in the air gap. To keep the magnetic flux constant,
therefore, the applied voltage to the traction motor is, to be made proportional to the synchronous
speed.

The rotor current depends upon the slip frequency of the rotor. By keeping this constant, the rotor
current is also kept constant. This is possible till the voltage is increased to the rated terminal
voltage of the traction motor. Thus in this mode the control is achieved by increasing the voltage
and frequency uniformly with respect to the actual speed of the rotation of the rotor and the required
slip frequency.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME III [196]

ii) Constant power mode : In this mode the voltage is already reached to the rated voltage. By
increasing the
frequency, the magnetic flux in the air gap is reduced proportionately. By keeping the slip frequency
constant, the motor current is kept constant. Thus the motor is made to give constant power output
till the maximum service speed is reached.

iii) Balancing speed stage: Once the maximum pre-determined speed is achieved, the same
power output from the traction motor may not be required and the output is to be matched to meet
the resistance of the train for running at the balancing speed. This is achieved by suitably reducing
the terminal voltage of the traction motor.
These functions are performed through micro processor control giving various inputs of parameters
like voltage, current and speed.

iv) Convertor/Invertor System : In order to achieve the above control requirements, the
convertor/ invertor system with a dc link is adopted. The convertor rectifies the ac voltage to dc and
feeds it to the dc link. The dc link supplies power to the invertor. The convertor output power is
controlled by controlling the output current keeping the dc link voltage constant. The invertor output
power is controlled by varying the terminal voltage initially till the full voltage is achieved. However
the motor output current is kept constant.

The control of output current of the convertor and output voltage of the invertor is achieved by pulse
width modulation control.

The Power circuit diagram of a typical 3-phase locomotive fitted with asynchronous motors is shown
in Fig. 11. 01.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME III [197]

 CHAPTER XII

TRAINING AND COMPETENCY CERTIFICATE

II. Para No Subject

31200 Introductory

31201 Planning of Training in Advance

31202 Categories to be Trained

31203 Initial Training

31204 Promotional Courses

31205 Refresher Courses

31206 Facilities for Training

31207 Training in General and Subsidiary Rules

31208 Responsibility of Officer and Supervisors

31209 Examination at the end of Training.

31210 Specialized Training

31211 Syllabi

31212 Authorized Person

31213 Competency Certificate

31214 Period of Training

31215 Drivers, Asstt. Drivers and Motormen

31216 Register of Certificates

31217 Service Record

31218 Inspections

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [199]

 CHAPTER XII
TRAINING AND COMPETENCY CERTIFICATES

I. TRAINING

31200 Introductory

Electric traction is a specialized field. Efficient operation and maintenance of the traction
installations and equipment is only possible if the staff concerned have acquired an intimate
knowledge of the details of construction, adjustments and operation of the equipment. A thorough
knowledge of the special rules and procedures on the part of the staff is also essential to ensure
safety of equipment and personnel. These requirements call for a degree of specialized training for
all categories of staff before they can be safely entrusted with the responsibility for maintenance or
operation.

III. 31201 Planning of Training in Advance

Before electric traction is commissioned on any section, adequate strength of well-trained operating,
maintenance and running staff should be kept ready for operating the services. Planning the
recruitment and training of such staff well in advance is one of the most important tasks of the open
line administration. This applies in particular to steam/diesel running staff who would become
surplus to requirements on introduction of electric traction and hence have to be absorbed as
running staff to operate electric rolling-stock. Timely release of such staff for training should be pre-
planned and ensured by the Electrical Department in co-ordination with the Mechanical Department.
It is also necessary to establish sufficiently in advance suitable training schools with qualified
instructors and facilities for imparting the training.

IV. 31202 Categories to be Trained

Categories of staff for whom special training is required to be organized are generally as under-

1. Degree and Diploma holders recruited directly as Supervisors.

2. Apprentice Mechanics to be absorbed as Supervisors.

3. Trade Apprentices to be absorbed as skilled artisans.

4. Diesel/ Steam Drivers to be trained as Drivers of electric locos and EMUs.

5. Artisans and supervisory staff to undergo Refresher Courses.

6. Running staff to be posted as TLCs etc.

V. 31203 Initial Training

1. Categories of staff mentioned below should receive a period of initial training in a training
establishment before they are posted to working posts-
a) Directly recruited supervisors.
b) All categories of running staff, whether directly recruited or absorbed from steam/diesel sections.

C) Skilled and semi-skilled artisan staff for maintenance.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [200]

d) Any other category to be approved by CEE.

2. The period of initial training for typical categories is given below, which may be modified by CEE
in accordance with local requirements-

a) Direct recruited supervisors (Degree and Diploma Holders)-

i) Electric Loco Section 18 months

ii) EMU Section 12 months

b) Steam/Diesel Drivers to be absorbed as Electric Running Staff-

1) Asst. Drivers 12 weeks

ii) Grade 'C' 20 weeks

iii) Grade 'B' or 'A' 48 weeks

c) Skilled artisans for maintenance-

i) Direct recruits 60 weeks

ii) To be absorbed from Diesel/Steam

or Electric general services 30 weeks

3. In addition to theoretical training, the trainees should receive thorough practical training on the
work they will have to perform on completion of training . In all cases they should have a period as
under-study to senior and experienced staff in actual execution of the type of work they have to
perform on completion of training.

4. For artisan staff the practical training should be oriented to enable them to understand and be
able to carry out independently skilled work of the type covered by 'Inspection books', 'Inspection
charts', 'trouble-shooting charts' and 'technical charts'.

VI. 31204 Promotional Courses

1. No employee can be promoted unless he passes the trade test or other prescribed departmental
test. The purpose of the semi-skilled category is to enable a man to study under the skilled man and
take the trade test in due course.

2. When an employees is promoted, he should, as a rule, receive a period of training to enable him
to discharge his responsibilities in the higher post e.g., a semi-skilled fitter on promotion as a skilled
fitter. Such training should precede the departmental tests to determine suitability for promotion. The
training should be generally on the same lines as initial training, but the period in most cases can be
curtailed since the employee would already have a certain amount of background knowledge on
account of his experience.

Particular attention should be paid to the older men, who although very proficient in the practical
aspects of their work, are unable to pass the prescribed trade tests etc. in regard to the theoretical
aspects because of their poor educational background. It often happens in consequence that they
are blocked for promotion although they are fit for promotion in every other respect. By paying
individual attention to such men and teaching them elementary tbeory, they could be made
sufficiently proficient to pass the trade tests in full. This not only ends their frustration, but boosts up
staff morale as a whole.
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [201]
VII. 31205 Refresher Courses
1. In accordance with instructions current on the subject, refresher courses should be arranged.
This is obligatory for those categories of staff dealing with "safety of train operation or having daily
contacts with the public". The following is an illustrative list of staff corning within the scope of these
instructions: -

Drivers, Asst. Drivers, Motormen, Shunters, Engine Turners, Supervisors and Artisans responsible
for examination and certification of fitness of running gear of locos and EMUs.

TLCs and Driving Inspectors

2. Similar refresher courses are also desirable for other categories of maintenance staff. The
categories of staff for whom refresher courses are to be arranged can be decided by the General
Manager in accordance with para 117(a) of the Indian Railway Establishment Manual.

3. The object of the refresher courses is to reinforce the knowledge of the staff and bring them up-
to-date in regard to the latest rules and procedures and instructions regarding operation and
maintenance in the light of operating experience. The duration of the refresher course for each
category may be decided by CEE to suit local conditions. The duration for typical categories is given
below for guidance-

a) Supervisors 3 weeks
b) Drivers/Asst. Drivers 3 weeks
c) Artisan Staff 2 weeks

4. For categories of staff liable for inter-divisional transfers, programming of refresher courses
should be arranged by the headquarters office. For staff confined to a particular division, the
programming should be done at the divisional level.

5. Apart from rules and regulations, the refresher courses for running staff should lay emphasis on
trouble- shooting procedures for various types of locos and EMUs. Drivers have to deal with some
types of failures only rarely and hence they tend to forget the details. Though such details are given
in the Trouble-Shooting, Manuals, actual drilling during the refresher course will be of great benefit.
This involves repetition of the same exercise several times so as to make a lasting impression and
not to be forgotten easily.

6. During the refresher courses, it will be very useful to arrange group discussions amongst the
trainees on specific problems encountered during the course of work. Such group discussions will
be of great assistance in view of the opportunity for exchange of information based on actual
experience in working.

VIII. 31206 Facilities for Training

1. Facilities have been provided on an All India basis for the intensive specialized training of officers
and staff of the Electrical Department. In addition the facilities available with the different Zonal
Railways have to be utilized to best advantage.

2. Training schools for Drivers are attached to major electric loco sheds. These schools should be
used to a limited extent for training of artisan staff and supervisors. Apart from cut-models, charts,
circuit diagrams etc. the training schools should contain simulators' to demonstrate the functioning
of locos, the circuit combinations resulting from operation of the master controller etc. These
simulators should be used to drill the trainees in the correct method of operation and systematic
trouble-shooting.
3. The 'simulator' provided consists of the HT and LT control apparatus as provided in the locos and
working models of items such as pantograph, tap-changer etc. A driving cab similar to the cab in a
loco is available, complete with master controller, brake controller, control switches, gauges,
indicator lamps etc. From this driving position
INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [202]
the equipment in the simulator can be operated to demonstrate the functioning of the various
components. By actually handling the controls, the trainees can learn the correct sequence of
operation and get a 'feel' of the equipment as actually functioning.
The Instructor can reproduce faults similar to those occurring in actual practice e.g., tripping of
circuit breaker due to overload, earth faults, traction motor faults etc. The trainees can get familiar
with the correct method of trouble-shooting as detailed in the trouble-shooting directory and by
repeated practice become fully acquainted with the correct procedure.

4. In any traction training establishment, the essential equipment to be provided for instructional
purposes should include the following-

a) Special tools and instruments used in electric traction.

b) Cut-models to show constructional details of equipment.

c) Circuit diagrams, sectionalising diagrams, etc., preferably illuminated and arranged to show the
sequence of operations

d) Samples of damaged equipment with tablets explaining the nature of failures and preventive
checks.

e) Publicity boards with slogans and illustrations emphasizing safe methods of working,

f) Boards illustrating 'Do's' and 'Dont's'.

g) Preferably full working models.

IX. 31207 Training in General and Subsidiary Rules

Electric running staff as well as supervisors, when required, should receive initial training as well as
refresher courses in General and Subsidiary Rules normally in the Zonal Transportation Schools,
which usually have excellent model rooms to facilitate the proper understanding of the rules and
systems of working. In exceptional cases when such training cannot be arranged conveniently in the
Zonal Schools, CEE may authorize the training in GRs & SRs to be included in the syllabus for
training in Loco Training Schools. Separate Instructors well-versed in the subject should, however,
be provided invariably.

X. 31208 Responsibility of Officer and Supervisors

Apart from those in-charge of training establishments, other officers and supervisors in-charge of
operation and maintenance should also take a keen personal interest in the training of all grades of
staff attached to them. They should deem it as part of their duty to guide the trainees and watch
their progress. Training is a continuous process which helps the officers as much as the trainees not
only in developing contacts on a personal level, but also in understanding the finer points of
operation and maintenance. A record of progress achieved, the period of training given etc. should
be maintained for every trainee.

XI. 31209 Examination at the end of Training

All trainees should pass prescribed examination on completion of training. The scope of
examination and the level of officers and supervisor responsible for examining will be laid down by
CEE. The examination should have a practical bias. The examination of Drivers, for instance,
should include practical tests in trouble shooting as well as correct driving and braking techniques.

INDIAN RAILWAYS - AC TRACTION MANUAL VOLUME Ill [203]

XII. 31210 Specialized Training

1. Selected supervisors and officers from the user railways should be deputed to CLW and ICF to
be associated with the production of each batch of electric loco and EMU stock. Such association of
the maintenance staff at the production stage will be of great help in giving them an insight Into
constructional details of the equipment.

2. Similarly when large contracts are entered into for supply of electric traction equipment
incorporating new designs and technology, it is usual practice to include in the contract a clause
which permits some staff of the consignee railways to be deputed to the manufacturer's works
during the production stage for practical training on the equipment, so that they may get thoroughly
acquainted with the operation and maintenance of the equipment, taking advantage of the training
facilities available with the contracting firms.
XIII. 31211 Syllabi
Guidelines for syllabus of two categories of staff are given below. Syllabus on the same lines shall
be prepared for all courses of trainings.

Driver Grade 'C' (Conversion from Steam/Diesel)

Duration: 20 weeks.

A. Theoretical:
(a) Basic principles of electricity - clear notions about voltage, current, power, resistance etc. - use
of electrical measuring instruments for measuring voltage, current and insulation resistance - clear
notions about ac and dc simple electrical circuits.

(b) Principles of ac and dc generators, transformers, rectifying devices - tap-changers, lead acid and
alkaline cells, relays, magnetic and pneumatic cotactors.

(C) Study of power and control circuits of different types of locos used in hauling freight trains
familiarization with the names, symbols and physical location of all equipment.

(d) Essential details of mechanical equipment of different types of locos used in freight trains.

(e) Details of pneumatic and brake equipment.

(f) Procedure for preparation of locos for service - principles of driving, acceleration, speed control,
use of gradient marks, procedure to be followed at neutral sections, correct use of electrical and
mechanical brakes.

(g) Study of rules specially applicable to electric traction.

(h) Safety precautions, prevention of wheel-slip and parting.

(i) Procedure for obtaining emergency power block for roof inspection.

0) Rules regarding fire fighting in electrical installations and practice use of common types of fire
extinguishers.

(k) Study of standing instructions.

(B) Practical:
(a) Work with the maintenance staff to get familiar with equipment.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [204]

(b) Detailed study of trouble-shooting directory for each type of loco and actual practice of each
case.

(c)Practice inspection of outgoing and incoming locos in shed.

(d)Driving under the supervision of a senior and experienced Driver after learning road.

2. Supervisor (Electric Loco) - Direct Recruits - Degree or Diploma Holders

Duration.: 18 months.

A. Theoretical:

(a) General principles of 25 kV traction Installations and rolling stock.

(b) Detailed study of mechanical and electrical details of all types of locos in the railway including
bogies and suspension, power transmission, braking system, hauling capacity, power and control
circuits and details of all traction and auxiliary equipment. Become thoroughly familiar with circuit
diagrams, symbols and physical location of all equipment.

(c)Maintenance organization in the shed- section-wise distribution of work with particular reference
to responsibility of each supervisor in the shed, functioning of PPO, Maintenance schedules,
inspection books, inspection chart, technical charts etc.

(d)Work done during POH of loco.

(e)Rolling-stock operation-outstation maintenance, loco links, control over running staff, Traction
Loco Control.

(f)Procedure for indenting and accountal of stores T & P Register.

(g)Rules and regulations -Factories Act, HOER, Payment of Wages Act, Workmen's Compensation
Act, Leave and Pass Rules, Rules for Overtime Working etc.

B. - Practical.

(a) In the shed some time should be spent in each section to study details of maintenance carried
out by designated workmen and some time to understudy the section supervisor. When attached to
E1 and M1 sections, the trainee should undertake trouble-shooting independently.

(b) In the POH shop, in a similar manner as above in each section.

II. COMPETENCY CERTIFICATES

XIV. 31212 Authorized Person

An "authorized person" is one who is duly authorized to perform specific duties pertaining to his
employment, the authorization being made by an official of the Railway Administration empowered
for that purpose.

XV. 31213 Competency Certificate

Each authorized person will be given a "Competency Certificate", defining the works which he is
authorized to carry out after he has been trained, examined and found fit.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [205]

The following categories of rolling stock staff shall be issued with the certificates by the official
indicated against each category after written/oral test as shown:

1. Asstt.Driver (Elec. Loco) TR-10 DEE(RS)/DEE(OP) after Written, oral

and
practical tests as prescribed.
2.Driver (Elec. Loco) TR-11 -do-
3. Motorman (EMU train) TR-12 -do-
4. Shunter/Engine Turner TR-13 -do-
XVI. 31214 Period of Training
XVII.
XVIII. The period of training mentioned in the following paragraphs may be modified, If considered
essential by CEE, taking local circumstances into account.

XIX. 31215 Drivers, Asstt. Drivers and Motormen

XX.
XXI. Drivers, Asst. Drivers and Motormen should undergo courses of training and tests indicated
below before they are issued with the Competency Certificates:-

XXII. 1. A prescribed course of training in General and Subsidiary Rules in the Zonal Training
School or other approved training establishment followed by a written. oral and practical test.
2. A course of training as indicated in paras 31203, and 31211 in the Electric Loco School in the
operation of the particular types of locos/ EMUs he is expected to work, including trouble- shooting
procedure to be followed by written, oral and practical tests.

3. Training for a period of one month to "learn the road" in the specified section, at the end of which
the
employee should sign a declaration that he is fully conversant with the road.

4. Practical training for a period of 2 months in the actual driving of the particular type of
Loco/EMUunder the
supervision of a qualified Driver or Driving Instructor followed, by a driving test by Sr.DEE
(RS)/Sr.,
DEE(OP).

5. Prescribed medical examination.

Fresh training to the extent authorized by CEE and tests as per items (2) and (4) above will be
required before the employee is allowed to operate any other type of Loco/EMU.

XXIII. 31216 Register of Certificates

XXIV.
XXV. A register of Competency Certificates shall be maintained in the office of every supervisory
official, as per proforma given in Annexure 12.01, showing all staff working under him who have
been issued with the Certificates:
31217 Service Record

An entry should be made in the service sheet of every employee who has been issued with a
Competency Certificate.
XXVI. 31218 Inspections
XXVII.
XXVIII. During inspections Officers and Supervisors should make it a point to check the certificates
in the possession of the various staff and also test-check their knowledge of the rules pertaining to
their work.

INDIAN RAILWAYS - AC TRACTION MANUAL - VOLUME Ill [206]

 APPENDIX- I
CODE ABBREVIATIONS FOR ELECTRIC LOCO COMPONENTS
------------------------------------------------------------------------------------------------------------------------------------
II. CODE ABBREVIATION ITEM
------------------------------------------------------------------------------------------------------------------------------------
A 1/1-1/2 Ammeters for cab-1

A 2/1-2/2 Ammeters for cab-2

AF Air flow indicator

ARNO Arno convertor

ASMGR 1 Auxiliary contacts on the air motor

of the tap changer 100 tap.

ASMGR 2 Auxiliary contacts on the air motor

of the tap changer 900 tap.

ATFEX Transformer for breaking excitation

BA Battery

BCR 1-2 Buzzer for air brake reservoir pressure

BL 1-2 Auxiliary contacts on the switch

boxes cab 1, cab 2.

BL 1-2 CP Automatic compressor switch

CPD Compressor direct switch

DJ High voltage circuit breaker switch

PRR Rear head light

LF Marker & Desks Lamps

LM Compartment Lamp switch

PR Head Light dim switch

PRF Front head light switch

PV Vacuum pump switch

QPV Switch for high speed of the Exhausters

cab-1, cab-2.

RA Heating switch
RDJ High voltage circuit breaker resetting
Switch.

SN Neutral section switch

VMT Traction motors blowers switch
ZLF Marker ( red & white ) lamps switch
BP1DJ Push button for testing DJ opening
BP2DJ Push button for testing DJ closing
INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [ 210 ]
------------------------------------------------------------------------------------------------------------------------------------
III. CODE ABBREVIATION ITEM
------------------------------------------------------------------------------------------------------------------------------------

BPLSGE Push button for testing VSGE

BPPI-2 Push button operating GR motor in
progression
BPQ 100 Push button for Q 100
BPRI-2 Push button operating GR motor in
regression
BV Auxiliary Contacts of HOM Switch
BVGR 1-2 Buzzer for vigilance control
BPT Push button for self check of signal
lamps

C 101 3-Pole contactor for motor compressor

C 105 3-pole contractor for the Traction Motor
Blower No.1
C 106 3-pole contactors for the Traction motor
blower No.2

C 107 3-Pole contactors for the transformer oil

cooler blower
C 111 3-Pole contactors for exhauster
No.1
C 118 Arno starting contactor
C 121 3-Pole contactor for exhauster
No.2
C 145 Braking excitation contactor
CCA Fuse for aux. control circuit
CAPTFWA 1-2 Condenser for TWFA
CAPTFP 1-2 Condenser for TFP
CAPTFP 3-6 Condenser for TFP terminals a3-
a6
CAPVS Condenser for VSGE
CCBA Fuse for batteries
CCCHBA Fuse for batteries charger
CCGE Fuse for Generator
CCDJ Fuse for EFDJ or MTDJ circuits
CCLC Fuse for Cab corridor H.T.
Compartment
Lighting and Wall Sockets
CCLF 1-2 Fuse for Marker and PC/Lamps
CCPT Fuse for control circuit
CCRA 1-2 Fuse for Cab Heaters
CCRT Fuse for RTPR
CCLS Fuse for signalling circuit
CCLSA Fuse for air brake signalling
circuit
CCTFS Fuse for Selsyn Transformer
CCUA Fuse for Volt meter UA1-2

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [ 211 ]

------------------------------------------------------------------------------------------------------------------------------------
IV. CODE ABBREVIATION ITEM
------------------------------------------------------------------------------------------------------------------------------------
LU 1-2 Lamps for voltmeter U1-2
( Traction Motor voltage)
LUA 1-2 Lamp for voltmeter UA 1-2
M 1-6 Traction meter 1-6
MCP 1-3 Main compressor motor
MCPA Auxiliary compressor motor
MF1-6 Main field for traction motor 1-6
MP 1-2 Master controller cab 1-2
MPF 1-2 Braking Controller
MPH Oil pump motor
MPJ 1-2 Reverser of the master Controller
MPS 1-2 Field weakening controller of the
master
controller
MPV 1-2 Vacuum pump (exhauster) motor
1-2
MTDJ High voltage circuit breaking
holding electrovalve
MVMT 1-2 Motor for traction motor blower
MVRF Motor for Braking resistor blower
MVRH Blower motor for oil cooler blower
MVSI 1-2 Silicon rectifier blower motor
MVSL 1-2 Blower motor for smoothing
reactor
MVT 1/ 1-1/ 2 Cab fan motors cab 1
MVT 2/1-2/ 2 Cab fan motors cab 2
P Couplers for connections
between the
locomotives
PCLX 1-3 Wall socket
PH Oil pump
PR 1-2 Head light cab 1, cab 2
PSA 1-2 Sanding electrovalve pedal
PT 1-2 Pantograph 1& 2
PV 1-2 Exhauster 1& 2
PVEF 1-2 Pedal switch for loco brake
elimination
Q 20 Over voltage relay
Q 30 No voltage relay
Q 44 High voltage circuit breaker
tripping relay
Q 45 Circuit breaker resetting relay
Q46 Tap changer protection relay
Q47 Relay for high speed for the
exhauster
motor
Q48 Slipping device time lag and
signalling
relay

INDIAN RAILWAYS AC TRACTION MANUAL VOLUME III [ 214 ]