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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RAILWAY BOARD

INDIAN RAILWAYS
MANUAL OF AC TRACTION
MAINTENANCE AND OPERATION
VOLUME II (PART I)
FIXED INSTALLATIONS

NOVEMBER, 2022
 INDEX

Chapter-1 Power Supply For Traction...............................................................................................1

20100 Supply System .....................................................................................................1
20101 Liaison with Power Supply Authorities. ..............................................................1
20102 Tariff for Traction.................................................................................................2
20103 Monthly Meter Readings .....................................................................................4
20104 Scrutiny of Bills ...................................................................................................4
20105 Power Factor Improvement..................................................................................5
20106 Shut-Downs of Traction Supply to be Pre-planned .............................................5
20107 Operating instructions for Grid Sub-stations .......................................................5
20108 Statistical Data Regarding Energy Consumption.................................................6

Chapter-2 Sub-Stations And Switching Stations........................................................7

20200 Introduction ..........................................................................................................7
20201 Organizational Set up ...........................................................................................7
20202 Duties of SSE, Power Supply Installation ...........................................................8
20203 Introduction ..........................................................................................................8
20204 Inspection Book and Log Book at Sub-Stations ..................................................9
20205 Overload Capacity of Traction Transformers ......................................................9
20206 Tap Setting on Traction Transformers..................................................................9
20207 Tests on Transformer Oil......................................................................................9
..........................................................................10
..........................................................................................10
20210 Insulation Resistance During Drying Out ..........................................................10
20211 Protective Devices..............................................................................................11
20212 Operation of Temperature Alarm or Trip ...........................................................11
20213 Operation of Differential Protection ..................................................................12
20214 Buchholz Relay ..................................................................................................12
20215 Introduction ........................................................................................................12
20216 Transformers ......................................................................................................12
20217 Circuit Breakers and Interrupters. ......................................................................15
20218 Guidelines for Maintenance of Circuit Breakers and Interrupters. ....................15
20219 Lead Acid Batteries ............................................................................................16
20220 Guidelines for Maintenance of Batteries. ..........................................................16

i
 20221 Protective Relays ...............................................................................................19
20222 Guidelines for Maintenance of Switching Stations ...........................................20
20223 Schedules of Inspection .....................................................................................20
20224 General ..............................................................................................................21
20225 General Inspection by a PSI Supervisor ............................................................21
20226 Battery ................................................................................................................22
20227 Bonding And Earthing .......................................................................................22
20228 Oil Level in Transformers, CTS ,PTs etc. ..........................................................22
20229 Insulators ............................................................................................................22
20230 Traction Transformers .......................................................................................22
20231 Operating Mechanism of Circuit Breakers and Interruptors..............................23
20232 Isolators ..............................................................................................................23
20233 Busbars, Clamps and Connectors ......................................................................23
20234 Control and Relay Panels. ..................................................................................23
20235 Batteries and Battery Chargers ..........................................................................24
20236 PTs and CTs .......................................................................................................24
20237 Booster Transformers- deleted ...........................................................................24
20238 Auxiliary Transformers ......................................................................................24
20239 General ...............................................................................................................24
20240 Traction Transformers ........................................................................................24
20241 Isolators ..............................................................................................................24
20242 Control and Relay Panels. ..................................................................................25
20243 General. ..............................................................................................................25
20244 Lightning Arrestors ............................................................................................25
20245 Bonding and Earthing ........................................................................................25
20246 Traction Transformers. .......................................................................................25
20247 Isolators ..............................................................................................................25
20248 Bus Bars and Connectors ...................................................................................26
20249 Control and Relay Panels ...................................................................................26
20250 Batteries and Battery Chargers ..........................................................................26
20251 PTs and CTs .......................................................................................................26
20252 Deleted (RDSO SPEC No. TI/SPC/PSI/HV CB /0121(MAY 2021) .............26
20253 Pre-Monsoon Check...........................................................................................26
20254 Overhaul Schedule for Equipment .....................................................................26

ii
Chapter-3 Overhead Equipment ............................................................................... 47
20300 Introduction ........................................................................................................ 47
20301 Duties of SSE (OHE) ......................................................................................... 47
20302 Duties of Field Supervisors................................................................................ 48
20303 Technician (Rly Bd. L.No. 2013/ELECT/148/1Dt.10.05.2019
Foot Patrolling by Technician) ........................................................................... 49
20304 Introduction....................................................................................................... 49
20305 Out of Plumb Masts ........................................................................................... 50
20306 Rail Level and Setting Distance......................................................................... 51
20307 Contact Wire Hard Spots and Wear.................................................................... 52
20308 Sparking During Current Collection .................................................................. 53
20309 Contact Wire Wear ............................................................................................. 53
20310 Splice Fittings .................................................................................................... 54
20311 Section Insulator Assembly ................................................................................ 55
20312 Short Neutral Sections Assembly ....................................................................... 58
20313 Jumper Connections ........................................................................................... 60
20314 Environmental Effect on OHE ........................................................................... 61
20315 Clearances in Tunnels and Other Overline Structures ....................................... 64
20316 Regulating Equipment ....................................................................................... 64
20317 OHE Inspection Car (Tower Wagon) ................................................................. 66
20318 Salient Features of OHE Inspection Cars .......................................................... 67
20319 Rules for Operation of OHE Inspection Car ...................................................... 69
20320 Schedule of Inspections ..................................................................................... 70
20321 General............................................................................................................... 71
20322 Foot-Patrolling of OHE...................................................................................... 71
20323 Footplate Inspection of OHE ............................................................................. 73
20324 Current Collection Tests .................................................................................... 73
20325 Special Checks ................................................................................................... 73
20326 Annual Maintenance and Checks by OHE Inspection Car .................................. 75
20327 Integrated Blocks .................................................................................................. 79
20328 Re-tensioning of Unregulated OHE ..................................................................... 80
20329 Periodical Overhaul .............................................................................................. 80
20330 Rehabilitation of OHE ....................................................................................... 82
20331 Transmission Lines ............................................................................................ 82
20332 General............................................................................................................... 84
20333 Documents to be kept with OHE Supervisors for Work on OHE ...................... 84

iii
20334 Permit to Work ................................................................................................... 84
........... 84
20336 Earthing before Commencement of Work ......................................................... 85
20337 Procedure for Providing Temporary Earths........................................................ 85
20338 Precautions in Regard to Discharge/Earthing Pole Assembly............................ 86
20339 Work on OHE or any Conductor having a Sectioning Point .............................. 86
20340 Protective Helmets ............................................................................................. 86
20341 Safety Belt.......................................................................................................... 86
20342 Rules for use of Ladders .................................................................................... 86
20343 Other Important Precautions to be taken while Carrying out Works on OHE ... 87
20344 Procedure for Effecting Shut-Down for Work on Auxiliary Transformers ......... 87
........................ 87
20346 Deleted ............................................................................................................... 87
20347 Isolators.............................................................................................................. 87
20348 Petroleum Sidings .............................................................................................. 88
20349 Records to be Maintained .................................................................................. 88
Chapter-4 Remote Control Equipment ................................................................... 105
20400 Introduction...................................................................................................... 105
20401 General............................................................................................................. 105
20402 Transmission Path ............................................................................................ 105
20403 Master Station Equipment................................................................................ 105
20404 Overall Screen Design &Real Time Display ................................................... 106
20405 Alarm Processing and displays: ...................................................................... 106
20406 SCADA Software ............................................................................................. 106
20407 Test Procedure& Diagnostics ........................................................................... 107
20408 Historical Data Storage .................................................................................... 107
20409 UPS and Batteries at RCC ............................................................................... 107
20410 Remote Terminal Unit (RTU) .......................................................................... 108
20411 RTU FUNCTIONAL DETAILS....................................................................... 108
20412 SCADA Equipment Capacity .......................................................................... 108
20413 Energy Management System (EMS): .............................................................. 109
20414 Special Features in SCADA Equipment........................................................... 109
20415 Duties of SSE(RC) ........................................................................................... 110
20416 Operation of RC Equipment ............................................................................ 110
20417 Investigation of Failures by SSE (RC)............................................................. 111
20418 Maintenance Schedule ..................................................................................... 111

iv
Chapter-5 Operation Of Traction Power Control ...................................................113
20500 Remote Control Centre .................................................................................... 113
20501 Manning of RCC.............................................................................................. 113
20502 Knowledge of Rules ........................................................................................ 113
20503 Entry into RCC ................................................................................................ 113
20504 Shift Duty......................................................................................................... 113
20505 Shift Duty Register .......................................................................................... 113
20506 Repair and Adjustment of RC Equipment........................................................ 114
20507 Switching Operations to be Deliberate ............................................................ 114
20508 Liaisons with Section Controller ..................................................................... 114
20509 Prompt Attention to Telephone Calls................................................................ 114
20510 Log Book ......................................................................................................... 114
20511 Movements of Maintenance Staff .................................................................... 114
20512 Checking of Time............................................................................................. 114
20513 deleted .............................................................................................................. 114
20514 Emergency Generator Set ................................................................................ 115
20515 Duties of Chief Traction Power Controller ...................................................... 115
20516 Duties of Traction Power Controller ................................................................ 115
20517 Failure of Traction Power Supply .................................................................... 116
20518 Failures of Grid Supply.................................................................................... 117
20519 Prolonged Power Supply Failures .................................................................... 117
20520 Faults on Railway Equipment and Lines ......................................................... 117
20521 Lowering Pantographs of Defective Locos...................................................... 118
20522 Isolation of Faulty Section ............................................................................... 118
20523 Faulty Section to be kept Isolated .................................................................... 118
20524 Advice to Section Controller ............................................................................ 119
20525 Information to Traction Staff ........................................................................... 119
20526 Action to Rectify OHE Fault............................................................................ 119
20527 Emergency Telephone Working ....................................................................... 120
20528 Breakdowns and Emergencies ......................................................................... 120
20529 Obstruction of Track - Protective Steps to be taken by TPC............................ 120
Chapter-6 Power Blocks And Permits-To-Work..................................................... 123
20600 Operation of Isolator Switches ........................................................................ 123
20601 Isolators in Yards and Sheds............................................................................. 123
20602 Maintenance Blocks......................................................................................... 123
20603 Power Blocks ................................................................................................... 124

v
20604 Emergency Power Block ................................................................................. 124
20605 Reporting Abnormalities in OHE ..................................................................... 124
20606 Request for Emergency Power Block .............................................................. 124
20607 Action to be taken by TPC ............................................................................... 125
20608 Precautions after Emergency Power Block is Imposed ................................... 125
...................... 125
20610 Telephone Messages......................................................................................... 125
.......... 126
20612 Pre-arranged Power Block ............................................................................... 127
20613 Restoration of Supply After a Permit-to-work is Returned ............................. 128
20614 Work by other than Authorized Persons ........................................................... 128
20615 Local Cancellation of Permit-to-Work When Telephones are Interrupted ....... 128
20616 Multiple Working Parties ................................................................................. 128
20617 Entries in the Log Book ................................................................................... 129
20618 Work Inside Loco Shed or Car Shed ................................................................ 129
20619 Local Block...................................................................................................... 129
20620 Protective Measures for Power Blocks ............................................................ 129
20621 Longitudinal Protection ................................................................................... 129
20622 Transverse or Cross Protection ........................................................................ 130
20623 Procedure for Arranging Longitudinal and Transverse Protection ................... 131
20624 Station Working Rules for Longitudinal and Transverse Protection ................ 131
20625 Protection of Dead Section .............................................................................. 131
20626 Shunting Movement Towards Dead Section .................................................... 132
20627 Movement of Other than Electric Trains ......................................................... 132
20628 Standard Forms for Power Block Messages .................................................... 133
Chapter-7 Signalling & Telecommnication And Permanent Way Installations
............................................................................. 147
20700 Introduction ...................................................................................................... 147
20701 Effects of 25 kV Traction on S&T Equipment ................................................. 147
20702 Types of Signals ............................................................................................... 148
20703 Locations of Signals ........................................................................................ 148
20704 Insulation of Wires and Point Rods.................................................................. 149
20705 Earthing of S&T Equipment ............................................................................ 149
20706 Signaling & Telecommunication Cables .......................................................... 149
20707 Block Instruments and Block Circuits ............................................................. 150

vi
20708 Track Circuits ................................................................................................... 150
20709 Bonding in Track Circuited Zones ................................................................... 150
20710 Signalling and Inter-locking Circuits ............................................................... 150
20711 Telecommunication Circuits ............................................................................. 151
20712 Principles of Tapping ....................................................................................... 151
20713 Power Supply Arrangement ............................................................................. 152
20714 Major Track Maintenance Works ..................................................................... 152
......................................................................... 153
Chapter-8 Breakdowns ............................................................................................. 155
20800 Knowledge of Rules ........................................................................................ 155
20801 Types of Breakdowns ....................................................................................... 155
20802 Breakdown Gangs............................................................................................ 155
20803 Emergency Stores and Breakdown Equipment................................................ 155
20804 Record of Staff Movements ............................................................................. 156
20805 Summoning of Emergency Staff ...................................................................... 156
20806 Traction Transformer Breakdowns ................................................................... 156
20807 Repair of Traction Transformer........................................................................ 156
20808 Mobile Power Van............................................................................................ 156
.................................................. 157
20810 Rail and Road Access....................................................................................... 157
20811 Procedure for Manning Sub-Stations And Switching Stations ......................... 157
20812 Restoration of Remote Control ........................................................................ 158

Switching Stations etc ...................................................................................... 158

20814 Importance of Expeditious Repairs ................................................................. 158
20815 Types of OHE Breakdowns .............................................................................. 158
20816 Look-out for OHE Defects .............................................................................. 158
20817 Action to be taken by TPC ............................................................................... 159
20818 Protective Steps ............................................................................................... 159
20819 Breakdown Staff .............................................................................................. 159
...................................................... 159
20821 Assistance to be sought .................................................................................... 160
20822 Continuous Communication with TPC ............................................................ 160
................ 160
20824 Preservation of Evidence ................................................................................. 160

vii
 20825 Safety Rules to be Observed ............................................................................ 160
.................................................. 161
20827 Clearance of Line for Steam/Diesel Traction................................................... 161
20828 Wiring Train ..................................................................................................... 161
20829 Interference with OHE During Restoration ..................................................... 161
20830 Temporary Diversions ...................................................................................... 161
20831 Funds Required for Dealing with Breakdowns ................................................ 163
20832 Log of Events and Reporting of Breakdowns.................................................. 164
20833 Protection of Staff ............................................................................................ 164
20834 Use of Cranes................................................................................................... 164
20835 Use of Road Vehicles during Emergencies....................................................... 164
20836 Driver’s Duties ................................................................................................. 164
20837 Operation of Road Vehicles ............................................................................. 165
20838 Precautions when Transporting Heavy Materials............................................. 166
20839 Transportation of Personnel ............................................................................. 166
20840 Parking ............................................................................................................. 166
20841 Maintenance of Road Vehicles......................................................................... 167
......................................................................... 167
Chapter-9 Preparation For Commssioning ............................................................ 171
20900 Introduction ...................................................................................................... 171
20901 Reference to Rules and Statutory Rules........................................................... 171
20902 Pre-Commissioning Inspections ...................................................................... 172
............................................................................. 172
20904 Planning of Power Supply ............................................................................... 172
20905 Commissioning of Traction Transformers ....................................................... 173
20906 Precautions During Commissioning of Traction Transformer ......................... 173
20907 Tests on Transformer Windings ........................................................................ 174
20908 Circuit Breakers and Interruptors .................................................................... 174
20909 Isolators............................................................................................................ 175
20910 Current and Potential Transformers ................................................................. 175
20911 Lightning Arrestors .......................................................................................... 175
20912 Shielding and Earthing..................................................................................... 175
20913 Busbars and Insulators ..................................................................................... 176
20914 Clearances ........................................................................................................ 176
20915 Auxiliary Power Supply for Traction Substations & Control Room ................ 176

viii
20916 Batteries & Battery Charger ............................................................................ 176
20917 General............................................................................................................. 177
20918 General Inspection of Substations and Commissioning .................................. 177
20919 Detailed Inspection of Transmission Lines ...................................................... 177
20920 Compliance with Rules and Approved ............................................................ 178
20921 Visual Inspection .............................................................................................. 178
20922 Clearances and Sag .......................................................................................... 178
20923 Earthing............................................................................................................ 179
20924 Insulators and Insulation Resistance ................................................................ 179
20925 Continuity Test ................................................................................................. 179
20926 Accessories ....................................................................................................... 179
20927 General inspection and Energization ............................................................... 180
20928 25 kV Feeders .................................................................................................. 180
20929 Testing of Protective Relays ............................................................................. 180
20930 Inspection of Setting of Relays and Calibration of Meters.............................. 180
20931 Protective Devices at Sub-stations ................................................................... 181
20932 Control Circuits and Wiring............................................................................. 182
20933 Fuses ................................................................................................................ 182
20934 Insulation and Lead Burden Measurement ...................................................... 183
20935 Current Transformer Ratio and Polarity Test ................................................... 183
20936 Primary Injection Test ...................................................................................... 184
20937 Voltage Transformer Ratio and Polarity Check ................................................ 184
20938 Electrical Operation of Indicators and Associated Devices ............................. 184
20939 Secondary Injection Test .................................................................................. 184
20940 Alarm and Trip Check ...................................................................................... 184
20941 Load Test.......................................................................................................... 185
................................................... 185
20943 Power Supply ................................................................................................... 186
20944 Installation of Equipment ................................................................................ 186
20945 Clearances ........................................................................................................ 186
20946 Auxiliary Transformers .................................................................................... 187
20947 General............................................................................................................. 187
20948 Interlocking ...................................................................................................... 187
20949 Feeding Posts ................................................................................................... 187
20950 Number Plates and Boards ............................................................................... 188
20951 Earthing and Bonding ...................................................................................... 188

ix
20952 Importance of Remote Control ........................................................................ 188
20953 Manning of Substations and switching posts ................................................... 189
20954 Level Measurements ........................................................................................ 189
20955 Detailed Inspection of RC Equipment ............................................................. 189
20956 Interlocking of the Bridging Interruptor .......................................................... 190
....................................................... 190
20958 Detailed Joint Inspection of OHE .................................................................... 191
20959 Compliance with Latest ................................................................................... 191
20960 Infringements ................................................................................................... 191
20961 Important Point to be Checked ........................................................................ 191
20962 Notices to be Displayed – Caution Boards and Number Plates ....................... 193
.......................................................... 193
................................... 193
20965 Lapping and Polishing of OHE........................................................................ 194
20966 Procedure for Final Test of OHE...................................................................... 194
20967 Insulation Tests ................................................................................................ 195
20968 Continuity Tests ............................................................................................... 197
................................................................ 197
................................................. 197
20971 Preparation by the Engineering Department .................................................... 199
20972 Preparation by the S&T Department ................................................................ 199
Chapter-10 Commissioning Of Electric Traction ................................................... 201
21000 General............................................................................................................. 201
21001 Preparation by Open Line ................................................................................ 201
21002 Organization for Inspection and Taking Over .................................................. 201
21003 Duties of Senior Divisional Electrical Engineer (TrD) .................................... 202
21004 Duties for Senior Divisional Electrical Engineer (RS) .................................... 203
21005 Responsibility of Construction Organization................................................... 203
21006 Commissioning of Traction Substations .......................................................... 204
......................... 205
21008 Sanction of Electrical Inspector to the Railway (EIG sanction)
& OHE energisation......................................................................................... 205
21009 Introduction of services on Electric Traction:.................................................. 207
21010 Inspection by CRS for the Introduction of Passenger Services
on Electric Traction:......................................................................................... 208

x
21011 Sanction of CRS for introduction of passenger services
on Electric Traction:......................................................................................... 208
21012 Anti-theft Energization ..................................................................................... 208
......... 208
21014 Contractor’s Responsibility During Guarantee Period .................................... 209
21015 Failure of Equipment After Commissioning and During
the Guarantee Period........................................................................................ 209
21016 History Sheet ................................................................................................... 210
............................................................................ 210
21018 Standard Forms ................................................................................................ 210
Chapter-11 Recent Developments ............................................................................ 229
21100 2x25 kV Auto-Transformer Feed System ......................................................... 229
21101 OHE Recording-cum-Test Car ......................................................................... 236
21102 Rail-cum-Road Vehicle .................................................................................... 237
21103 Transportable Self Propelled Trolley ................................................................ 237
21104 Microprocessor Based Numerical Integrated Feeder Protection Module ........ 237
21105 Composite Insulators........................................................................................ 238
21106 Automatic Phase Switching Section (in place of Neutral Section)
and Numerical Control Logic Relay: Deleted .................................................. 238
21107 HIGH RISE OHE ............................................................................................. 240
21109 Spring type ATD ............................................................................................... 247
21110 Open Access- Optimization of Traction Power Procurement Cost ................... 248
............................................... 251
21200 Introduction ...................................................................................................... 251
21201 Planning of Training in Advance...................................................................... 251
21202 Categories to be trained ................................................................................... 251
21203 Initial Training ................................................................................................. 251
21204 Promotional Courses ........................................................................................ 252
21205 Refresher Courses ............................................................................................ 252
21206 Facilities for Training....................................................................................... 253
21207 Training in General and Subsidiary Rules ....................................................... 254
...................................................... 254
21209 Examination at the End of Training ................................................................. 254
21210 Specialized Training......................................................................................... 254

xi
 21211 Syllabi .............................................................................................................. 254
21212 Authorized Person ............................................................................................ 255
.................................................................................... 255
21214 Period of Training ............................................................................................ 256
21215 OHE Inspection Car Driver ............................................................................. 256
21216 Knowledge of Rules ........................................................................................ 256
..................................................................................... 256
21218 Service Record ................................................................................................. 257
21219 Inspections ....................................................................................................... 257

xii
 CHAPTER-1
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 2x25 kV Auto Transformer (AT) feed system are indicated in Chapter XI.

20101 Liaison with Power Supply Authorities.

For ensuring continuity and reliability of power supply for traction it is important that effective liaison

lines be taken:
1. A system of periodic meetings at different levels at mutually agreed intervals needs to be evolved.
2. Reliability of supply involves also the maintenance of traction voltage between 25 kV and 27.5
kV at the feeding posts and frequency between 48.5 Hz and 51.5 Hz. The serious repercussions

Supply Authorities.
3. 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.
4. 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 PCEE 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.

Railway with the concerned Supply Authority before the supply is actually taken. Where this has

6. 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.

1
Indian Railways - AC Traction Manual - Volume-II Part-I

7. 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

cost of the equipment borne by Railways.

20102 Tariff for Traction

1. In Electric Traction the energy cost forms a substantial portion of the total operating and maintenance

parameters. The implications of the various parameters should be studied carefully to keep the
energy cost to the minimum possible level.
2. 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.

2
 Chapter-1 Power Supply For Traction

3. 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.

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.
b. Energy charge Paise/kwh

d. Penalty for low power factor: The penal charge is prescribed as an extra amount leviable in Rs/

on consumer providing PF correcting equipment and do not permit power factor lower than a
prescribed value.

is higher.
f. 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

excess energy as under:

MD = Maximum Demand
CD = Contract Demand
The Contract demand therefore, has to be carefully determined and reviewed periodically and

g. Minimum Guarantee

by the pattern of energy consumption in traction. However, minimum guarantee in some cases

Demand with the units consumed.

If a few heavy trains operate in a section raising the Maximum Demand high, the average load

if contract demand is too low, exceeding it and attracting penal changes becomes a possibility.

h. 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

V - RMS value of fundamental voltage.

3
Indian Railways - AC Traction Manual - Volume-II Part-I

the fundamental and shall be calculated using the following expression:

20103 Monthly Meter Readings

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

these aspects should be embodied in the Agreement with the Supply Authorities.
2. The monthly meter readings should be taken on an agreed date each month jointly by 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

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 Authority’s network
may be made at appropriate level and if necessary concrete proposals initiated for making power

20104 Scrutiny of Bills

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 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 PCEE as well as the operating Department to take special steps to arrange for movement of

2. 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:
a. Arithmetical accuracy
b. Meter readings shown on the bill tally with those received earlier from the subordinates.
c. The tariff applied is in terms of the agreement.
d. 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.

4
 Chapter-1 Power Supply For Traction

e. The time allowed for payment is in accordance with the agreement.

f. There is no duplication in billing.
g. The payee as provided for in the agreement is clearly indicated. The full particulars of the payee

h. Each new bill should be analyzed and compared with earlier bill and the reasons for any

20105 Power Factor Improvement

1. 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.
2. 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 variations are wide.

at the time of planning.

20106 Shut-Downs of Traction Supply to be Pre-planned

1. 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

which may have to re-schedule trains and take other measures as necessary.
2. 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 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.
1. Procedure for carrying out switching operations at the sub-station.
2. Procedure for interchange of message of pre-planned or emergency shut downs.
3. 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.
4. Records to be maintained by grid sub-station operator and TPC regarding emergency feed
arrangements.

contacted in an emergency.

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Indian Railways - AC Traction Manual - Volume-II Part-I

6. 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 regard to energy consumption at each supply point:-

1. Energy consumption (kWh)
2. Maximum demand (kVA)
3. Average power factor (kWh/kVAh)
4. Monthly average load factor (percent)
5. Payment for energy
6. Payment for maximum demand
7. Payment towards meter rent
8. Payment of fuel surcharges, if any
9. Payment for P.F. surcharge/penal charge
10. Payment of covering the minimum guarantee load, if any

12. Total amount of bill under all heads

13. Average total cost per kWh.
A consolidated statement giving the above details for all supply points should be furnished by Sr. DEE/
TRD to PCEE each month by a stipulated date. PCEE will in turn furnish a monthly statement in the

*****

6
 CHAPTER-2
SUB-STATIONS AND SWITCHING STATIONS

20200 Introduction
1. This chapter is divided into 4 sections as under –
Section I Organization: A broad set up of the organisation and duties of SSE (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 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)

RDSO (Appendix IX)

I 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

envisages separate Sr. Subordinate to be incharge of each activity viz. sub-station, OHE, workshop,

function. For territorial set up, the SSE incharge will perform his duties keeping all functions in view,

Remote Control system or protective relay testing being a specialized activity, SSE (RC) and SSE/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 SSEs in territorial charge, should keep a
constant liaison between themselves since these aspects will have an element of dual control.

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Indian Railways - AC Traction Manual - Volume-II Part-I

20202 Duties of SSE, Power Supply Installation

He is the senior supervisor working under the control of DEE/ADEE/TRD and directly responsible

sub-stations (when owned by the railway), switching stations, booster transformer 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, SSE(OHE), Supply Authorities
and render assistance when required to ensure reliability of power supply;
3. keep his organization 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;

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;

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 ADEE/TRD and Sr. DEE/DEE(TRD);

when required;

15. Carry out inspections as indicated at Annexure 2.01.

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.

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 Chapter-2 Sub-Stations and Switching Stations

20204 Inspection Book and Log Book at Sub-Stations

An “inspection Book” shall be maintained at every sub-station in which observations made by

a log book should also be maintained to keep a record of the traction transformer oil temperature,

every morning. If there is any thing abnormal unusual, SSE/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 = 50 degree 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 115degree C for an ambient temperature of 50degree C.
4. Interval of time permissible between two successive overloads (after continuous working at
maximum ambient temperature of 50 degree C is 3 hours for both 50% overload for 15 min. and
100% overload for 5 min.

20206 Tap Setting on Traction Transformers

Low Capacity Traction Power Transformer (13.5/18.9MVA & 21.6/30.24 MVA) are provided with
the off load tap changers in steps of 5% and High Capacity Traction Power Transformer (30/42MVA
and 40/56MVA) are provided with the on load tap changers with per tap voltage as mentioned in the

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 at least 3 typical days. Based on the readings

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 SSE/PSI should keep in touch with the supply authorities in regard to
system changes 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.

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Indian Railways - AC Traction Manual - Volume-II Part-I

2. 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

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.

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.

may be used. These are normally operated from 240 V single phase supply taken from the 100 kVA

transformers should make themselves familiar with the supplier’s 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:
1. Initially the insulation resistance drops down to a low value because of rise in temperature of the
oil upto about 75 degree C.
2. 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.
3. 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.
4. As the oil cools off, the insulation resistance will rise much above the leveling off point at the end
of stage (C). This is because the insulation resistance value doubles for a fall in temperature of
about 10 degree C to 15 degree C.

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 Chapter-2 Sub-Stations and Switching Stations

20211 Protective Devices

A number of protective devices are provided to ensure safe operation of traction transformers and other
equipment (under normal and extended feed condition with appropriate adjustment of settings). Alarm
and trip circuit operations are tele-signalled and indicated at the RCC. The TPC shall in every such
case advise SSE, so that he could arrange for the inspection of the sub-station to investigate the cause
and take necessary corrective action and submit a detailed report to Sr. DEE/DEE(TrD).

20212 Operation of Temperature Alarm or Trip

Alarm and trip contacts are provided to operate should the temperature of transformer windings or
transformer oil exceed pre-set limits. If alarm or the trip contacts have operated, both of which are
indicated at the RCC, SSE should personally inspect the installation. If the dial settings are correct,
the reason for excessive temperature rise should be investigated. Normally instantaneous overloads of
over 150% of full load are taken care of by protection relays, while sustained overload below 150% are
cleared by thermal protection. It is advisable to connect a recording ammeter and get a 24 hour chart
showing the current loading of the transformer in services. The shape of the load curve would give
valuable clues as to corrective action to be taken.
If the alarm and trip circuits operate frequently during peak periods, attempt should be made with
Operating Department to space out the trains more uniformly throughout the day so as to reduce the
peak load. If, on the other hand, it is a suburban section and the peak load cannot obviously be brought

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Indian Railways - AC Traction Manual - Volume-II Part-I

down, the second standby 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

20214 Buchholz Relay

The Buchholz relay assembly is provided on transformers to detect evolution of gas caused due 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 di-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,

3. The tightening torque for fasteners of various sizes is given in Annexure 2.08.

20216 Transformers
1. Condition Monitoring

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

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 Chapter-2 Sub-Stations and Switching Stations

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

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. Overhauling of Traction Power Transformer can be undertaken either at site (Traction Sub-

TI/MI/0039 Rev.02 (or latest). In addition to this, if transformer overhauling is required at OEM
/Approved manufacturer premises, same to be decided by Sr. DEE/TRD.Before commencing
the work ensure that spare gaskets of proper quality are available. Drain out the oil, disconnect
all 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

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 odor 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 manufacture’s 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

to the windings. Traces of the sludge left over in inaccessible places are best removed by

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

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Indian Railways - AC Traction Manual - Volume-II Part-I

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

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

should be taken to have the wedges fully home and tighten up the pressure screws where they
are provided.
g. Finally put back the core assembly inside the tank, assembly the bushing check tightness of

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.

3. Investigation into causes of Failures of Transformers.

In most cases the causes of the fault can be surmised by careful observation of the condition of the
windings, e.g. displacement of the turns or coils, coil insulation (brittle or healthy), evidence of

The following notes may be of help in identifying the cause.

a. Failure due to lightning discharge or over voltages. 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

be healthy.
b. Sustained overloads – The windings in one or all phases would show signs 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.

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.

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 Chapter-2 Sub-Stations and Switching Stations

f. If the oil shows a low BDV, it does not necessarily mean that it has caused the breakdown.

between the live parts and earth, which will leave corresponding tell-tale marks.

20217 Circuit Breakers and Interrupters.

The following types of circuit breakers and interrupters are now in use.
Circuit Breakers:
1. 220/132/110/66 KV Double pole
- SF6 type
2. 25 KV single pole
- Vacuum type
3. Interrupters
- 25 kV Double pole
- Vacuum type
4. Single and Double Pole Interrupters: (RDSO SPEC No. TI/SPC/PSI/HV CB /0121(MAY 2021) &
(RDSO SPEC No. TI/SPC/PSI/LV CB /0120(DEC 2013)
- Vacuum type
Oil type circuit breakers/interrupters 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 interrupters are now standardized.
Manufacturer’s detailed instructions may be referred to for installation, commissioning, operation and
maintenance for all types of breakers/interrupters. RDSO’s additional instructions on maintenance

maintenance of circuit breakers and interrupters, in general, are given in the succeeding paragraphs.

20218 Guidelines for Maintenance of Circuit Breakers and Interrupters.

1. Deleted (RDSO SPEC No. TI/SPC/PSI/HV CB /0121(MAY 2021) &
(RDSO SPEC No. TI/SPC/PSI/LV CB /0120(DEC 2013)
2. SF 6 Circuit Breakers:
a. 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

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.

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Indian Railways - AC Traction Manual - Volume-II Part-I

b. 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.
c. 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.
3. Vacuum Circuit Breakers
Maintenance is to be conducted as per the maintenance instruction no. TI/MI/0054 or latest. (RDSO
Letter No. TI/PSI/CVINT/POLICY/Dt.13.09.2017)

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.

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.
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

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 Chapter-2 Sub-Stations and Switching Stations

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

forms.

fuse protection for short circuit in the wiring between the battery and distribution switch board should
be provided.

it drops to 1.150 the cell may be considered discharged. These values vary with the type of battery,
temperature, age and working conditions.

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.

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.

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

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

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

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Indian Railways - AC Traction Manual - Volume-II Part-I

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

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

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.

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

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

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 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

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

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

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 Chapter-2 Sub-Stations and Switching Stations

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

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

20221 Protective Relays

the maintenance overhauling, testing adjustment and calibration of protective relays as well as
indicating, integrating and recording instruments. Such specialist staff shall hold competency

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 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 PCEE. 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.
6. The normal maintenance attention required for relays in service is generally as under:

tight, so that the instrument is dust-tight.

These tests should be carried out by atleast at the level of ADEE 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.

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Indian Railways - AC Traction Manual - Volume-II Part-I

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.

if any and measurement of coil resistance and other datain case of electro mechanical relays.
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.
However, if numerical relays are provided, periodic calibrations should be done with the help of
suitable Relay Test Kit. It shall also be ensured the healthiness of the cable/wiring and tightness
of the connection of wires terminal with the TBs after testing.
Note : Existing relays are numerical relays and has no moving part if numerical relays are used
then measurement of coli resistance and other data in relay shall not be required.

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

of these from the electrical point of view to the SSE(P. Way) so that they in turn may warn their

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

indicated at Annexure 2.01.

should be independent of other tasks. They will not be of routine nature but shall be carried out in
depth to identify:

b. Lack of skill amongst staff.

20
 Chapter-2 Sub-Stations and Switching Stations

c. Inadequacies in maintenance facilities.

d. Constraints experienced.
e. Conditions of environment, which lead to poor quality of work if any.

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.

local requirements with the approval of PCEE.

5. As regards new equipments, if schedules have not been drawn up, tentative schedules may be
evolved, based on the Original Equipment Manufacturer’s guidelines and RDSO’s recommendations,
keeping in view the local conditions also and followed with the approval of PCEE.
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.

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

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

outer periphery; cut any tree branches likely to come in the vicinity of live lines.

material is in the vicinity.

3. Examine all “Caution”, “Danger”, “Shock Treatment” and other boards, whether they are clean

serviceable.
4. Inspect structure and plant foundations for any sinking or cracking. Go round the structural work
for checking tightness of various bolts and nuts.

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Indian Railways - AC Traction Manual - Volume-II Part-I

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.

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, CTS ,PTs etc.

Check oil level in sight 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

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

moisture. If changing color due to moisture, replace it with dry gel and recondition the old silica
gel. If the (silica-gel is too wet, check di-electric strength of transformer oil. (RDSO SPEC No.
ETI/SI/118(10/93) A&C Slip No. 10 August 2012
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.

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 Chapter-2 Sub-Stations and Switching Stations

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

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. In addition to this, for 25kV Vacuum Circuit Breaker and Interrupter, Maintenance
is to be conducted as per the maintenance instruction no. TI/MI/0054 or latest.
(RDSO Policy Letter No. TI/PSI/CV INT/POLICY/17 Dt. 13.09.2017)

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;

20234 Control and Relay Panels.

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.

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Indian Railways - AC Traction Manual - Volume-II Part-I

QUARTERLY MAINTENANCE

20235 Batteries and Battery Chargers

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

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- deleted

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

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 Maker’s
drawing.
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

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

blades are fully horn between the contacts when handle is in closed position.

24
 Chapter-2 Sub-Stations and Switching Stations

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.However, in case of Numerical Relays this
may not be applicable.
3. Examine fuses for signs of overheating or aging, springiness and cleanliness of contact making
parts. Clean up and lightly apply vaseline 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 insects 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 diaphragms for any damage.
5. Check rod gap setting.

20244 Lightning Arrestors

Annual maintenance of the Lightening arrestors is to be conducted as per the maintenance instruction
no. TI/MI/0041 rev.01 (or latest).

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 buried 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

corresponds to position of main contacts.

5. Paint transformer tank on such parts as required.

20247 Isolators

Vaseline.

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Indian Railways - AC Traction Manual - Volume-II Part-I

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.

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 Deleted (RDSO SPEC No. TI/SPC/PSI/HV CB /0121(MAY 2021) &

(RDSO SPEC No. TI/SPC/PSI/LV CB /0120(DEC 2013)
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

as stipulated in SMI no. TI/MI/0039 Rev.02 (or latest).

2. Operating mechanism of Circuit Breaker and Interrupters: Maintenance of Circuit Breakers and
Interrupters is to be conducted once in six years as per the maintenance instruction no. TI/MI/0054
or latest.

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 Chapter-2 Sub-Stations and Switching Stations

Annexure 2.01
(Para 20202, 20223)

SCHEDULE OF MONTHLY INSPECTIONS

SN. Nature of Inspection Sr. DEE DEE ADEE SSE* JE*
1. Traction sub-station 1 1 2 4 4
2. Switching stations 1 2 3 4 4
3. PSI Depots 1 2 4 - -
4. Grid Sub-station 2 in a Yr. 1 2 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.

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Indian Railways - AC Traction Manual - Volume-II Part-I

Annexure 2.02
(Para 20223)

CHECK LIST FOR INSPECTIONS

a. OHE/PSI Depots
Check
i. Staff grievance register
ii. Quarter Register.
iii. Attendance register
iv. Cleanliness of depot
v. Upkeep of stores.
vi. Stock position in Stores
vii. Compliance of audit & account inspection notes.
viii. Test & Trial report

x. Planning and Progress of Section works.

Check
i. Attendance register.
ii. Compliance of audit & account inspection notes.

iv. Test & Trial report

vi. Progress & Planning of section works.

2.0 Inspection of Grid Sub-station.

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
i. For vegetation growth and spreading of pebbles.
ii. Painting of fencing and equipments.
iii. Condition of cable trenches & trench covers.
iv. Condition of approach road.
b. Power Transformer:
Check
i. OTI and WTI temperature – present and maximum readings.
ii. Oil level in conservation tank

28
 Chapter-2 Sub-Stations and Switching Stations

iii. Tap changer position of standby & service transformer.

iv. For abnormal humming.
v. Colour of silica gel.
vi. For leakage of oil on transformer body, conservator tank, oil drain valve and radiator.
c. Circuit Breaker and Interrupters
Check
i. Control box gaskets for water and dust tightness.
ii. Operation by local & remote control.
iii. Operating mechanism for smooth operation
iv. Closing time of interruptor.
v. Number of trippings since last replacement of oil in case of circuit breaker and counter reading
of interruptor.
d. PT, CT, AT.
Check
i. Leakage of oil
e. Isolator
Check
i. Locking arrangements.

iii. For correct matching & alignment of arcing horns,

f. Control Panel
Check
i. Fuses for the correct size, overheating or aging signs.
ii. For loose connections at terminal boards.
iii. Functioning of Alarms and visual indication on control panel.
iv. Functioning of auxiliary relays.
g. Battery charger & Batteries.
Check
i. Acid level
ii. Presence of sedimentation

iv. Presence of sulphation and tightness of inter cell connectors.

v. Size of fuses of battery charger.
vi. Voltmeter and ammeter readings.
h. Energy meter
Check
i. Recorded maximum demand.
ii. Condition of the seal.
i. Earthing
Check
i. Soundness of earth connection to each electrical equipment and structure.

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Indian Railways - AC Traction Manual - Volume-II Part-I

ii. Last recorded earth resistance readings.

iii. Buried rail connection.
j. Remote Control Equipment
Check
i. General function of relays and selectors.
ii. Wiring for loose connection if any.
iii. For presence of dust & condition of cubicle gaskets.
k. General
Check

ii. Working of TPC Phones and emergency sockets.

iii. Inspection register and remarks made therein
iv. History sheets of various equipments.

4.0 Switching Stations

a. Switch yard.
Check
i. For vegetation and spreading of Pebbles.
ii. Painting of fencing and equipments
iii. Condition of cables trenches & trench cabins.
b Interruptors
Check
i. Control box gaskets for water and dust tightness.
ii. Operation by local & remote control.
iii. Operating mechanism for smooth operation.
iv. Interlocking of interruptors and under voltage relay operation at SP.
c. PT & AT
Check
i. Leakage of oil
d. Isolator
Check
i. Locking arrangements

e. Battery charger & Batteries.

Check
i. Acid level.
ii. Presence of sedimentation.

iv. Presence of sulphation & tightness of inter-cell connectors.

v. Size of fuses of battery charger.
vi. Voltmeter & ammeter readings.

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 Chapter-2 Sub-Stations and Switching Stations

f. Earthing
Check
i. Soundness of earth connection to each electrical equipment & structures.
ii. Last recorded earth resistance readings.
g General
Check

ii. Inspection register and remarks made therein

iii. History sheets of various equipments.

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Indian Railways - AC Traction Manual - Volume-II Part-I

Annexure 2.03 A
(Para 20207)

Oil Parameter IS:335 (Type-II) and

RDSO letter no. TI/PSI/INSOIL/POLICY/19/01 dated 26/29.07.2019

Parameter IS:335:2018 (Type II)

Viscosity at 40 oC, Max 15 mm2/s,
Viscosity at 0oC, Max 1800 mm2/s
Pour Point, Max 0oC
Water Content, Max 40 mg/kg
Breakdown Voltage, Min. New 30kV
Filtered 70 kV
Density at 20 oC, Max 0.895 g/ml
DDF at 90 oC, Max. 0.005
Particle content No general requirement
Appearance Clear, free from sediment and suspended matter
Acidity, mg KOH/g Max 0.01
Interfacial Tension Min 40 mN/m
Total Sulphur Content No general requirement
Corrosive Sulphur Not Corrosive
Potentially Corrosive Sulphur Not corrosive
DBDS <5 mg/kg
Inhibiters according to IS 13631/ Inhibited Oil (0.2 to 0.3)%
IEC 60666
Metal Passivator additives <5 mg/kg
Other additives Supplier to declare
2-Furfural and related compounds (<0.05 mg/kg) for each individual compound
contents
Oxidation Stability (mg KOH/g)
a. Total Acidity Max 0.2
b. Sludge Max 0.8% 0.05%
c. DDF at 900C
Max 0.5
Gassing Tendency No general requirement
ECT No general requirement
Flash Point Min 140 oC
PCA Max 3%
PCB < 2 mg/kg

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 Chapter-2 Sub-Stations and Switching Stations

Annexure 2.03 B
(Para 20207)

Application and interpretation of tests on Transformer oil in service

(Ref: IS 1866)

SN Tests Value as per IS: 1866 To be re-conditioned To be replaced

Permissible limits
1. 2. 3. 4. 5.
1. Electric strength (break Min Less than the value
down voltage)
Below 72.5 kV 30 kV
72.5 and less than 145 kV 40 kV
145 kV and above
50 kV
2. Above 10 x 1012 Between 1 x 1012 to 10 Below 1 x 1012
(resistivity) Ohm/cm at x 1012
27oC
3. Water content Max Greater than the value -
Below 145 kV 35 ppm
Above 145 kV 25 ppm
4. Dielectric dissipation 0.01 or less Above 0.01 to 0.1 Above 0.1
factor, Tan delta at 90oC
5. Neutralization value mg 0.5 or less Above 0.5 Above 1.0
KOH/g of oil
6. Interfacial tension N/m at 0.02 or more 0.015and above but below Below 0.015
27 oC 0.02
7. Flash point in oC 140 or more 125 and above but below Below 125
140
8. Sludge Non- detectable Sediment Perceptible Sludge
9. Dissolved gas analysis Refer Annex 2.04

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Indian Railways - AC Traction Manual - Volume-II Part-I

Annexure 2.04
(Para 20216)

GUIDELINES FOR CONDITION MONITORING OF TRACTION POWER

TRANSFORMER BY DISSOLVED GAS ANALYSIS (DGA) TECHNIQUE
(Reference RDSO’s circular No. ETI/PSI/M/4 dated 5.2.91)

1.0 Introduction
1.1 Dissolved gas analysis (DGA) is a powerful 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

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.

of the thermal and electrical stresses to produce hydro-carbon gases, hydrogen and carbon oxides.

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

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, carbon 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.

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 Chapter-2 Sub-Stations and Switching Stations

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 hydro carbon gases and hydrogen. Acetylene 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

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

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

The main product during particle discharge is hydrogen, though small amounts of methane and
other gases would also be present depending upon thermal degradation. 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/CO2 (carbon oxides)
Oil overheating C2 H4 (Ethylene)
Particle discharge H2(Hydrogen)
Arcing C2H2 (Acetylene)

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Indian Railways - AC Traction Manual - Volume-II Part-I

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 oil increases with temperature and that of CO2, C2H2, 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 homogeneity or the gases in the oil is dependent on the rate of gas generation, access of the

5.0 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.

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 Roger’s Analysis is adopted.
5.4 Rodger’s 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.

36
 Chapter-2 Sub-Stations and Switching Stations

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
Methane 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

Table III
Gas levels for different fault conditions
(All concentrations are in ppm)
Fault gases Hydrogen Methane Ethane Ethylene Acetylene Carbon Dioxide
H2 CH4 C2H6 C2 H4 C2H2 CO2
Arcing 500-1000 20-130 10-30 10-30 40-100 3000-4000
Partial discharge 500-1000 20-130 10-30 10-30 10-15 3000-4000
Hot spot 20-150 10-30 10-30 150-200 10-15 3000-4000
Gradual 20-150 10-30 150-200 10-30 10-30 3000-4000
Overheating

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Indian Railways - AC Traction Manual - Volume-II Part-I

Table- IV
Gas composition by volume (%) with reference to volume of oil due to arcing faults

Insulation H2 CO CO2 CH4 C2H6 C2H4 C2H2 O2 H2

Oil only 60 0.1 0.1 3.3 0.05 2.1 2.1 2.4 6.3
Oil/Kraft paper 52 14 0.2 3.8 0.05 8 12 3 6.7
Oil/ Press board 48 27 0.4 5 - 5 6 2 6.2
laminate
Oil, Alkyl paint 55 20 0.2 4 - 5 8 2.4 7
Oil/ Polyure 60 1 0.1 9 - 11 10 2 6
thane enamel
Oil/ PVA 61 5 0.1 6.0 - 14 5 2.5 6.5
enamel
Oil/ Epoxy 57 2 0.1 14 - 10 8 2.5 6.5
glass clothes
Oil/ 55 11 4 8 - 8 5 - -
Isophthalate
cotton tape

Table V
Roger’s method of diagnosis by Hydro-carbon gas ratios

Methane Ethane Ethylene Acetylene Diagnosis % of

Hydrogen Methane Ethane Ethylene transformers
sampled
0 0 0 0 If Methane/ Hydrogen less than 0.1- partial 2.0
discharge
Normal deterioration 34.2
1 0 0 0 Slight overheating below 150 oC 11.8
1 1 0 0 Slight overheating 150oC -200oC 9.0
0 1 0 0 Slight overheating 200oC -300oC 7.8
0 0 1 0 Normal Conductor overheating 11.1
1 0 1 0 Circulating currents and/or overheated joints 9.0
0 0 0 1 Flashover without power follow through 2.1
0 1 0 1 Tap changer selector breaking current 1.1
0 0 1 1 Arc with power follow through or persistent 9.7
arcing

CH4 - Methane
C2H6 - Ethane
C2H4 - Ethylene
C2H2 - Acetylene
H2 - Hydrogen

38
 Chapter-2 Sub-Stations and Switching Stations

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

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

39
Indian Railways - AC Traction Manual - Volume-II Part-I

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 1000 The ordinary inspection is inspection performed
operation by 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 turning
3000operation 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.

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. Remove”O” 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.

1.3 Inspection and Servicing Procedure

Point/Location Item or Part/Procedure Patrol Ordinary Detailed
Inspection Inspection Inspection
Appearance for 1. Check the porcelain x x x
damage
2. Check the main terminal for discoloration x
3. Check the foundation bolts for looseness x x x
4. Check the grounding pad for looseness x x
5. Check the position indicator x x
6. Drain water from air reservoir x x x
7. Record the number of circuit breaker x x x
operation
Interruption unit 8. Inspection of contact and renewal if x
necessary

40
 Chapter-2 Sub-Stations and Switching Stations

9. Renewal of absorbent x
10. Measurement of resistance of interrupting x
units
Gas system 11. Record of gas pressure and temperature x x x
12. Check the valve B is open and valve A is x x
closed
13. Supply the gas, if the pressure less than x x x
prescribed value
14. Check the setting of gas pressure switch x x

Operating Mechanism Pressure gauge:

Housing
1. Ensure that needle indicates rated x x x
operating pressure
2. Ensure that needle indicates with in x x
tolerance(1.5% of full scale) when air is
released thoroughly from air tank
Air leakage:
1. Check pneumatic system such as valves x x x
and piping for air leak sound
Space heater:
1. Check for disconnection x x x
Operating counter:
1. Check number of operations x
2. Ensure that counter counts with operation x x
Draining:
1. Drain water from air tank x
Water penetration & rust:
1. Check penetration of rain water and rust x x
Fastened Joints:
1. Ensure that nuts and bolts etc. are not x x
loosened
Control circuits:
1. Check connections of control circuit x x
wiring for fastening
1. Tripping Check the dimensions of tripping solenoid
Mechanism magnet:
1. Check the clearance “ST” (Solenoid x x
magnet stroke) between armature and
Core
2. Check the clearance “GT” between x x
plunger and trigger
3. Check ST -GT x x
Part replacement and relubrication (Grease):
1. Remove pin “B” and control valve x
assembly
2. Tripping 3. Roller lever of control valve Assy:
Mechanism
1. Close the breaker and fully drain out the x x
the air from air reservoir. Operate control
valve by pushing down trip coil plunger
with soft mallet. Rotate rollers (c) and
(D) to check that they rotate freely.
Open the breaker by using Manual jack
assembly.

41
Indian Railways - AC Traction Manual - Volume-II Part-I

Closing mechanism Check the dimensions of closing solenoid

magnet:
1. Check the clearance “SC” (solenoid x x
magnet stroke) (between armature (27)
and core (28))
Check the pumping prevention pin to latch
distance:
1. Check the clearance “P” between anti x x
pumping pin and latch
Main piston rod Relubrication (Grease)
1. Wipe contaminated grease off piston rod x
and apply new grease in closed position.
Operating mechanism Operating Mechanism Stroke:
1. Check Stroke “S” from closed position to x x
completely opened position
2. Check over-stroke “So” from completely x x
opened position to stopped position
Testing Manual Operation
1. Remove closing and opening lock pins, x x
and charge air upto 15 kg/cm2 . Operate
closing solenoid magnet and opening
solenoid magnet to check operation.
Check of minimum operating pressure:
1. Make sure that circuit breaker is opened x x
at air pressure of 11 kg/cm2
Air Pressure switch:
1. Make sure that air pressure switch is x x
properly set.

42
 Chapter-2 Sub-Stations and Switching Stations

Annexure 2.07
(Para 20223)

MAINTENANCE OF VACUUM CIRCUIT BREAKERS

1.0 General
The maintenance and check execution standard depends upon the working conditions of VCB, such
as the environmental condition, current switching frequency and others. Preventive maintenance is to
be conducted as per the maintenance instruction no. TI/MI/0054 or latest.The checks to be carried out,
their frequency and scope are broadly as under:
Type of check Frequency Scope
Patrol check Daily Check VCB under daily operating
condition.
Ordinary check Once every 3 years or once every 1000 Check VCB after disconnection main
switching times supply and local Remote switch in
LOCAL position.
Detailed check Every 6 years “
Provisional check When a trouble occurs “
For the minimum number of operation without replacement of vacuum bottle para 1.5 below may be
referred.

1.1 Patrol Check

Patrol check shall be done visually. If any abnormality is found, stop the operation forthwith and
examine.
Item Check items Checking parts & key points. Explanation
No.
1. General parts Dust and moisture condensation and
evidence of ingress of rain water in
operating box.
Unusual sound, small and decolouration.
Condition of open-close indication. "On in red, closed condition; "off" in
green, open condition.
Working condition of charge indicator

2. Temperature Main circuit terminals and electrode pole Check if the operating voltage and
assembly control voltage are kept at the respective

3. Control Voltage Check carefully if the terminal section is

discoloured and also, the air is waving
with heat.

IV.95 Ordinary Check

The standard checking items and servicing intervals (given by years or number of operation) are
generally suggested in table below. However, it is recommended that the checking intervals shall
be determined according to the actual working conditions including the installed atmosphere and
operating frequency of the circuit breakers.

43
Indian Railways - AC Traction Manual - Volume-II Part-I

Item Checking Recommended Remarks

No. &Servicing Checking &Servicing Standard
procedure checking
intervals.
1. General parts Cleaning. Remove dust sticking to circuit 3 years
each part breakers, especially the insulators
Tightened Looseness in bolts and nuts, and also 3 years
parts break &drop off of washers, snap
rings, snap retainer etc.
2. Operating Units Operating mechanism Check the movement 3 years
&link mechanism Check the deformation &rust. Check
limit Switches for proper function
Condition of links and collars and 3 years
damage in them
Leakage of oil in the speed regenerator. 3 years
Control circuit Looseness of the terminations of wires. 3 years
Counter Number of operations 3 years
Open close indicator Operating condition 3 years
Charge indicator Operating condition 3 years
3. Check of operation Open-close operation Close and open several times each 3 years
in manual and electrical operations.
Spring charging operation
4. Measurement of Across main conductive More than 500 M. ohms the general 3 years
insulation parts and ground and standard (by 1000 megger)
across poles.
IV.95 Detailed Check
Checking shall be performed as per items listed in ordinary check and as per items listed below:
Item Checking Recommended Remarks
No. &Servicing Checking &Servicing Standard
procedure checking
intervals.
1. VI Vacuum check Contact manufacture 6 Years 3000
operations
2. Operating units Operating mechanism Lubrication to rotary part, sliding 6 years
parts and pin engaging part (use low
viscosity machine oil or equivalent)
Check of adjusting Gap between trip hook and roller 6 years
dimensions of each part followers and other adjusting
dimensions Refer to clause 5-6
Spring Rust, damage and deformation 6 years
Coils Breaking of wires and others. 6 years
3. Check of Operating Min. operating voltage Tripping Voltage: under 70% rated 6 years
Condition voltage
Closing Voltage: under 85% rated
voltage

1.6. 25 Kv Vacuum Interruptor

The minimum numbers of operations of Interrupter without replacement of vacuum bottle is as follows:
1. At a rated breaking current of 4 Ka 4600 nos.
2. At a breaking current of 2 Ka 8000 nos.
3. At a breaking current of 1.2 Ka 10,000 nos.
4. At a breaking current of 0.4 Ka - 10,000 nos.
5. At a breaking current of 600 A - 10,000 nos.

44
 Chapter-2 Sub-Stations and Switching Stations

TORQUE FOR VARIOUS SIZES OF BOLTS IN kg.m

Annexure 2.08
(Para 22015 and 20304)

Bolt Size Nominal Stress Steel Stainless Steel

10 58 4.73 5.91
12 84.3 8.25 10.31
14 115 13.14 16.42
16 157 20.61 25.61
18 192 28.18 35.23
20 245 39.96 49.95

*****

45
 CHAPTER-3
OVERHEAD EQUIPMENT

20300 Introduction

Section I

Section II

Section III

Section IV
Section V

I ORGANISATION

20301 Duties of SSE (OHE)

47
Indian Railways - AC Traction Manual - Volume-II Part-I

proper condition.

20302 Duties of Field Supervisors.

48
 Chapter-3 Overhead Equipment

condition

20303 Technician (Rly Bd. L.No. 2013/ELECT/148/1Dt.10.05.2019 Foot Patrolling

by Technician)

Assistant

II GUIDING NOTES ON MAINTENANCE

20304 Introduction

49
Indian Railways - AC Traction Manual - Volume-II Part-I

20305 Out of Plumb Masts

 Chapter-3 Overhead Equipment

20306 Rail Level and Setting Distance

Indian Railways - AC Traction Manual - Volume-II Part-I

20307 Contact Wire Hard Spots and Wear

 Chapter-3 Overhead Equipment

20308 Sparking During Current Collection

20309 Contact Wire Wear

Indian Railways - AC Traction Manual - Volume-II Part-I

20310 Splice Fittings

 Chapter-3 Overhead Equipment

20311 Section Insulator Assembly

provided.
Indian Railways - AC Traction Manual - Volume-II Part-I

STANDARD SECTION INSULATOR ASSEMBLY

 Chapter-3 Overhead Equipment

Light Weight Section Insulator Assembly:

(Rly Bd L.No. 2003/RE/161/1Dt. 03.03.2005)

train operation.
Indian Railways - AC Traction Manual - Volume-II Part-I

20312 Short Neutral Sections Assembly

 Chapter-3 Overhead Equipment

Short Neutral Section Assembly

Indian Railways - AC Traction Manual - Volume-II Part-I

Short Neutral Section Assembly

20313 Jumper Connections

 Chapter-3 Overhead Equipment

20314 Environmental Effect on OHE

61
Indian Railways - AC Traction Manual - Volume-II Part-I

is restored.

62
Chapter-3 Overhead Equipment
Indian Railways - AC Traction Manual - Volume-II Part-I

20315 Clearances in Tunnels and Other Overline Structures.

20316 Regulating Equipment

(RDSO Spec No. TI/SPC/3 PHT ATD/0150 & TI /SPC/ 5 P ATD/0130)

2.1 MONTHLY CHECKS

64
 Chapter-3 Overhead Equipment

2.2 Annual Checks:

2.2.1 Auto Tensioning Device:

hex pipe

2.2.2 STAINLESS STEEL WIRE ROPES:

stainless steel wire rope

lubricated wire rope.

2.2.3 ATD & WIRE ROPE COMBINED

X-Y dimensions

2.3 CHECKS DURING POH

Indian Railways - AC Traction Manual - Volume-II Part-I

Three Pulley Type ATD

20317 OHE Inspection Car (Tower Wagon)

66
 Chapter-3 Overhead Equipment

20318 Salient Features of OHE Inspection Cars.

67
Indian Railways - AC Traction Manual - Volume-II Part-I

68
 Chapter-3 Overhead Equipment

20319 Rules for Operation of OHE Inspection Car.

69
Indian Railways - AC Traction Manual - Volume-II Part-I

inspection car into the section ahead.

position.

III MAINTENANCE SCHLEDULES FOR OHE

20320 Schedule of Inspections

 Chapter-3 Overhead Equipment

20321 General

20322 Foot-Patrolling of OHE

71
Indian Railways - AC Traction Manual - Volume-II Part-I

72
 Chapter-3 Overhead Equipment

20323 Footplate Inspection of OHE

20324 Current Collection Tests

20325 Special Checks

Indian Railways - AC Traction Manual - Volume-II Part-I

74
 Chapter-3 Overhead Equipment

noticed.

20326 Annual Maintenance and Checks by OHE Inspection Car

2. Masts, portals and cantilever supports:

Indian Railways - AC Traction Manual - Volume-II Part-I

3. Contact and Catenary Wires:

4. Droppers:

5. Turn outs

76
 Chapter-3 Overhead Equipment

6. Section Insulators Assemblies:

7. Isolators:

8. Short Neutral Section Assemblies

a. Overlaps:

9. Contact Wire thickness:

77
Indian Railways - AC Traction Manual - Volume-II Part-I

10. Neutral Sections:

11. Overline, Structures/Tunnels

12. Level Crossings

13. Regulating Equipment:

14. Bonds & Earthing Connection.

attended to.
15. Masts:

16. Sites affected by accidents:

78
 Chapter-3 Overhead Equipment

17. Feeder Lines:

18. PG clamps:

19. Cleaning of Composite Insulators

1.

2.

4.

20327 Integrated Blocks

79
Indian Railways - AC Traction Manual - Volume-II Part-I

20328 Re-tensioning of Unregulated OHE

20329 Periodical Overhaul

Chapter-3 Overhead Equipment

81
Indian Railways - AC Traction Manual - Volume-II Part-I

20330 Rehabilitation of OHE

20331 Transmission Lines

82
Chapter-3 Overhead Equipment
Indian Railways - AC Traction Manual - Volume-II Part-I

IV. SAFETY RULES FOR OHE

20332 General

in each depot.

20333 Documents to be kept with OHE Supervisors for Work on OHE

20334 Permit to Work

84
 Chapter-3 Overhead Equipment

20336 Earthing before Commencement of Work

20337 Procedure for Providing Temporary Earths

Indian Railways - AC Traction Manual - Volume-II Part-I

20338 Precautions in Regard to Discharge/Earthing Pole Assembly

20339 Work on OHE or any Conductor having a Sectioning Point

20340 Protective Helmets

20341 Safety Belt

20342 Rules for use of Ladders

86
 Chapter-3 Overhead Equipment

20343 Other Important Precautions to be taken while Carrying out Works on OHE

20344 Procedure for Effecting Shut-Down for Work on Auxiliary Transformers

20346 Deleted

20347 Isolators

87
Indian Railways - AC Traction Manual - Volume-II Part-I

20348 Petroleum Sidings

Precautions

V. FORMS AND REGISTERS

20349 Records to be Maintained

88
Chapter-3 Overhead Equipment

89
Indian Railways - AC Traction Manual - Volume-II Part-I

Annexure 3.01

SCHEDULE OF MONTHLY INSPECTIONS

1. 1 1 2 2 2 2
2. 1 2 4 4 6
Car

section in section in

4. 1 2 4 4
1 1 2 4 4 4
6. 1 1 2 2 2
7. 1 1 1 1
 Chapter-3 Overhead Equipment

Annexure 3.02

CHECK LIST FOR INSPECTIONS

2.0 Station

91
Indian Railways - AC Traction Manual - Volume-II Part-I

92
Chapter-3 Overhead Equipment
Indian Railways - AC Traction Manual - Volume-II Part-I

Annexure 3.03

1.

2.

4.

1.

2.

4.

6.
1.

2.

1.
2.

4.

94
 Chapter-3 Overhead Equipment

1.

2.

1.
2.

4.

1.

2.

1.

2.

4.

1.
2.

1.

2.
Indian Railways - AC Traction Manual - Volume-II Part-I

1.
2.

4.

6.

7.
8.

9.

11.

12.

96
 Chapter-3 Overhead Equipment

Annexure 3.04

PROFORMA 03-1

Type of work Locations Staff/ Supervisor

Type of work Locations Staff/ Supervisor

6.1
6.2

6.4

97
Indian Railways - AC Traction Manual - Volume-II Part-I

PROFORMA 03-2

Register for Foot Patrol Report

Section______________________

attended
proposed

PROFORMA 03-3

Tower wagon/ Cantilever Assembly Maintenance Register

Con
ca ance dition
9T
tion can per
done
tion visor
vers

98
 Chapter-3 Overhead Equipment

PROFORMA 03-4

Record of Contact Wire Wear and splices

03-04 & 03-15 merged (ACS 13)

no. provision
strands

hard spot

PROFORMA 03-5

Register for Features of overline structure

Contact
no..

at ends
and

Pipes Protective Pr.

screen

99
Indian Railways - AC Traction Manual - Volume-II Part-I

PROFORMA 03-6

Register of Earth Resistance Measurements

PROFORMA 03-7

Record of current collection test

Corrective
action corrective
action
 Chapter-3 Overhead Equipment

PROFORMA 03-8

Record of Implantation & Foundation (ACS 13)

no. distance

To To
per

PROFORMA 03-9

Register of Break-downs/ Accidents involving OHE

Indian Railways - AC Traction Manual - Volume-II Part-I

PROFORMA 03-10

Regulating Equipment

Tension
oC

oC done
Contact
one
1 2 4 6 7 8 9 11 12 14 16 17 18 19

PROFORMA 03-11

Isolator Switches

Condition
section
connected
1 2 4 6 7 8
 Chapter-3 Overhead Equipment

Performa 03-12

TRACTION DISTRIBUTION BRANCH

Turnout and Cross Overs

1
crossover(Givethe

7
8

11

12

14
Indian Railways - AC Traction Manual - Volume-II Part-I

16

17

18

19

21
22

24

(Proforma 03-13) merged with 3-08

(Proforma 03-14)

TRACTION DISTRIBUTION SECTION

Condition
Contact

road

1 2 4 6 7 8 9

(Proforma 03-15) merged with 3-04

*****
 CHAPTER-4
REMOTE CONTROL EQUIPMENT

I. GENERAL

20400 Introduction

II. SCADA EQUIPMENT

20401 General

20402 Transmission Path

20403 Master Station Equipment

105
 Indian Railways - AC Traction Manual - Volume-II Part-I

20404 Overall Screen Design &Real Time Display

20405 Alarm Processing and displays:

20406 SCADA Software

106
 Chapter-4 Remote Control Equipment

20407 Test Procedure& Diagnostics

RTU Diagnostics

RCC Diagnostics

20408 Historical Data Storage

20409 UPS and Batteries at RCC

Input:
Indian Railways - AC Traction Manual - Volume-II Part-I

Output:

Battery:

20410 Remote Terminal Unit (RTU)

20411 RTU FUNCTIONAL DETAILS

20412 SCADA Equipment Capacity

 Chapter-4 Remote Control Equipment

20413 Energy Management System (EMS):

20414 Special Features in SCADA Equipment

 Indian Railways - AC Traction Manual - Volume-II Part-I

III OPERATION AND MAINTENANCE OF RC EQUIPMENT

20415 Duties of SSE(RC)

20416 Operation of RC Equipment

110
 Chapter-4 Remote Control Equipment

20417 Investigation of Failures by SSE (RC)

20418 Maintenance Schedule

111
 CHAPTER-5
OPERATION OF TRACTION POWER CONTROL

20500 Remote Control Centre

The Remote Control Centre (RCC) constitutes the ‘heart’ of the control system from where the

20501 Manning of RCC

20502 Knowledge of Rules

20503 Entry into RCC

20504 Shift Duty

20505 Shift Duty Register

113
Indian Railways - AC Traction Manual - Volume-II Part-I

20506 Repair and Adjustment of RC Equipment

20507 Switching Operations to be Deliberate

20508 Liaisons with Section Controller

20509 Prompt Attention to Telephone Calls

20510 Log Book

20511 Movements of Maintenance Staff

20512 Checking of Time

20513……………..deleted
 Chapter-5 Operation Of Traction Power Control

20514 Emergency Generator Set

20515 Duties of Chief Traction Power Controller

20516 Duties of Traction Power Controller

115
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20517 Failure of Traction Power Supply

 Chapter-5 Operation Of Traction Power Control

20518 Failures of Grid Supply

20519 Prolonged Power Supply Failures

20520 Faults on Railway Equipment and Lines

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20521 Lowering Pantographs of Defective Locos

20522 Isolation of Faulty Section

20523 Faulty Section to be kept Isolated

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 Chapter-5 Operation Of Traction Power Control

20524 Advice to Section Controller

20525 Information to Traction Staff

20526 Action to Rectify OHE Fault

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20527 Emergency Telephone Working

20528 Breakdowns and Emergencies

20529 Obstruction of Track - Protective Steps to be taken by TPC

Chapter-5 Operation Of Traction Power Control

*****
 CHAPTER-6
POWER BLOCKS AND PERMITS-TO-WORK

20600 Operation of Isolator Switches

1. Before considering the procedure for obtaining power blocks, attention isdrawn 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 JE, SSE (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. It
may be opened when there is no train in the sub sector in double/multiple line sections.

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

20601 Isolators in Yards and Sheds

1. Isolator switches provided for isolating sidings and yards and also to feed OHE inside running

2. the entire section is visible; and

3. 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:

diesel locomotive hauled. This will be required whenever heavy repair have to be carried out. A

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

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 Indian Railways - AC Traction Manual - Volume-II Part-I

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

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

2. In all cases of power block TPC shall put red warning caps on control switches corresponding to

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 Power Block” 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:
1. 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;
2. A damaged catenary or contact wire fouling the vehicle gauge;
3. A damaged electric locomotive getting damaged to rectify which the Driver requires the permit-to-
work;

supply is considered necessary by TPC or the Section Controller, in the interest of safety.

20605 Reporting Abnormalities in OHE

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

essential information such as his name, designation, kilometerage where the abnormality has been

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 Chapter-6 Power Blocks And Permits-To-Work

noticed, its nature and place from where he is reporting. He should leave the place only with the
permission of the TPC.

enable the TPC to decide upon the course of action to be taken.

20607 Action to be taken by 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

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

issue a message supported by private number.

correct method of identifying and describing any section of the OHE where shutdown is required.

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:
in the direction of power supply i.e., from the feeding post/substation towards the neutral section or

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 section from the feeding post/sub-station on the down line, fed by interrupter 02.

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

followed is as detailed below -

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 Indian Railways - AC Traction Manual - Volume-II Part-I

permit-to- 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.

of the person who has received it.

3. 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.
4. The same person who asks for and obtains a power block should also cancel it before power supply

the telephone.

it. Each message shall be recorded by the sender as well as by the receiver in message books
maintained for the purpose.
6. To avoid confusion, use words “Open” and “Close” shall be used instead of phonetically similar

(e.g.,1 (one) 4 (four) and not fourteen), B for Bombay, C for Calcutta and so on.

work in the danger zone of traction equipment, or who require OHE and or bonding staff to be present

1. the nature of the work and the date on which it is to be performed;

2. by whom the work isto be carried out
3. location of the work and the section of the lines to be blocked;
4. The trains between which the block is required; and

consolidated statement forwarded to the Senior Divisional Operating Manager concerned, by 12

from TPC.

who asked for the blocks).

5. Most of the traction sub-stations have two sets of traction power transformers and associated
switch gear. Maintenance of equipment of the traction sub-station, therefore, does not necessitate

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. Similarly at the switching stations normally the alternative feed is

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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

1. On the scheduled day about two hours before the block period, i.e., at about 8.00 hours, TPC will

10-00 hrs.
2. The TPC will pass on information to the JE of the maintenance gang that the power block, as
already arranged, will be 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.

Station Master on duty at all stations concerned to arrange for “longitudinal” and “cross” protection

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

9. On receipt of the above message TPC will open the interruptors concerned and issue messages

that the isolators have been opened, TPC will close the interruptors restoring power supply to

issue a permit-to-work message in the prescribed form to the authorized person in charge of the
maintenance gang.

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

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.

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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 -
1. all men and materials have been withdrawn from the electrical equipment and its vicinity,
2. all earths provided for the protection of the working parties have been removed; and
3. all staff, who have been deputed to work, are warned that the power supply is to be restored.

permit- to-work was issued, has been completed, the men and materials have been withdrawn from the

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

person.

Electric Traction Branch not below the rank of a Senior Technician.

work getting an acknowledgment on the other copy. A duplicate copy of every permit-to-work card

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-

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

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

elementary section, the permit -to-work shall be issued by the TPC only to one authorized person

permit-to-work. Other party or parties may work on the same portion of electrical equipment only
with the permission of this authorized person. The authorized person shall cancel the permit-to-

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.

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period shall take the permit-to-work and then permit the other party to start his work by a message

permit-to-work of completion of work and removal of earths and withdrawal of men and material

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,

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 SSE, JE or Charge-man (RS) who shall arrange for the issue of the permit- to-work after

permit-to-work must be received for cancellation from the person in-charge of the work by the SSE,
JE or JE (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

1. The Station Master, Cabin Assistant Station Master, and others responsible for the movement of

2. TPC shall be informed before and after the shut-down is effected.

3. Isolators may only be opened after due precautions prescribed in para 20600, 20622 and 20625.
4. Earthing of equipment and issue of permit-to-work isdone as prescribed in these rules.
5. Local power blocks shall be recorded in form ETR-4 prescribed for the purpose.

20620 Protective Measures for Power Blocks

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 are
therefore given at some length in the following para graphs.
The protective measures are -
1. 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.
2. Transverse or Cross Protection: To stop movement of electric rolling-stock running into a section,
which has been made dead, from another track or from a siding through cross-overs.

20621 Longitudinal Protection

1. At all points where interrupters or isolator switches are provided the overhead lines are sectioned
and insulated (air gap) overlap span is provided. The arrangement adopted is shown in Fig. 6.01.

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 Indian Railways - AC Traction Manual - Volume-II Part-I

is normally in closed position, it connects the two OHE together and, therefore, they are both
energized at the same voltage

destructive arcing resulting in severe damage to the pantograph and the contact wire.
3. To avert such disastrous effects, under no circumstances should electric rolling-stock be admitted
into the insulated overlap separating the dead section on which a power block has been taken from
live sections.

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.
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 lll). 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 OHE 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.

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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 live section.

20623 Procedure for Arranging Longitudinal and Transverse Protection

1. Before a power block is granted the Section Controller should advise the Station Master, 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

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. 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-

It is the duty of every Station Master, Yard Master and Assistant Yard Master to be thoroughly

measures prescribed.

a. rules to be generally observed byall stations;

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.

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 operate isolators under instructions from TPC.

20625 Protection of Dead Section

The protection of a dead section is achieved by the following means:
1. In the normal running direction, movements of trains are generally controlled by signals. Protection

2. If the points and signals are locally operated, they should be locked and the keys controlling the

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

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This action must be taken by the Cabin Assistant may be, in respect of each and every movement

Section Controller to enable him to agree for the

of messages with private member.

20626 Shunting Movement Towards Dead Section

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

beyond the point.

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

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.

20627 Movement of Other than Electric Trains

Goods or Passenger trains hauled by other than electric locomotives may be allowed to pass through
the dead section subject to the following conditions :-

2. Steam or diesel engine or trains hauled by such engines shall be brought to a stand at the station
preceding the station/section at which power block is granted and the Station Master or this station
shall satisfy himself by personal inspection that there is no electric locomotive in the train in
question.

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3. He shall also give a Caution Order to the Driver of such engine or train warning him of the power
block ahead and instructing him to watch for hand signals and observe them.

of the preceding station that there is no electric locomotive or Inspection Car with pantograph
raised in the train.

and this para, it shall be replaced back on the signal control lever immediately after the movement
is completed.
For purposes of the above rule the term “Electric Rolling -Stock” does not include electric rolling-

locked down.

20628 Standard Forms for Power Block Messages

Typical forms for power block messages are attached at the end of this Chapter.

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in adjacent rooms, the messages will be made out in duplicate and sent to the other party obtaining

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.

Form ETR. 1
Part A.
RAILWAY
POWER BLOCK MESSAGE FOR BLOCKING OF LINES FOR ELECTRIC TRACTION
PURPOSES

Date .......................................
Time Hr ............. Mts ............
From, To,
Traction Power Controller Section controller

at ........ ...................... Section

....................... ..(Place)

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 ...

Sent by .........................

Received by ..................

*Score out whichever is not applicable.

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 Chapter-6 Power Blocks And Permits-To-Work

Form ETR. 1

Part B

................... RAILWAY

POWER BLOCK MESSAGE FOR BLOCKING OF LINES FOR ELECTRIC TRACTION

PURPOSES

Time Hr . ......... Mts ........

From To,
Section Controller Power Controller
at ............................. at.........................
................(Place)

Line/s Duration

..........................................to Hr .......................... Mts ......

Particulars of line/s Reasons

............................................................. ...................................................................................
............................................................. ...................................................................................

Sent by ..............................

Received by ...........................

*Score out whichever is not applicable

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 Indian Railways - AC Traction Manual - Volume-II Part-I

Form ETR-1
Part-C
........... RAILWAY

POWER BLOCK MESSAGE FOR BLOCKING OF LINES FOR ELECTRIC TRACTION

PURPOSES

Time Hr............. Mts ...........From, To,

Traction Power Controller Section Controller
at .............................
...........................Section
............................(Place)

The following line/s have been made alive and the block imposed on these line/s may be cancelled:-

Sent by ..............................

Received by ...........................

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 Chapter-6 Power Blocks And Permits-To-Work

Form ETR-2
Part-A.
................... RAILWAY
SHUT DOWN NOTICE ON TRACTION OVERHEAD OR OTHER ELECTRICAL
EQUIPMENT

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
shall be earthed according to standing instructions before commencing any work or prior to issue of
Permit-to-work :-

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

Sent by ........................................

Received by ..................................

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Form ETR-2

Part-B.

................... RAILWAY

SHUT DOWN NOTICE ON TRACTION OVERHEAD OR OTHER ELECTRICAL

EQUIPMENT

Time Hr . .................... Mts...,

From, To,
.................................. Traction power controller,
at....................... at................................

Local earths have been applied at the following points:-

The following permit to work have been issued on the authority and I am responsible for the permit to
work:-

(1)....................................(2).............................................(3)......................................

Date of issue ....................................................................................... ..............................

Time of issue ........................................................................................ .............................
Dept. Issued to ....................................................................................... ..............................
Person in-charge ofwork ..................................... .................................................. .............................

Sent by .............................................

Received by ...........................................

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 Chapter-6 Power Blocks And Permits-To-Work

Form ETR-2

Part-C

................... RAILWAY

SHUT DOWN NOTICE ON TRACTION OVERHEAD OR OTHER ELECTRICAL

EQUIPMENT

Time Hr................Mts..................
From, ............................. To,
......................................... Traction Power Controller
at ....................................... at....................................

I 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. All 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.

Sent by .............................

Received by .............................

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Form ETR-3

Part-A.

.................. RAILWAY

PERMIT-TO-WORK ON OR NEAR AC TRACTION ELECTRICAL EQUIPMENT

From, .................................... To,

................................................ .....................................................
at .......................................... at....................................................

I 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.

Elementary Section, etc.)

.......................................................
......................................................

The equipment shall not be alive until this Permit-to-work is returned duly signed by the person in-
charge of the work.

Controller at ....................................................... at ................... Hr ............

Mts . ..................... on ................................... (date).
Signature ................................
(of the authorized person)

Designation ..................
Date ............ Hr ............ Mts.......

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 Chapter-6 Power Blocks And Permits-To-Work

Fnorm ETR-3

Part-B.

.................. RAILWAY

PERMIT-TO-WORK ON OR NEAR AC TRACTION ELECTRICAL EQUIPMENT

From, .................................... To,

................................................ .....................................................
at .......................................... at....................................................

Received the original foil of this Permit to work, I fully understand the portion of electrical equipment
which is dead, isolated and earthed and that all other parts are dangerous.

Signature ................
(of the authorized person)

Designation ..................
Date ............ Hr ............ Mts.......

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Form ETR-3

Part-C

.................................. RAILWAY

PERMIT-TO-WORK ON OR NEAR AC TRACTION ELECTRICAL EQUIPMENT

From, To,
.............................................. ............................................
at........................................... at...............................................

all men and materials under my charge have been withdrawn the men have been warned that it is no

Signature ...............................
(of the authorized person)

Designation........................
Date...............Hr.............Mts.......

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 Chapter-6 Power Blocks And Permits-To-Work

Form ETR-3

Part-D

.................................. RAILWAY

PERMIT-TO-WORK ON OR NEAR AC TRACTION ELECTRICAL EQUIPMENT

From, To,
.............................................. ............................................
at........................................... at...............................................

at ...... Hr ...... Mts ......

Signature ...............................
(of the authorized person)

Designation........................
Date...............Hr.............Mts.......

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Form ETR-4

Part A

................................. RAILWAY

LOCAL BLOCK

Hr ....................... Mts ............................

From, To,

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

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

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 Chapter-6 Power Blocks And Permits-To-Work

Form ETR-4

Part B

...........................................RAILWAY

LOCAL BLOCK

At......................................Hr.......................................Mts..........................................
................................................................
Signature of the station Master/Yard Master
Place....................................................

145
 Indian Railways - AC Traction Manual - Volume-II Part-I

Form ETR-4

Part C

................................. RAILWAY

LOCAL BLOCK

.....................Hr...............Mts............
From,

Designation .............................. ............................................

The *Interruptor number

*Isolator number opened by me has been closed and the overhead equipment of the ............................

Signature .................................................

Copy to :- (1) Traction Power Controller Section Controller.

(2) Section Controller

*****

146
 CHAPTER-7
SIGNALLING & TELECOMMNICATION AND PERMANENT
WAY INSTALLATIONS IN ELECTRIFIED SECTIONS

20700 Introduction
The important points concerning the signalling, telecommunication and permanent way installations in

I. Signals and associated equipments

IV. Permanent way installations

I. SIGNALS AND ASSOCIATED EQUIPMENT

20701 Effects of 25 kV Traction on S&T Equipment

147
 Indian Railways - AC Traction Manual - Volume-II Part-I

20702 Types of Signals

20703 Locations of Signals

height.

148
20704 Insulation of Wires and Point Rods

20705 Earthing of S&T Equipment

equipment in switching stations.

20706 Signaling & Telecommunication Cables

149
Indian Railways - AC Traction Manual - Volume-II Part-I

earths or traction masts.

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

Volume

20712 Principles of Tapping

a. All electric loco sheds,

Indian Railways - AC Traction Manual - Volume-II Part-I

maintenance

20713 Power Supply Arrangement

III. PERMANENT WAY INSTALLATIONS

20714 Major Track Maintenance Works

*****
 CHAPTER-8
BREAKDOWNS

I. GENERAL

20800 Knowledge of Rules

20801 Types of Breakdowns

20802 Breakdown Gangs

20803 Emergency Stores and Breakdown Equipment

155
 Indian Railways - AC Traction Manual - Volume-II Part-I

20804 Record of Staff Movements

20805 Summoning of Emergency Staff

II. SUB-STATION AND SWITCHING STATION BREAK-DOWNS

20806 Traction Transformer Breakdowns

20807 Repair of Traction Transformer

20808 Mobile Power Van

156
 Chapter-8 Breakdowns

20809 Breakdown of Circuit Breakers, Interruptors

20810 Rail and Road Access

III. BREAKDOWNS OF REMOTE CONTROL EQUIPMENT

20811 Procedure for Manning Sub-Stations And Switching Stations

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 Indian Railways - AC Traction Manual - Volume-II Part-I

20812 Restoration of Remote Control

20813 Breakdown of Tele-Communication Between TPC and Sub-Stations,

Switching Stations etc.

IV. OHE BREAKDOWNS

20814 Importance of Expeditious Repairs

20815 Types of OHE Breakdowns

20816 Look-out for OHE Defects

158
 Chapter-8 Breakdowns

20817 Action to be taken by TPC

20818 Protective Steps

20819 Breakdown Staff

159
 Indian Railways - AC Traction Manual - Volume-II Part-I

20821 Assistance to be sought

20822 Continuous Communication with TPC

20824 Preservation of Evidence

20825 Safety Rules to be Observed

160
 Chapter-8 Breakdowns

20827 Clearance of Line for Steam/Diesel Traction

20828 Wiring Train

20829 Interference with OHE During Restoration

20830 Temporary Diversions

161
 Indian Railways - AC Traction Manual - Volume-II Part-I

162
 Chapter-8 Breakdowns

Para 20830(a) Temporary Speed Restrictions

20831 Funds Required for Dealing with Breakdowns

163
Indian Railways - AC Traction Manual - Volume-II Part-I

20832 Log of Events and Reporting of Breakdowns

20833 Protection of Staff

20834 Use of Cranes

V. ROAD VEHICLES

20835 Use of Road Vehicles during Emergencies

20836 Driver’s Duties

 Chapter-8 Breakdowns

20837 Operation of Road Vehicles

165
 Indian Railways - AC Traction Manual - Volume-II Part-I

20838 Precautions when Transporting Heavy Materials

20839 Transportation of Personnel

20840 Parking

166
 Chapter-8 Breakdowns

20841 Maintenance of Road Vehicles

167
 Indian Railways - AC Traction Manual - Volume-II Part-I

Annexure 8.01
PANTO ENTANGLEMENTS : ITEMS TO BE CHECKED ON PANTOGRAPH

168
 Chapter-8 Breakdowns

Annexure 8.02
PROFORMA FOR RECORDING MEASUREMENT/OBSERVATION IN RESPECT OF
OHE IN CASE OF PANTO ENTANGLEMENT.

*****

169
 CHAPTER-9
PREPARATION FOR COMMSSIONING

20900 Introduction

20901 Reference to Rules and Statutory Rules

171
Indian Railways - AC Traction Manual - Volume-II Part-I

20902 Pre-Commissioning Inspections

I. TRACTION SUB-STATIONS

20904 Planning of Power Supply

 Chapter-9 Preparation For Commssioning

20905 Commissioning of Traction Transformers

20906 Precautions During Commissioning of Traction Transformer

173
 Indian Railways - AC Traction Manual - Volume-II Part-I

20907 Tests on Transformer Windings

20908 Circuit Breakers and Interruptors

174
 Chapter-9 Preparation For Commssioning

20909 Isolators

20910 Current and Potential Transformers

 Indian Railways - AC Traction Manual - Volume-II Part-I

20913 Busbars and Insulators

20914 Clearances

connection

20915 Auxiliary Power Supply for Traction Substations & Control Room

176
 Chapter-9 Preparation For Commssioning

20917 General

20918 General Inspection of Substations and Commissioning

177
 Indian Railways - AC Traction Manual - Volume-II Part-I

20921 Visual Inspection

20922 Clearances and Sag

178
 Chapter-9 Preparation For Commssioning

20924 Insulators and Insulation Resistance

20925 Continuity Test

20926 Accessories
Indian Railways - AC Traction Manual - Volume-II Part-I

20927 General inspection and Energization

20928 25 kV Feeders

III. PROTECTIVE EQUIPMIENT

20930 Inspection of Setting of Relays and Calibration of Meters

 Chapter-9 Preparation For Commssioning

(Ref RDSO Spec TI/SPC/PSI/PROTCT/6071)

181
Indian Railways - AC Traction Manual - Volume-II Part-I

20932 Control Circuits and Wiring

20933 Fuses
 Chapter-9 Preparation For Commssioning

20935 Current Transformer Ratio and Polarity Test

183
 Indian Railways - AC Traction Manual - Volume-II Part-I

20936 Primary Injection Test

20939 Secondary Injection Test

184
Chapter-9 Preparation For Commssioning
 Indian Railways - AC Traction Manual - Volume-II Part-I

20943 Power Supply

20944 Installation of Equipment

20945 Clearances

186
 Chapter-9 Preparation For Commssioning

20946 Auxiliary Transformers

20947 General

20948 Interlocking

20949 Feeding Posts

187
 Indian Railways - AC Traction Manual - Volume-II Part-I

20950 Number Plates and Boards

20952 Importance of Remote Control

188
 Chapter-9 Preparation For Commssioning

20955 Detailed Inspection of RC Equipment

Indian Railways - AC Traction Manual - Volume-II Part-I
 Chapter-9 Preparation For Commssioning

VI. OVERHEAD EQUIPMENT

20958 Detailed Joint Inspection of OHE

20960 Infringements
Indian Railways - AC Traction Manual - Volume-II Part-I
 Chapter-9 Preparation For Commssioning

20962 Notices to be Displayed – Caution Boards and Number Plates

Indian Railways - AC Traction Manual - Volume-II Part-I

20966 Procedure for Final Test of OHE

 Chapter-9 Preparation For Commssioning

20967 Insulation Tests

Indian Railways - AC Traction Manual - Volume-II Part-I
 Chapter-9 Preparation For Commssioning

20968 Continuity Tests

Indian Railways - AC Traction Manual - Volume-II Part-I
 Chapter-9 Preparation For Commssioning

*****
 CHAPTER-10
COMMISSIONING OF ELECTRIC TRACTION

21000 General

21001 Preparation by Open Line

21002 Organization for Inspection and Taking Over

201
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21003 Duties of Senior Divisional Electrical Engineer (TrD)

202
 Chapter-10 Commissioning Of Electric Tractiondowns

21004 Duties for Senior Divisional Electrical Engineer (RS)

21005 Responsibility of Construction Organization

203
 Indian Railways - AC Traction Manual - Volume-II Part-I

21006 Commissioning of Traction Substations

204
 Chapter-10 Commissioning Of Electric Tractiondowns

energisation
 Indian Railways - AC Traction Manual - Volume-II Part-I

206
 Chapter-10 Commissioning Of Electric Tractiondowns

2. Introduction of Electric traction in yard lines/loop lines/ sidings

207
 Indian Railways - AC Traction Manual - Volume-II Part-I

21010 Inspection by CRS for the Introduction of Passenger Services on Electric

21012 Anti-theft Energization

208
 Chapter-10 Commissioning Of Electric Tractiondowns

21014 Contractor’s Responsibility During Guarantee Period

21015 Failure of Equipment After Commissioning and During the Guarantee Period
 Indian Railways - AC Traction Manual - Volume-II Part-I

21016 History Sheet

21018 Standard Forms

SN Particulars Proforma

210
 Chapter-10 Commissioning Of Electric Tractiondowns

SN Particulars Proforma

For Introduction of Electric Traction :

Proforma 10-1
INDIAN RAILWAYS
“PUBLIC NOTIFICATION”

211
 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma 10-02
INDIAN RAILWAY
INTRODUCTION OF ac 25 kV TRACTION
“WARNING TO ROAD USERS”

212
 Chapter-10 Commissioning Of Electric Tractiondowns

Proforma 10-03
CERTIFICATE REGARDING OHE

Proforma 10-04
CERTIFICATE REGARDING BONDINGAND EARTHING

Proforma 10-05
CERTIFICATE REGARDING SAFETY PROCEDURES AND PRECAUTIOINARY
MEASURES FOR STAFF

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 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma 10-07

214
 Chapter-10 Commissioning Of Electric Tractiondowns

Proforma 10-8

Proforma- 10-09
COMPLETION CERTIFICATE
 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma 10-10
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV
1. 25 kV Feeder Lines

Proforma 10-11
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV

2. Overhead Equipment

216
 Chapter-10 Commissioning Of Electric Tractiondowns

Proforma 10-12
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV
3. Switching Stations

217
 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma 10-14
(Proforma deleted and its contents included in proforma (10-08) via ACS-3)
CLEARANCE CERTIFICATE FOR ENERGIZATION ON 25 kV

Proforma 10-15

218
Chapter-10 Commissioning Of Electric Tractiondowns

Proforma 10-16
 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma 10-17

220
 Chapter-10 Commissioning Of Electric Tractiondowns

Profarma 10-19

Infringement of maximum and minimum dimensions (Form XVII) Rule 5(5).

structures actual sanctions to

section and and

221
 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma-10-20

Form XV-2

222
 Chapter-10 Commissioning Of Electric Tractiondowns

Proforma-10-21
-------------- RAILWAY
JOINT SAFETY CERTIFICATE NO.SLC/BG/01/2004

restriction
speed of speed speed restriction
the section

1 2 3 4 6 7 8 10 11 12

223
 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma-10-22

BRIEF PARTICULARS OF TRACTION INSTALLATlON

(Sample)

224
 Chapter-10 Commissioning Of Electric Tractiondowns

Proforma-10-23

POWER SUPPLY INSTALLATION ABSTRACT

1 2 3 4
1
stations
2
station
3
stations
4

6
 Indian Railways - AC Traction Manual - Volume-II Part-I

Proforma-10-24

MAINTENANCE DEPOT ABSTRACT

1 2 3 4

Proforma-10-25

RESTRICTED OHE CLEARANCE ABSTRACT

Whether
contact static
line anchored

structure

1 2 3 4 6 7 8

226
 Chapter-10 Commissioning Of Electric Tractiondowns

earthed part
earth
1 2 3 4

Proforma-10-26

Whether
clearance as

1 2 3 4 6 7

*****

227
 CHAPTER-11
RECENT DEVELOPMENTS

21100 2x25 kV Auto-Transformer Feed System

BRIEF DESCRIPTION OF THE 2 X 25 kV SYSTEMS.
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.
In 2x25 kV system, power is fed from the TSS at 50 kV and utilization is achieved at 25 kV by
providing Auto-transformers of adequate capacity and by providing one additional conductor normally
referred as feeder wire (similar to the return conductor in BT/RC system). Centre point of the Auto
Transformer is connected to the earth/Rail. This arrangement facilitates +25 kV Voltage between OHE
and rail and -25 kV voltage between earth/Rail and the Feeder Wire.

Advantage of 2X25kV system:-

1. The 2X25 kV AT feeding system is suitable to meet larger power supply needs with the inherent
advantage of less voltage drop in feeder circuit for a given spacing of traction substations. To
meet the larger power supply requirements, 2X25kV system is used in various countries including
DFCCIL in India.

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2. Power is generally obtained from 220 kV or 132 kV three phase networks from the power utility to
reduce voltage unbalance on the transmission network. In the 2X25kV TSS, the three phase supply
is utilized at the Traction Sub-station.
3. The 2X25 kV Auto Transformer (AT) system is having feeding voltage of 50 kV from the substation
which is dropped to 25 kV by the AT installed at about 10 to 18 Km spacing along the track for
supply to overhead equipment and rolling stocks. A pilot project for this system was provided in
Bina-Katni Section. The design of the system was done with the help of Japanese Consultants.
4. Better voltage regulation even at higher load currents.
5. Minimized rail currents resulting in reduction in rail potential rise. Return current through ground
also reduces considerably.

in the feeder wire is opposite to the direction of current in the catenary wire, it minimizes the effect
of the electromagnetic Interference in the proximity of the traction line.
7. Preferred solution across the globe to meet higher power requirement for Traction Purpose.

Schemes proposed for 2X25kV System along with various Transformers

Scott Connected Transformer Scheme:

1. In this scheme two Scott connected Transformers & four Auto-transformers are to be installed at
a TSS along with associated switchgear for Control & protection. The two windings of a Scott
transformer i.e. Main and Teaser windings are of equal power rating and feed either side of the TSS
independently. The supply of both the windings is at a phase difference of 90 degree and separated
by neutral section provided near TSS. Out of two Scott transformers, only one is in operation and
the other is on standby.

2. Scott Connected Transformer:

Scott- connected transformer of 60/84/100 MVA (ONAN/ONAF/OFAF) is used to feed power to
the traction system. It has a voltage input of 220kV or 132kV, 3 phase, 50 Hz and two independent
secondary winding for output at 50 kV. The Transformer has two secondary windings, known as the
main winding and teaser winding. The two windings are identical in voltage and current rating but
are in phase difference of 90 degree. These two windings of equal power rating i.e. Main & Teaser
windings, feed power on either side of the TSS. The feed of different phase is separated by neutral
section provided near TSS. The Scott Connected Transformer in ONAN Mode shall feed the 30MVA
Power to each side of the TSS.

230
Chapter-8 Breakdowns

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3. Auto Transformers:
Auto- transformers are used at TSS, SP and SSP. The transformer winding of 50kV with Centre tapped
neutral with both the terminals of the Autotransformer winding connected to feeder and contact /
Catenary wire. The neutral terminal of the ATs is connected to rail.
Two adjacent ATs feeding on the network share train loads on the section between them and transfer
the load current on 25 kV circuit to 50 kV circuit, consisting of contact wire and AT feeder. This
reduces the voltage drop on feeding network remarkably. Furthermore, it minimizes the return current
on the rail, which results in reducing induced voltage on nearby telecommunication lines.
In the Scott connected arrangement for 2 Line section, 12.3 MVA Auto transformers are to be installed
at the TSS and 8MVA Auto transformers to be used at the SP & SSP, as adopted by DFCCIL in Western
Corridor. Further, the Scott connected arrangement for 3 Line and 4 line sections have been provided
with 12.3 MVA auto transformers at TSS and 16.5 MVA auto transformers at SP/SSP. Moreover, no
independent AT post has been proposed in any scheme.

4. V Connected Transformer Scheme:

In this scheme, three single phase transformers are connected to different pairs of three phase of
incoming supply forming an open delta connection on the primary side. Out of the three single phase

remains as standby and third transformer feeds the OHE on the other side of the TSS. The power
supply on either side of TSS is at a phase difference of 120 degree and therefore separated by a neutral
section provided near TSS.

5. V- Connected Transformer:
In the above arrangement, three 38/53/63 MVA (ONAN/ONAF/OFAF) Transformers are provided at
TSS along with associated switchgear for Control and Protection. Each single phase transformer has
a voltage input of 220kV or 132kV, 50 Hz and two independent secondary windings, to be connected
externally in such a manner (two inner terminals of these secondary windings are connected with each
other and also connected to earth/Rail) so as to give an output voltage of 2X25kV. The outer terminals
of the windings are connected to Feeder wire and overhead contact/catenary wire respectively. Two
transformers shall be in operation at a time and one shall be on standby. In the V connected Scheme,
each transformer in ONAN mode shall feed the 38MVA Power in either side of the TSS.

6. Auto Transformers:
i. Auto- transformers are used at SP and SSP. The transformer winding is 50 kV with Centre
tapped neutral with both the terminals of the winding connected to AT feeder and the contact
wire. The neutral terminals of the ATs are connected to rail.
ii. Two adjacent ATs feeding on the network share train loads on the section between them and
transfer the load current on 25 kV circuit to 50 kV circuit, consisting of contact & catenary wire
and AT feeder. This reduces the voltage drop on the feeding network remarkably. Furthermore,
it minimizes the return current on the rail, which results in reducing the induced voltage on
nearby telecommunication lines.
iii. Auto transformers are not used at the TSS. However, these have been provided at SP/SSP of
16.5 MVA capacities. Moreover, no independent AT post has been proposed.

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 Chapter-8 Breakdowns

7. Scott connected vs V Connected Scheme

i. Considering the three phase utilization equally in the Scott Connected scheme, it is better
in reducing the unbalancing at point of common coupling with the utility as compared to

RDSO Instruction no. TI/IN/0019 (09/09).

ii. The Voltage Unbalance in Scott Connected Transformer Scheme is least and therefore the
Railways should preferably provide Scott Connected Transformer wherever the voltage
unbalance problem is seen. The detailed study regarding this is available in clause no. 2.1.13
of Chapter 1, Part-II in Volume-1 of Treatise on Electric Traction Distribution, which can be
readily referred (page no. 125 of Volume-1).The problem of unbalancing has been raised by few
power utilities and therefore Scott or V connected arrangement should be chosen judiciously
after coordinating with the power utilities.
iii. Scott Connected Transformer is more complex and costlier than the V connected Transformer
but Scott connected Transformer effectively checks the voltage unbalance.
iv. Initially, in Bina-Katni Section of IR, the Scott Connected Transformers were imported;
however, Transformers for V connected scheme were supplied by an Indian Manufacturer.
v. The maintenance/Overhauling of the Scott Connected Transformer is more complex in
comparison to Single Phase Transformer. V connected scheme is economical in comparison to
Scott Connected scheme.
vi. Since, no AT is to be used at the TSS of V connected scheme; it is simpler than Scott Connected
scheme.

8. Utilisation of Scheme:
Considering the complexities involved of the unbalancing (as deliberated under Para 4.3 above), space
constraints and other site problems, the Scott connected or V connected arrangement may be chosen by
the Zonal Railways after coordinating with the power utilities and with the approval of PCEEs.

9. Spacing of the TSS & Switching post (SP/SSP):

Two-line section – Considering the load requirement of 0.5MVA/TKM in ONAN mode on the main
line section, the spacing of TSS in Scott connected scheme of 60-70 Km is suggested. In the proposed
V connected scheme, the transmission of full power from the transformer is not at 50 kV and therefore
the spacing of the TSS in V connected scheme for 2 Line system has been kept same as in Scott
connected scheme i.e. 60-70 KM with power requirement of around 0.6MVA/TKM in ONAN mode.
Three line sections – In the 3 Line section, the loading in MVA/TKM basis will be less than the 2 line
system as all the three lines will not be fully loaded at a time. Therefore, the load requirement of around
0.4 MVA/TKM in ONAN Mode for 3 Line section has been considered and accordingly the spacing of
TSS in Scott connected scheme is suggested as 50-60 KM. In the proposed V connected scheme for 3
line, the transmission of full power from the transformer is not at 50 kV and therefore the spacing of
the TSS in V connected scheme for 3 Line system has been kept same as in Scott connected scheme
i.e. 50-60 KM with power requirement of around 0.5 MVA/TKM in ONAN mode.
Four line section– In the 4 Line section, the loading in MVA/TKM basis will be less than the 3 line
system as all the four lines will not be fully loaded at a time. Therefore, the load requirement of less
than 0.4 MVA/TKM in ONAN Mode for 4 Line section has been considered and accordingly the
spacing of TSS in Scott connected scheme is suggested as 40-50 KM. In the proposed V connected
scheme for 4 line, the transmission of full power from the transformer is not at 50 kV and therefore the

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 Indian Railways - AC Traction Manual - Volume-II Part-I

spacing of the TSS in V connected scheme for 4 Line system has been kept same as in Scott connected
scheme i.e. 40-50 KM with a power requirement of around 0.5 MVA/TKM in ONAN mode.
The sectioning and paralleling post (SP) is to be constructed at approx. midway between consecutive
TSS and SSP may be constructed at approx. midway between TSS & SP.
The transformer is provided with ONAF/OFAF mode to meet the power requirement under feed
extension condition and to account for the margin of 10 KM given in the spacing.
Wherever the Traction Sub Station feeds a mix of 2 line- 3 line sections, 3 line-4 line sections etc., the
spacing and location selection of the Traction Sub Station may be decided by considering the above
power requirement in ONAN mode on TKM basis as per the scheme adopted. In such cases, the power
requirement on each side of Traction Sub Station may be done separately and accordingly the TSS and
SP to be located in terms of spacing. The SSP may be provided at approximately mid of TSS and SP.

10. Operational Philosophy

The spacing of the Traction Sub Station has been proposed in the above Para considering the ONAN
ratings of the Traction Power transformers and considering the load requirement of normal operation.
In the case of feed extension from a particular Traction Sub Station due to failure of the adjacent
Traction Sub Station, the Transformer of the healthy TSSs may be utilized on the ONAF/OFAF mode
and it will be possible to take the full load of the failed Traction Sub Station.
In Scott connected scheme, there are two double pole feeder circuit breakers for either side of the
Traction Sub Station. One Circuit Breaker feeds the OHE with/without interrupters and another is kept
redundant for each side of the Traction Sub Station.
In V connected scheme, the secondary voltages of the traction transformers are out of phase by 120O
from each other and therefore it is required to understand the operation. The standby transformer
provided in the middle can feed in either direction through the motorized coupling isolator provided on
the bus, in case of failure of any of the outer transformer. Also, there are two double pole feeder circuit
breakers for either side of the Traction Sub Station. One Circuit Breaker feeds the OHE with/without
interrupters and another is kept redundant for each side of the Traction Sub Station.
SP and SSP for 2 Line systems have been proposed separately for Scott connected arrangement and V
connected arrangement. The SP/SSP for 2 Line V connected arrangement is of common Bus type. The
SP/SSP for 3 lines and 4 Lines section have been proposed of common bus type and may be used with
both kind of feeding arrangement i.e. Scott connected or V connected arrangement.
In Common Bus type of SP & SSP, the fault on common Bus may hamper the train operation. Therefore,
the Bypass Motorised Isolator (for off-load sectioning or off-load feed extension) has been provided
to continue the train operation even in fault at common Bus. Further, the common Bus type SP/SSP
may be used as a boundary post for interfacing 2Line/3Line/4Line sections of 2X25 kV sections with
each other.

11. Interlocking
a. Scott Connected TSS
i. The Closing of the LVCB on the secondary side of Traction Transformer (i.e. 50kV, SF6CB)
shall be possible only when any one of the Circuit Breaker of associated Autotransformer at
TSS is in closed condition.
ii. The automatic opening of the LVCB on the secondary side of Traction Transformer (i.e. 50kV,
SF6CB) shall happen as soon as all the Circuit Breakers of the associated Autotransformers
at the Traction Sub Station are opened.

234
 Chapter-8 Breakdowns

iii. The closing of coupling motorised isolator between Main Bus and Teaser Bus should be
possible only when all the LVCBs of the Transformer are open. This coupling isolator has
been provided for the feed extension in case of failure of TSS.
iv. To ensure above, necessary interlock shall be provided.

b. V Connected TSS
In this scheme the middle Traction transformer is to be used in either direction in case of failure
of any one of the outer transformer. Therefore necessary interlock is to be provided between
Motorised Coupling Isolator and LV Circuit Breaker in order to avoid wrong phase coupling as
well as to ensure off load operation of the Motorised isolator.
There is off load circuit tap changer on primary side of the transformer with 6 tap positions
(including principal tap) for voltage adjustment. Therefore, the tap changer should be operated
only when both the primary and secondary circuit breakers are in open condition.

12. Three Phase connectivity to TSS:-

Railways to work out for new 3 phase, transmission line or extending/upgrading the existing
transmission line on 3 phase to new location for connecting different TSS on these routes considering
the economics of building this transmission line. In case the new Line is constructed, the line should
support the capacity of transformer and adequate redundancy. To meet the power requirement with
adequate redundancy, the provision of double circuit Transmission line may be considered. As per the

Level, The transformation capacity of any single sub-station for meeting loads shall not normally
exceed 75MVA. In view of this limitation, if 66kV incoming supply is there, only ONAN Mode
Transformer i.e. 60MVA Scott Connected or 38X2= 76MVA, V connected can be used. To address the
huge power requirement for future load, it is suggested to not to take feed from the utility at 66 kV.
Therefore, it is suggested to use 220kV or 132kV incoming Voltage only.

Interface of 25kV system with 2X25kV system and extension of feed from 25kV system to 2X25kV
System and vice versa:
The SP may be proposed as an interface between subject two systems as the SP have been provided with
adequate AT capacity to cater the feed extension. However, the overloading of the Autotransformer/
Autotransformers installed at SP shall determine the extent of feed extension.

Extension of feed between 2 x25 kV system and 1x 25 kV system

General Principle
Generally speaking, extension of feed from 1x 25 kV section to 2x 25 k V section and vice versa is
possible with following remarks concerning capacity of AT at the boundary of both systems.
a. Extension of feed from 1x 25 k V section to 2x 25 kV section.

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 Indian Railways - AC Traction Manual - Volume-II Part-I

In this case, AT-1 at boundary of both systems is burdened with all the train loads which are located
at right side of AT -2 and nearly half of the train loads between AT-1 and AT-2 Therefore, overload of
AT-1 shall be observed.

21101 OHE Recording-cum-Test Car

1. For satisfactory current collection, the geometry of the overhead equipment is required to be
maintained within very stringent limits. Presently monitoring of various parameters of overhead
equipment like height, stagger, wear of contact wire, condition at the cross-overs and overlaps, is
being done manually which could introduce errors in measurement due to individual’s judgment.
Moreover, it is time consuming. For the very high reliability of operation expected of electric
traction system, mechanized monitoring of various parameters is essential.

being increased gradually. Heavier freight trains hauled by one or two consists of locomotives will
draw heavy currents from the substation. For meeting the requirement of increasing passenger

to ascertain potential of the existing OHE and pantograph contact system for effecting requisite
improvement and developing newer designs to achieve satisfactory current collection at higher
speeds and heavier loads.
3. For achieving these objectives, efforts are on to develop an Overhead Equipment Recording cum
Test Car. This car will be used to measure and record various parameters of OHE and pantograph
both under static and 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;

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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 Microprocessor Based Numerical Integrated Feeder Protection Module

1. For the distance protection of the overhead equipment, the relay which was in use is the
electromechanical type. 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

capacity at TSS.
2. To overcome the above problem, the integrated microprocessor based numerical 25 kV feeder
protection module comprising of Polygonal characteristic distance protection, Wrong Phase

(OCR) , Potential Transformer Fuse Failure (PTFF) Alarm and Trip, Auto Reclosure Relay, CB
Trip Circuit Supervision Relay, Breaker backup (LBB) has been developed for Railway traction
application. For its full utilization in controlling / monitoring of protection system, the module is
capable of communicating with the RTU based on standard IEC 60870-5-103 protocol for transfer
of information stored in relays to the RTU.
3. Concept of Numerical Relay: The numerical relay comprises of the following components.
a Central Processing Unit
b. Memory (RAM & ROM)
c. ADC (Analog to Digital Converter)
d. IO modules (Input/output Modules)
e. Communication module (RS 232/485/Ethernet)
The numerical relay measures electric parameters (V, I) and convert them into digital data with the
help of ADC which undergoes mathematical and logical analysis based on the program stored in the
memory and to take action on tripping if fault occurs in the power system.
As the numerical relay is communicable the fault data stored in the relay can be transferred to RCC
through SCADA and the analysis of retrieved data is possible.

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4. The integrated microprocessor based numerical 25 kV feeder protection module comprising of

Polygonal characteristic distance protection, Wrong Phase Coupling (WPC), 2 stage (Stage 1

Failure (PTFF) Alarm and Trip, Auto Reclosure Relay, CB Trip Circuit Supervision Relay, Breaker
backup (LBB) has been developed for Railway traction application. For its full utilization in
controlling / monitoring of protection system, the module is capable of communicating with the
RTU based on standard IEC 60870-5-103 protocol for transfer of information stored in relays to
the RTU. To avoid malfunction of relay due to load encroachment, the load impedance area of
the polygonal shall be settable for non-tripping in case the impedance falls in this area. For other

referred.

Parallelogram characteristic distance protection element

21105 Composite Insulators

The conventional porcelain insulators have poor impact withstand capability. The sheds of such
insulators are easily broken due to acts of vandalism. Also, conventional porcelain insulators have
a limitation of creepage distance i.e. 1050 mm and glazed surface of porcelain also does not have
good hydrophobic property. These limitations can be overcome with the use of Silicone composite

(FRP) rod’ and injection moulded sheds of High Temperature Vulcanising (HTV) Silicone rubber.

ingress of moisture and direct tracking along the length of the core. Such insulators have excellent
impact withstand capability and excellent Hydrophobic & anti- tracking properties”.

21106 Automatic Phase Switching Section (in place of Neutral Section) and
Numerical Control Logic Relay: DELETED
Automatic Phase Switching Section (APSS) has been developed for 25 kV Single Phase 50 Hz AC
Traction Power Supply System of Indian Railway to facilitate automatic changeover of supply coming

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from different phases as soon as the Electric Loco/EMU negotiates the IOLs meant for phase separation
without affecting the status of loco/EMU circuit breaker (DJ). No neutral section is required in APSS
for separation of different phase supply at SP and hence, Loco Pilot can run the train at desired speed
without any hassle and stress and worrying about DJ ON/OFF Boards giving instructions for opening
and closing of electric loco/circuit breaker (DJ) which were required in case of neutral section. Three
insulated overlaps along with CBs, CTs & PTs at SP (or any desired location) associated with Automatic
Phase Switching Section (APSS) has to be provided. Circuit Breaker rated for APSS operation will be

the manufacturer of the Numerical Control Logic Relay (NCLR) may be referred.

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21107 HIGH RISE OHE

1. RDSO Design Document No. TI/DESIGNS/OHE/2014/00001(Rev-1) for ‘Overhead Equipment

Board letter No. 2014/RE/161/19 dated 14.09.2017.

2. OHE PARAMETER FOR HIGH RISE OHE
Height of Double Stack Container : 6809 mm & 7100 mm

Height of Contact Wire at Support from Rail : 7570 mm

Level

Height of Contact Wire at mid Span from Rail : 7520 mm

Level

Height of Catenary Wire at Support from Rail : 8970 mm

level

Presag at mid spa : 50 mm

Maximum Span length : To be decided as per New wind zone as per

Table 4.13(i) & 4.13(iii) of Design Document
(54 metres for wind load 155 kg/Sq. m)

Maximum Stagger at Tangent Track : +150 mm

Maximum Stagger at Curves : +250 mm

Standard Encumbrance : 1.400 metres

Dropper Schedule to be followed : 1.400/1.400 metres Encumbrance Generally.

(Based on Site conditions other prescribed
standard Encumbrance may be followed)

Mast Length : 11.4 metres

Minimum Implantation : 2.8 metres

Tension in Catenary Wire : 1000 kgf

Tension in Contact Wire : 1000 kgf

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 Chapter-8 Breakdowns

Maximum Tension Length : 1.5 km

Catenary Wire : 65 Sq. mm

Contact Wire : 107 Sq.mm

MERGING WITH EXISTING OHE

For Mainline OHE : 5.80 metres

(Height of Contact Wire
at support)

For High Rise OHE : 7.57 metres

(Height of Contact Wire
at support)

Difference : 1.77 metres

The High Rise OHE shall be merged with Conventional OHE

with the Contact wire gradient of @ 10mm/metre . With restricted speed contact wire gradient may
be adopted as per EN 50119.
3. OTHER DETAILS:
Type of Auto Tensioning Devices :

/0060 Rev. 1 with A & C Slip No. 1 - For total OHE

Tension of 2000 kgf
Stainless Steel Wire Rope :
with A & C Slip No. 1 to 4
Anchor Height : As per RDSO Drawing No. TI/DRG/ OHE/GUYHR/
RDSO/ 00001/13/0 (Sheet 1 to 4)
Distance of bottom of Counter Weight : 2300 mm at 35o C
Assembly from top of muff
X-Y Adjustment Chart : As per RDSO Drawing No. TI/DRG/ OHE/ATD/
RDSO/ 00003/99/0 - Three Pulley ATD
Guide Tube : As per RDSO Drawing No. ETI/OHE/ G/01505

Schedule of Dimensions for 25 KV Electric Traction with High Rise OHE:

Minimum Height of Overhead Structure above rail level for a distance of 1600mm on either side of
centre of Track shall be as under:
(Reference: ACS 21 of IRSOD(BG) Revised 2004)
1. Light Overhead Structure such as Foot Over Bridges: 8430mm

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2. Heavy Overhead Structures, such as Road Over Bridges and Flyovers: 8050mm
3. Heavy Overhead Structures, Such as Road Over Bridges and Flyovers, if any turnout or crossover
is located under that heavy overhead structure or within 40meters from its nearest face: 8430mm
Note:
1. Necessary provision shall be made in overhead structure and overhead equipment to permit an
extra allowance for raising of track in future to cater for modern track structure in the form of
increased ballast cushion of 350mm, larger sleeper depth of 230mm and heavier rail section of
200mm including 10m thick rubber pad by using longer traction overhead mast, if necessary.
2. In case of restricted height of existing overhead structures, minimum height of overhead structure
for a distance of 1600mm on either side of centre of track for provision of high rise OHE as per
note (iii) below, to permit operation of double stack container having height as 6809mm shall be as
under:
a. Light Overhead Structure such as Foot Over Bridges: 7568 mm
b. Heavy Overhead Structures, such as Road Over Bridges and Flyovers: 7468mm
c. Heavy Overhead Structures, Such as Road Over Bridges and Flyovers, if any turnout or
crossover is located under that heavy overhead structure or within 40meters from its nearest
face: 7568mm
For these minimum restricted heights, catenary wire shall be terminated outside overhead
structure (Road Over Bridges & Flyovers/Foot Over Bridges)
3. In case of restricted height of existing overhead structures, bridges and tunnels the minimum height
of underside of the contact wire from rail level can be reduced to 7166mm. In such cases a special
study shall be made before 25kV AC traction is introduced as explained below:
(a) Height of Rolling stock 6809mm
(b) Short duration electrical clearance 200mm
(c) Additional electrical clearance for oscillation of contact wire (For OHE 50mm
span length of 49.5m or below)
(d) Allowance for track upgradation/maintenance 50mm
(e) Rise in rolling stock height under dynamic condition 57mm
Minimum Height of contact wire 7166mm

4. Extra vertical clearance shall be provided on curves as under:

Extra vertical clearance (mm) = Width of MMD(mm)X Super elevation (mm)/Dynamic Gauge(mm)
This extra vertical clearance on curve should be with respect to inner rail of curve.

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5. Clearances for Power Line Crossings including Telephone Line Crossings of Railway Tracks:
SN Overhead crossing Minimum clearance from Rail Level Minimum clearance
voltage Existing power New power line between highest traction
line crossing for crossing or conductor and lowest
existing Non- crossing planned transmission line crossing
for alteration conductor

(1) (2) (3) (4) (5)

1 Upto & including 11 kV By underground cable
2 Above 11 kV& upto 33 10860 16660 2440
kV
3 Above 33 kV& upto 66 11160 16960 2440
kV
4 Above 66 kV& upto 11760 17560 3050
132 kV
5 Above 132 kV& upto 12660 18460 4580
220 kV
6 Above 220 kV& upto 14460 20260 5490
400 kV
7 Above 400 kV& upto 15360 21160 7940
500 kV
8 Above 500 kV& upto 18060 23860 7940
800KV

Note:

i. All height/clearances are in mm and under maximum sag condition

ii. If the crossing is provided with a guarding, a minimum clearance of 2000mm shall be maintained
between bottom of guard wire and heighest traction conductor
iii. Power line crossing in yards & station area shall be avoided.

existing crossings can continue, if dimensions are as per Column (5) above, even if dimensions

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6. DRAWINGS APPLICABLE FOR HIGH RISE OHE:

The following Standard RDSO Drawings pertain to High Rise OHE.
Sl. No. Description Drawing No.
(i) Employment Schedule for OHE Mast (11.4 metre) TI/DRG/CIV/ES/00001/13/0
Wind Pressure 178 kgf/ m2 for High Rise OHE. (Sheet – 1)
(ii) Employment Schedule for OHE Mast (11.4 metre) TI/DRG/CIV/ES/00001/13/0
Wind Pressure 155 kgf/ m2 for High Rise OHE. (Sheet – 2)
(iii) Employment Schedule for OHE Mast (11.4 metre) TI/DRG/CIV/ES/00001/13/0
Wind Pressure 136 kgf/ m2 for High Rise OHE. (Sheet – 3)
(iv) Employment Schedule for OHE Mast (11.4 metre) TI/DRG/CIV/ES/00001/ 13/0
Wind Pressure 105 kgf/ m2 for High Rise OHE. (Sheet – 4)
(v) Employment Schedule for OHE Mast (11.4 metre) TI/DRG/CIV/ES/00001/ 13/0
Wind Pressure 73 kgf/ m2 for High Rise OHE. (Sheet – 5)
(vi) Volume Charts & Equivalent Charts of TI/DRG/CIV/FND/00001/13/0
Foundations(Side Bearing, Side Gravity & WBC) for (Sheet - 1)
High Rise OHE
(vii) Volume Charts & Equivalent Charts of TI/DRG/CIV/FND/00001/13/0
Foundations(NG Type) for High Rise OHE (Sheet – 2)
(viii) Volume Charts & Equivalent Charts of Foundations TI/DRG/CIV/FND/00001/13/0
for Dry Black Cotton Soil(NBC Type, 3.0 metre (Sheet – 3)
Depth)for High Rise OHE
(ix) Volume Charts & Equivalent Charts of New Pure TI/DRG/CIV/FND/00001/13/0
Gravity Foundations(500 mm exposed) for High Rise (Sheet – 4 )
OHE
(x) Volume Charts & Equivalent Charts of Foundations TI/DRG/CIV/FND/00001/13/0
for Dry Black Cotton Soil(NBC Type, 2.5 metre (Sheet – 5)
Depth)for High Rise OHE
(xi) Schedule of Anchor Blocks for B G Tracks for High TI/DRG/OHE/
Rise OHE GUYHR/00001/14/0 (Sheet - 1)
(xii) Schedule of Anchor Blocks for B G Track for Black TI/DRG/OHE/
Cotton Soil for High Rise OHE GUYHR/00001/14/0 (Sheet - 2)
(xiii) TI/DRG/OHE/
GUYHR/00001/14/0 (Sheet - 3)
(xiv) Anchor arrangement with Dwarf Mast For ETI/OHE/HR/G/01402
Conventional & High Rise OHE
(xv) 11.4 m long Standard Traction Mast (Fabricated with TI/DRG/CIV/B-Mast/ 00001 /13/0
Batten Plates “B” Series) for High Rise OHE
(xvi) Standard Plan Height Gauge for level crossing (For TI/DRG/CIV/H Gauge-HR/
clear span up to 7.3 meter) Details of structure and RDSO/00001/20/0
foundation for High Rise OHE (7.52 mtr at mid span
at LC gate)
(xvii) Standard Plan Height Gauge for level crossing (For TI/DRG/CIV/H Gauge-HR/
clear span above 7.3 mtr upto 12.2 meter) Details of RDSO/00002/20/0
structure and foundation for High Rise OHE (7.52 mtr
at mid span at LC gate)

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(xvi) BFB Type Portal TI/DRG/CIV/BFB-PORTAL/

00001 /13/0 (Sheet 1 & 2)
(xvi) N Type Portal TI/DRG/CIV/N-PORTAL/00001
/13 /0 (Sheet 1 & 2)
(xviii) P Type Portal TI/DRG/CIV/P-PORTAL/00001
/13/0 (Sheet 1 & 2)
(xix) O Type Portal TI/DRG/CIV/O-PORTAL/00001
/13/0 (Sheet 1 & 2)
(xx) G Type Portal TI/DRG/CIV/G-PORTAL/00001
/13/0
(xxi) R Type Portal TI/DRG/CIV/R-PORTAL/00001
/13/0 (Sheet 1 & 2)
(xxii) TTC Mast TI/DRG/CIV/TTC/00001/13/0
(Sheet 1 to 2)
(xxii)) Dropper Schedule for High Rise OHE(Encumbrance TI/DRG/OHE/DROP/00001/10/1
1400mm/1400mm)
(xxiv) Dropper Schedule for High Rise OHE(Encumbrance TI/DRG/OHE/DROP/00002/10/1
1400mm/900mm)
(xxv) Dropper Schedule for High Rise OHE(Encumbrance TI/DRG/OHE/DROP/00003/10/1
1400mm/750mm)
(xxvi) Auxiliary Transformer for High Rise OHE TI/OHE/HR/AT/G/05522
(Sheet 1 to 2)
(xxvii) Standard arrangement of Drop arm for supporting ETI/C/HR/0076
Cantilever on the boom of portals and two track
cantilever for Normal as well as High Rise OHE.

7. SALIENT TECHNICAL FEATURES OF HIGH REACH PANTOGRAPH:

(Already used for trial)

for high rise Pantograph)

MAIN FEATURES
i) Operating Voltage : a) Nominal - 25 kV, 50 Hz
b) Max. (Cont.) - 27.5 kV.
c) Short time Max. - 30 kV. for 10 Seconds.
ii) Rated current : 600 Amps. (Minimum)
iii) Mounting : 4 Supports (Indian Railways existing arrangement
of four support 807 mm along the length of
loco x 1160 mm along the width of loco, shall be
preferred.)
iv) Maximum Extension : At least 3.5 meters from the locked
down height
v) Working Range : 0.15 meters to 3.3 meters (for
satisfactory current collection)
vi) Maximum Weight : 180 kg. Approx. (Without Insulators)

vii) Static Up-thrust : 7 ± 0.4 kgf.

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viii) Maximum Speed : 140 kmph.

ix) Width of Pantograph 2032 mm + 5 mm
Pan
x) Overall length : 2000 mm.
(Including Shunt) (In folded condition)
From rear Panto mounting Foot Insulator
xi) Total forces : As low as possible
(the value to be furnished by the
Tenderer)
xii) Wearing Strip : Metallised Carbon Strips as per RDSO’s
material
/0097 ,Rev.‘0’
xiii) Maximum Folded : 295 ± 5 mm.
height above [So as to be within existing Maximum
mounting insulator Moving Dimension (MMD) of Electric
Loco]
xiv) Compressed Air : The compressed Air supply in the loco
Supply may vary between 5.5 kg/cm2 and 11
kg/cm2 depending upon the type of
Stock, Compressor operation etc.
Pantograph shall start lowering if the Air
pressure drops below 4.5 kg/cm2.
xv) Raising time for the Pantograph to reach an extension of about
3.5 meters in 6 to 15 seconds.
xvi) Lowering time for the Pantograph to fold on its stops from 3.5
meters –
less than or equal to 15 seconds.
Break from the Contact wire should be rapid and controlled
throughout the remaining lowering operation.
Folding on to the stops should be without any jerk.
xvii) The resistance of Pantograph between carrier i.e. from Contact
Strip and Power take off point on the base frame shall not exceed
10 milli-ohms.
xviii) Adequate lowering effort and retaining force in the lowered
condition shall be ensured to lower and retain the Pantograph in
the lowered position without undue vibrations at speeds up to 140
kmph.

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21108 Copper Magnesium Catenary wire

Presently, Cadmium Copper Stranded Catenary wire is being used in Indian Railways. Copper-cadmium
has a good combination of properties but is no longer accepted in most applications as a conductor
alloy, on account of the toxicity hazard and risk of respiratory disease associated with cadmium, both
in initial manufacturing and later in recycling. In service, copper-cadmium poses no threat to health.
Hence, RDSO has developed Copper Magnesium Stranded catenary wire, with properties similar to
copper cadmium catenary wire so that existing copper cadmium catenary wire can be replaced with
non-hazardous alloy without compromising electrical and mechanical properties. Copper Magnesium
has good resistance in natural and industrial atmosphere (maritime air too). Prototype testing has been

CHEMICAL COMPOSITION
Element %ppm
Cu+Ag Remaining
Mg 0.1% - 0.7%
Bi < 10 ppm
Pb <5 ppm
P <50 ppm
Oxygen <20 ppm

PROPERTIES OF STANDARD MAGENESIUM COPPER (Cu-Mg) STRANDED CONDUCTOR

Nominal No. of Approx. Weight Per Km. Resistance per km Minimum Calculated
equivalent strands and overall at 20°C corrected to breaking area of
Area of diameter 0f Diameter Standard Weight load of Magnesium
Hard Wire Conductor Copper.
Drawn Std Max Min Std Max
Copper
mm2 mm2 mm Kg Kg Kg Ohm Ohm Kgf mm2
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
19.84 7/2.10 6.3 217.60 221.76 213.58 0.8958 0.9132 1432.7 24.05
53.50 19/2.10 10.5 594.40 605.78 583.41 0.3322 0.3387 3915.9 64.85
103.62 37/2.10 14.7 1163.52 1185.79 1142.01 0.1717 0.1750 7625.7 125.60

21109 Spring type ATD

Spring type Auto Tensioning Device can be used at locations having space constraint for providing
Counter Weights like tunnel, viaduct , bridges etc.
Spring ATD is full maintenance-free system with the anticipated service life more than 30 years. It’s
installation and operation are easier than pulley type regulating equipment. It also minimizes the
human/material resources for maintenance due to Lower weight & Small size. It provides safeguard
against accidents due to no hanging counter weight as pulley type regulating equipment. Prototype

Spring ATD can be used for higher tension and high speed.

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21110 Open Access- Optimization of Traction Power Procurement Cost

Indian Railways (IR), along with national highways and ports, is the backbone of India’s transport
infrastructure. The reach and access of its services are expanding with continuous improvement
through its committed team of about 1.3 million employees and use of cutting-edge technologies.
Ministry of Railways has been relentlessly working on multiple fronts to speed up growth of Indian

for its traction applications during 2018-19 which is about 1.3% of total electrical energy generated in

have been very conscious about saving energy and accordingly consistently been working towards
controlling its energy bill on traction side by adopting multi-pronged strategies including procuring
energy from open market.
Earlier IR has been procuring electricity as an ordinary consumer for its traction applications despite
being the single largest user of energy in the country. Accordingly, it has been paying higher tariffs
for energy duly taking the burden of distribution losses, cross subsidy and other surcharges of Power
Distribution Companies (DISCOMs). The Electricity Act 2003 conferred Deemed Licensee status on
IR being Central Government department due to its involvement in transmission &distribution of
energy from the time electricity came to India. Accordingly, IR had been working to get this provision
of Electricity Act operational; however it didn’t come through for quite some time due to various
factors.
Ministry of Railways took up this task with fresh impetus and subsequently a strategy was drawn.
In line with this, Indian Railway approached Central Electricity Regulatory Commission (CERC)
for issue of necessary guidelines to all State Transmission Utilities (STUs) and State Load Dispatch
Centers (SLDCs) to facilitate Open Access to Indian Railways on existing transmission network as
Deemed Licensee. This was made to enable Indian Railways to procure energy from any generating
unit, including captive generating plants, traders, or through power exchange up to the interconnection

In its historic judgment on 5th Nov.’15, CERC in Petition No. 197/MP/2015 ordered that:
“Indian Railways is an authorized entity under the Railways Act to undertake transmission and
distribution activities in connection with the working of the railways, independent of its status under
the Electricity Act. Indian Railways is a deemed Licensee under third proviso to Section 14 of the
Electricity Act and no separate declaration to that effect is required from the Appropriate Commission.
All concerned RLDCs, State Transmission Utilities and SLDCs are directed to facilitate long term
access and medium term access in terms of Connectivity Regulations from the generating stations or
other sources to the facilities and network of Indian Railways.”
Finally, IR’s vision of drawing electrical energy as deemed licensee was realized on 26th Nov.’15
when it started drawing about 200 MW power on Central Railway from Ratnagiri Gas Power Pvt. Ltd.

under open access as a distribution licensee using state distribution network. IR contracted about
540 MW from RGPPL for consumption in the states of Maharashtra, Gujarat, M.P., and Jharkhand

completed by 22nd Jan.’16. Further, IR also contracted 50 MW through open tender for taking on its

The salient features of CERC/SERC regulations regarding open access are as under.
Eligibility for Open access:
1. Application for open access should be made in prescribed format.

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 Chapter-8 Breakdowns

2. Valid Power Purchase agreement between Generator/Trader and Power Procurer.

3. Applicable fees as prescribed by respective regulatory authority shall be paid by open access
applicant.
4. All fees and charges applicable shall be paid as decides by respective regulatory authority.
5. No resale of Energy allowed in open access.
6. Distribution Franchisee not eligible for Open access.
7. No surcharge or cross-subsidy to captive generation plant for carrying the electricity to the
destination of his own use.
A Consumer having Contract Demand of 1 MW and above with a Distribution License shall be eligible
for Open Access for obtaining supply of electricity from one or more
a. Generating Plants or Stations, including Captive Generating Plants;
b. Trading Licensees
c. Power Exchanges
d. Other Distribution Licensees
e. Any other sources, or a combination thereof and all collectively called ‘Sources’:
Provided that, for the purpose of unit conversion from MVA to MW, the unity power factor shall be
considered;

Completion of Works
1. Where the grant of Open Access is agreed to but requires the completion of works relating to
extension or augmentation of lines, transformers, metering arrangements, etc., or the commissioning
of new Sub-Stations, the Distribution Licensee shall complete such works within the time limits

Meter Reading

of commencement of Open Access: in presence of representatives of consumer and distribution

licensee.

Settlement of Dues
1. A Consumer applying for Open Access to the Distribution System shall settle all dues of the
Distribution Licensee prior to applying for Open Access:

Open Access Agreement

1. An Open Access Agreement shall be entered into upon grant of Medium or Long Term Open
Access in the format prescribed.

Categories of Open Access

The application procedure, application fee and the time frame for processing applications for Open
Access shall depend on the inter-se location of drawl and injection points, i.e. on whether
1. Both are within the same Distribution System;
2. Both are within the State but in different Distribution Systems;
3. Both are in different States.

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Duration of Open Access

Open Access Category Duration
Long-term Open Access (LTOA) Exceeding twelve years but not

Medium-term Open Access (MTOA) Exceeding three months but not

exceeding three years
Short-term Open Access (STOA) Not exceeding one month
Day ahead open access With in 24 hrs.
The procedure for Inter-State Open Access shall be as per the Central Commission’s Regulations
whereas for Intra-State Open Acess shall be as per respective state commissions regulations.

APPLICABLE CHARGES:
1. The bill will be raised on the Open Access Generator / Open Access consumer The bill will include
the following charges:
a. Wheeling Charges / Transmission Charges, as may be applicable;
b. Cross Subsidy Surcharge, as may be applicable;
c. Additional Surcharge on the Charges of Wheeling;
d. Standby Charges;
e.Voltage Surcharge, as may be applicable;
f. System Operating Charges& Market operating charges
g. Charges in case of over or under drawl with reference to the scheduled power. from the grid.
h. Any other charge or other sum recoverable.

Metering and Communication

All Open Access Consumers and Generating Stations shall install Special Energy Meters (‘SEM’s):
Railways have unveiled Mission 41K on the occasion of “Roundtable discussion with Stakeholders”
on 17th January 2017 at Ministry of Railways. According to Mission 41K, it is estimated that on
account of Open Access, in the period from 2015 to 2025 a cumulative saving of about ` 41,000 cr.
shall be achieved in electric traction bill. Due to power procurement under open access IR has achieved
a saving of over ` 12,500 crores in traction bills from 2015 to 2019-20.

*****

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 CHAPTER-12
TRAINING AND COMPETENCY CERTIFICATES

I. TRAINING

21200 Introduction

21201 Planning of Training in Advance

21202 Categories to be trained

21203 Initial Training

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21204 Promotional Courses

21205 Refresher Courses

252
21206 Facilities for Training

253
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21207 Training in General and Subsidiary Rules

21209 Examination at the End of Training

21210 Specialized Training

21211 Syllabi

254
 II. COMPETENCY CERTIFICATES

21212 Authorized Person

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Indian Railways - AC Traction Manual - Volume-II Part-I

21214 Period of Training

21215 OHE Inspection Car Driver

21216 Knowledge of Rules

21218 Service Record

21219 Inspections
Indian Railways - AC Traction Manual - Volume-II Part-I

Annexure 12.01

test and periodical

issue
conducted is posted
at present

CERTIFICATE OF COMPETENCY No. TR-1

CERTIFICATE OF COMPETENCY No.TR-2
Indian Railways - AC Traction Manual - Volume-II Part-I

CERTIFICATE OF COMPETENCY No. TR-3

CERTIFICATE OF COMPETENCY No. TR-4
Indian Railways - AC Traction Manual - Volume-II Part-I

CERTIFICATE OF COMPETENCY No. TR-5

CERTIFICATE OF COMPETENCY No. TR-6
(For Supervisors of PSI)
Indian Railways - AC Traction Manual - Volume-II Part-I

CERTIFICATE OF COMPETENCY No. TR-7

CERTIFICATE OF COMPETENCY NO.TR-8
Indian Railways - AC Traction Manual - Volume-II Part-I

CERTIFICATE OF COMPETENCY No. TR-9

CERTIFICATE OF COMPETENCY No.TR- 10

ASSURANCE
Indian Railways - AC Traction Manual - Volume-II Part-I

CERTIFICATE OF COMPETENCY No.TR- 11

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